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SSANGYONG Actyon 2012.12, Manual

The SSANGYONG Actyon 2012.12 user manual is a comprehensive guide that allows you to fully understand and operate this exceptional vehicle. Available for free download at manualshive.com, this manual provides step-by-step instructions, helpful tips, and essential information, ensuring a seamless driving experience for all Actyon owners.

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02-11

0000-00

4. GUIDELINES ON ENGINE SERVICE

To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and 

unit inspection/repair and to secure optimum engine performance and safety after service works, basic 

cautions and service work guidelines that can be easily forgotten during engine service works are 

described in.

Cautions before service works

For safe and correct works, you must observe the working procedures and instructions in this 

manual. And, use the designated tools as follow:

Engine stand / Heavy duty engine jack

To prevent the engine from starting abruptly, do not allow anybody to get in the vehicle while 

servicing in engine compartment.

Before work on engine and each electrical equipment, be sure to disconnect battery negative (-) 

terminal.

Before service works, be sure to prepare the works by cleaning and aligning work areas.

Do not allow the foreign material get into the fuel injection system.

When removing the engine, use only the safety hook on engine and engine hanger. Do not support 

the bottom of oil pan with a jack.

Engine and accessories

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Completely drain the engine oil, coolant and fuel from engine before removal.

Before disassembling/assembling the engine components, carefully read the working procedures in 

this manual.

Make sure to keep the specified tightening torques during installation.

Clean and properly lubricate the parts before reassembly.

Carefully check that there are not any interference while servicing.

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Summary of Contents for Actyon 2012.12

Page 1: ...0 3 0000 00 1 DIMENSIONS Unit mm Top view Side view Front view Rear view ...

Page 2: ...0 4 2 SPECIFICATIONS ...

Page 3: ...0 5 0000 00 ...

Page 4: ...DTR The engine number is stamped on the upper rear left hand side of the cylinder block The chassis number is stamped on the frame behind the front right tire The engine number is stamped on the lower area of cylinder block behind the Intake manifold The certification label is located on the driver s door sill ...

Page 5: ...0 7 0000 00 4 MAINTENANCE INTERVAL 1 Diesel Engine EU ...

Page 6: ...0 8 ...

Page 7: ...0 9 0000 00 ...

Page 8: ...0 10 2 Diesel Engine GENERAL ...

Page 9: ...0 11 0000 00 ...

Page 10: ...0 12 ...

Page 11: ...0 13 0000 00 3 Gasoline Engine ...

Page 12: ...0 14 ...

Page 13: ...0 15 0000 00 ...

Page 14: ... FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels when adding or replacing the fluids ...

Page 15: ...0 17 0000 00 6 JACK UP POINTS ...

Page 16: ...el and consists of 16 pins Pin no 1 Pin no 2 Pin no 3 Pin no 4 Pin no 5 Pin no 6 Pin no 7 Pin no 8 Pin no 9 Pin no 10 Pin no 11 Pin no 12 Pin no 13 Pin no 14 Pin no 15 Pin no 16 STICS C1 Ground Signal ground CAN HIGH Engine ECU ABS ESP UNIT 2 AIR BAG UNIT 9 TCU B12 6 AT A18 5 AT TCCU 21 CAN LOW STICS B21 Battery ...

Page 17: ...0 19 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 18: ...0 20 2 Components Locator ...

Page 19: ...0 21 0000 00 9 STANDARD BOLTS SPECIFICATIONS ...

Page 20: ...ng works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of above torque table ...

Page 21: ...0 3 0000 00 1 GLOSSARY ...

Page 22: ...0 4 ...

Page 23: ...0 5 0000 00 ...

Page 24: ...0 6 ...

Page 25: ...0 7 0000 00 ...

Page 26: ...0 8 ...

Page 27: ...0 9 0000 00 ...

Page 28: ...0 10 ...

Page 29: ...01 3 0000 00 Right view Left view Rear view Front view 1 ENGINE LAYOUT ...

Page 30: ... steering pump pulley Oil pressure switch Idler pulley No 2 Water pump pulley Alternator pulley Auto tensioner Idler pulley No 1 A C compressor pulley Rear view E EGR valve Fuel temperature sensor Fuel HP pump assembly Coolant temperature sensor IMV valve Crankshaft position sensor Isolation damper ...

Page 31: ...sensor Oil dipstick tube gauge assembly E VGT actuator E VGT turbocharger Coolant screw plug Oil drain plug Left view Thermostat assembly Variable swirl valve assembly E EGR valve E EGR solenoid valve EGR cooler Electronic throttle body Oil cooler assembly ...

Page 32: ...oil level and add Ssangyong genuine engine oil if necessary Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine Operating vehicle with insuffi cient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary Power steering fluid reservoir Brake fluid reservoir Fuse relay Engine oil dipstick gauge Washer fluid rese...

Page 33: ...e every 20 000 km The service interval should be shortened under severe conditions General Clean every 7 500 km change every 15 000 km The service interval should be shortened under severe conditions 2 Specification and Capacity Severe condition Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below fre...

Page 34: ...erwise some electric or electronic components could be damaged 2 Servicing 1 Lifting up the vehicle Always keep the safety precautions To prevent the vehicle from rolling down put the chocks under the tires when using a 4 post lift Make sure to support the correct lifting points when using a 2 post lift 2 Exhaust system Wear the safety glove when removing the exhaust pipe Make sure that the exhaus...

Page 35: ...ed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system When working on the fuel line between priming pump and injector including return line always plug the openings with caps to prevent foreign materials or dust from entering to the openings and connections The HP fuel supply pipe HP pump to fuel rail and HP fuel pipe Fuel rail to inject...

Page 36: ...uring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ...

Page 37: ... 200 20Nm 180 20 660 720 Nm Not reusable Oil pan M6 20 18 10 1Nm M6 35 2 10 1Nm M6 85 2 10 1Nm M6 120 2 10 1Nm M8 40 2 25 2 5Nm Mounting nut for high pressure pump M14 1 5 8 1 1 65 5Nm Mounting bolt for high pressure pump M8 30 3 25 2 5Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1Nm M8 60 4 25 2 5Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket M11 40 1 30 3Nm Chain tensioner...

Page 38: ...rger 2 10 1Nm EGR valve M8 22 3 25 2 5Nm EGR pipe bolt to exhaust manifold M8 16 2 10 1Nm EGR pipe bolt to EGR cooler M8 16 2 25 2 5Nm Name Size Numbers of fastener Tightening torque Nm Note total tightening torque Hot water inlet pipe M6 12 2 10 1Nm Alternator M10 90 1 LO 25 2 5Nm M10 116 1 HI 46 4 6Nm Air conditioner compressor M8 85 4 25 2 5Nm Air conditioner bracket M6 25 4 10 1Nm Intake manif...

Page 39: ... 21 10 1Nm Oil dipstick gauge cover M6 16 1 10 1Nm Oil filter cap 1 25 2 5Nm Fuel rail M8 25 2 25 2 5Nm Injector clamp bolt M6 44 2 9 1 0Nm 130 10 High pressure pipe between high pressure pump and fuel rail assembly M17 1 30 3Nm High pressure pipe between fuel rail assembly and injector M17 4 30 3Nm Crankshaft position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8 25 3 25 2 5Nm ...

Page 40: ...elect 5 speed A T DC 5 AT Select 6 speed A T DSI 6 AT Select Pressure sensor for A C refrigerant NO Select the appropriate system Type Pressure sensor for A C refrigerant Immobilizer NO Select YES if the vehicle has immobilizer YES YES Vehicle speed input type CAN Select CAN if the vehicle has ABS or ESP CAN WIRE Fan 2 relays Select PWM PWM fan PWM fan Auto cruise NO Select YES if the vehicle has ...

Page 41: ... 35 mm Exhaust 0 1 to 0 35 mm Camshaft position sensor Distance between Camshaft position sensor and sprocket 0 20 to 1 80 mm Valve Clearance between valve and piston Intake 1 12 mm Exhaust 1 09 mm Valve recess Intake 0 6 to 1 0 mm Exhaust 0 6 to 1 0 mm Cylinder block Piston protrusion 0 475 to 0 745 mm Piston ring TOP ring end gap 0 20 to 0 40 mm 2nd ring end gap 0 35 to 0 50 mm 3rd ring end gap ...

Page 42: ...200 20 Nm 180 20 660 to 720 Nm Not re usable Oil pan M6 20 18 10 1 Nm M6 35 2 10 1 Nm M6 85 2 10 1 Nm M6 120 2 10 1 Nm M8 40 2 25 2 5 Nm HP pump main nut M14 1 5 8 1 1 65 5 Nm HP pump bolt M8 55 3 25 2 5 Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1 Nm M8 60 4 25 2 5 Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket bolt M11 40 1 30 3 Nm Chain tensioner screw bolt M38 1 5 1 25...

Page 43: ...sensor M8 28 2 20 5Nm Cam position sensor M8 14 1 10 14Nm Booster pressure sensor M6 20 2 10 1Nm Exhaust manifold M8 10 40 4Nm Turbocharger M8 3 25 2 5Nm Support bolt 1 25 2 5Nm Support nut M8 1 25 2 5Nm T C oil supply pipe M6 block side 1 10 1 0Nm M6 turbo side 1 17 2 0Nm T C oil return pipe M6 16 turbo side 2 10 1Nm M6 16 block side 2 10 1Nm EGR valve M8 22 2 25 2 5Nm EGR pipe bolt Intake side M...

Page 44: ...6 16 1 10 1Nm Oil filter cap 1 25 2 5Nm Fuel rail M8 35SOC 2 25 2 5Nm Injector clamp bolt M6 60 2 10 1Nm 120 10 High pressure pipe between HP pump and fuel rail M17 1 30 3Nm High pressure pipe between fuel rail and injector M17 4 30 3Nm Crank position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8x25 4 25 2 5Nm Power steering pump M8 100 3 25 2 5Nm Cylinder head front cover M6 10...

Page 45: ... gasket This test provides current engine operating status Before cranking the engine make sure that the test wiring tools and persons are keeping away from moving components of engine e g belt and cooling fan Park the vehicle on the level ground and apply the parking brake Do not allow anybody to be in front of the vehicle Measurement Warm the engine up to normal operating temperature 80 C Discon...

Page 46: ...e test procedure do not inject the engine oil into the combustion chamber Test condition normal engine operating temperature 80 C Specified value Whole engine below 25 at valve and cylinder head gasket below 10 at piston ring below 20 Crank the engine for approx 10 seconds by using the start motor 2 Record the test result and measure the compression pressure of other cylinders with same manner 3 I...

Page 47: ...02 9 0000 00 Position the piston at TDC and measure the piston protrusion from crank case mating surface 3 Piston protrusion check Specified value 0 475 to 0 745 mm Measure it at both ends of crankshaft ...

Page 48: ...6 to 1 0 mm Exhaust valve 0 6 to 1 0 mm Measure the cylinder head height A 1 If the height is less than the limit the cylinder head must be replaced Insert the valves into the valve guides and measure the recesses 2 If the measured value is out of the specified range machine the valve seat as much as necessary until the specified value is achieved Valve recess a 0 6 to 1 0 mm 2 Cylinder head press...

Page 49: ...n the vehicle while servicing in engine compartment Before work on engine and each electrical equipment be sure to disconnect battery negative terminal Before service works be sure to prepare the works by cleaning and aligning work areas Do not allow the foreign material get into the fuel injection system When removing the engine use only the safety hook on engine and engine hanger Do not support ...

Page 50: ... not allow the fluid and engine oil to make contact with the body paintwork and hoses If work on the fluid system such as fuel and oil working area should be well ventilated and smoking should be prohibited Gasket or seal on the fuel lubrication system should be replaced with new ones and bolts and nuts should be tightened as specified After removal installation works be sure to check whether ther...

Page 51: ... Accessories Drive design to make a compact layout Components HPS Hydraulic Power Steering 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 Idle pulley 1 9 Idle pulley 2 10 Power steering pump pulley ...

Page 52: ...lity and durability for the system And the belt tension is decreased to minimize the friction loss and improve the belt operating noise 1 Crankshaft Pulley Isolation Damper 1 Overview 2 Sectional drawing Axial radial bearing Sleeve Hub Isolation pulley rubber Pulley Damper rubber Inertia ring ...

Page 53: ... Decrease crankshaft torsion Improve belt NHV Reduce unbalance speed to crankshaft due to irregular combustion Minimize noise Anti vibration from crankshaft and belt Post bonded type rubber damper Improve durability of rubber damper 1 2 3 4 ...

Page 54: ...this deviation automatically In D20DTR engine one of the mechanical tensioner pivot damped tensioner is used to keep the damping force system reliability and durability The single belt drive system needs to use the automatic belt tensioning device to transfer the power to pulleys effectively To get this the tensioner uses the spring and damping unit 2 Location Belt tensioner ...

Page 55: ...uum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid This pump is single vane type and displacement is 210 cc rev The lubrication oil is supplied through the hole in hollow shaft Components EGR cooler bypass valve This valve is controlled by ECU When the engine is cooled the exhaust gas goes to combustion chamber without passing through EGR cooler because the valve ...

Page 56: ...02 18 1 Location 2 Operation The vacuum pump is engaged to the exhaust camshaft Connection between vacuum pump and exhaust camshaft Oil supply and driving Vacuum pump Exhaust camshaft ...

Page 57: ... Location Insulator Front mounting insulator Right side Location Insulator 3 ENGINE MOUNTING D20DTR engine uses 3 point mounting type that supports the engine and transmission simultaneously Components Rear mounting insulator 2WD 4WD A T M T A T M T ...

Page 58: ...ting insulator Right side Type Rubber mounting Function Supports the torque reaction Front mounting insulator Left side Type Rubber mounting Function Supports the torque reaction Rear mounting insulato Type Rubber mounting Function Supports the powertrain rod ...

Page 59: ...duced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas 2 Exhaust Manifold Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts EGR port is integrated in cylinder head Components Components For detailes refer to Chapter Intake System Exhaust manifold For detailes refer to Chapter Exhaust System ...

Page 60: ...D COVER AND OIL SEPARATOR The cylinder head cover is made by high strength plastic to reduce the weight The multi twist type oil separator improves the oil consumption Components 1 Cylinder Head Cover Front view Cylinder head cover ...

Page 61: ... the particle in blow by gas to minimize the engine oil consumption and reduces the inflow oil from intake system into the combustion chamber The separated oil returns to oil pan through cylinder head Oil separator Blow by outlet hose 1 Overview 2 Layout ...

Page 62: ...ft position sensor Components Cylinder head Cylinder head contains cam position sensor vacuum pump intake manifold exhaust manifold and valve assembly Vacuum pump and the high pressure HP pump are driven by Camshaft and valves are install in vertical direction This enables the compact layout in cylinder head assembly 6 CYLINDER HEAD ...

Page 63: ...e by gravity casting and the water jacket is integrated type The cylinder oil passage is drilled and sealed by cap The Camshaft bearing cap is also made by casting and installed on the cylinder head 2 Features Front Rear Coolant expansion plug M21 Oil gallery expansion plug M10 Intake side ...

Page 64: ...ears Camshaft operates the intake exhaust valves vacuum pump and HP pump and transfers the engine oil to vacuum pump through the internal oil passage 2 Location Exhaust Camshaft Exhaust Camshaft Octagon cam for tooling Thrust journal Connected to vacuum pump Intake Camshaft Closed flow type water jacket improving cooling performance ...

Page 65: ...e clearance reduces the valve noise Roller type finger follower reduces the friction loss Vertical installation Simple and compact design reduces the moving operation improving valve following and fuel consumption at high speed 1 2 3 4 5 2 Arrangement Hydraulic lash adjuster Upper valve spring retainer Lower valve spring retainer Valve spring Exhaust valve Intake valve Finger follower ...

Page 66: ... cylinder head block profile stopper backland stopper Material MLS Multi Layer Steel Gasket 3 layers Thickness of gasket 3 types 1 2 1 3 1 4 mm 1 2 3 4 2 Thickness of cylinder head gasket There are three types of gasket to managing the compression ratio Piston protrusion Piston protrusion Thickness 0 475 to 0 540 mm 1 2t 0 541 to 0 649 mm 1 3t 0 650 to 0 745 mm 1 4t ...

Page 67: ...shaft sprocket Exhaust camshaft sprocket Teeth 42 EA 1 Chain Drive 1 Overview The drive chain is single chain drive system with simple design and variable performance and it utilizes the hydraulic tensioner to reduce the wave impact generated by the chain This chain is light weight and has high durability through single bush chain Shoulder bolts are used for better NHV 7 CHAIN AND GEAR DRIVE SYSTE...

Page 68: ...bush type 60 EA 2 Tensioner Tensioner adjusts the chain tension to keep it tight during engine running This reduces the wear in guide rail and spoke Operating principle Use the spring tension in tensioner and hydraulic pressure Tensioner type Compensation and impact absorbing Static and dynamic force Spring Hydraulic pressure 1 2 3 Plunger Housing Spring Check valve Hydraulic tensioner assembly ...

Page 69: ... and impact absorbing Static and dynamic force Spring 4 Guide rail The guide rail is used for optimizing the movement of chain drive system And it also prevents the chain from contacting each other when the chain is loose and reduces the chain wear The guide rail is made of plastic nylon Teflon etc The guide rail is specially required when the distance between two spokes is too great It pushes the...

Page 70: ...02 32 Screw plug Oil seal Timing gear case cover 5 Timing gear case cover Timing gear case cover TGCC ...

Page 71: ...al and screw plug on the timing gear case cover Do not touch the inner lip of crankshaft front seal Be careful not to damage the screw thread when removing the lock pin to release the chain tensioner Be careful not to damage the O ring when installing the screw plug A671 997 01 46 Crankshaft front seal Location of chain tensioner screw plug ...

Page 72: ...02 34 Oil pan sassembly 8 OIL PAN The oil pan in D20DTR engine improves the NVH Especially the oil draining is much easier than before Components ...

Page 73: ...ing the irregular speed of crankshaft due to unbalanced combustion Improving the power train NVH Improving the driving performance Reducing the clutch noise by using ball bearing Improving the durability of DMF by using strong arch spring 2 Layout Spring guide Drive plate Primary cover Primary flywheel Internal external ring Secondary flywheel Ring gear ...

Page 74: ...ansaxle by absorbing the impact 3 Operation Compensating the irregular operation of engine The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more less pulsation absorbing effect Transaxle protection function Reduces the torsional vibration to powertrain transaxle by re...

Page 75: ...ch range Stable revolution of the primary and secondary wheel by using planetary gear Works as auxiliary damper against spring changes Less heat generation due to no direct friction against spring surface Plastic material is covered on the spring outer surface Increased durability by using plastic bushing extends the lifetime of grease 6 Drive Plate Drive plate receives the power from the start mo...

Page 76: ...02 38 10 PISTON CRANKSHAFT CYLINDER BLOCK The crankshaft and the cylinder block convert the compression pressure to the rotating energy Components Cylinder block Piston Connecting rod Crankshaft ...

Page 77: ...and snap ring The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy 2 Layout 1 ring Oil ring Snap ring 2 ring Material B2 Skirt coating MoS2 Piston cooling gallery for connecting rod Wide bawl type CR 16 5 Cooling jet ...

Page 78: ...inder bore and prevents the leaked combustion gas from 1 ring from leaking into the crank chamber Oil ring Scrapes the engine oil on the cylinder bore Piston pin Connects the piston the connecting rod and transfers the linear movement of piston to connecting rod to convert it to rotating energy Snap pin Locks the piston pin 4 Assembling the piston Install the piston rings with the Y mark on the ri...

Page 79: ...Engine Piston Cylinder bore Part NO Marking NO D20DTF 671 030 06 17 671 037 07 01 A A 671 037 08 01 X X 671 037 09 01 B B 671 037 10 01 5 671 037 11 01 10 Selecting piston oversize Top of piston Top of cylinder block ...

Page 80: ...he rotating movement of crankshaft The big end is connected to connecting rod bearing and the crank pin journal and the small end is connected to the piston pin 2 Components Piston pin bush Connecting rod Connecting lower bearing Connecting rod cap Connecting rod cap bolt Connecting rod upper bearing ...

Page 81: ... 815 0 063 2 Y 1 808 Y 1 809 0 016 54 614 1 812 1 812 50 960 0 062 3 B 1 812 R 1 806 0 015 1 816 1 809 0 061 Min 0 015 Max 0 063 3 Selection of crankshaft pin journal bearing The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections Three sets in the table below have nearly same oil clearance 0 015 0 063 mm of bearing Identification Coloe mark on bearing side surface Oil c...

Page 82: ... is installed on the cylinder block 2 Arrangement Crankshaft main bearing upper Crankshaft main bearing upper Upper thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower Lower thrust bearing Crank pin journal Main journal ...

Page 83: ...d 66 513 66 519 3 Selection of crankshaft main bearing Mark Color Thickness of main bearing mm V Violet 0 030 0 025 W White 0 025 0 020 R Red 0 020 0 015 Y Yellow 0 015 0 010 B Blue 0 010 0 005 2 25 2 25 2 25 2 25 2 25 Bottom of cylinder block Selection of upper main bearing Mating surface of crankshaft sprocket Selection of lower main bearing ...

Page 84: ...ck 1 Overview The major dimensions in D20DTR are similar to D20DTR engine It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation 2 Layout Right side Right side Expansion plug Screw plug ...

Page 85: ...02 47 0000 00 Left side Expansion plug 3 Features For simple manufacturing the crankcase blow by gas passage and the oil return hole are made by casting on the cylinder block ...

Page 86: ... from cylinder head to inlet port of water pump is integrated in cylinder head The engine oil from oil pump is supplied to the main oil gallery through oil channel oil filter module and cross bore in cylinder block without using external pipes This oil is supplied to main bearing cylinder head and MBU And it is sprayed to the chain through the chain tensioner connected to cross bore Crankcase cros...

Page 87: ...ure 1800 bar High pressure fuel pump Type Eccentric cam Plunger type Operating type Gear driven type Normal operating temperature 40 125 C Operating pressure 1800 bar Operating temperature 30 120 C Low pressure fuel pump Type Vane type Gear ratio pump engine 0 5 1 Pressure 6 bar Fuel tank Capacity 75 L Material Steel Fuel sender Single sender type Change interval EU every 40 000 km GEN every 45 00...

Page 88: ...ystem Wash your hands and do not wear working gloves 1 2 3 Follow the below procedures before starting service works for fuel system If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in this manual At this point thoroughly clean the related area in engine compartment 4 Clean the engine com...

Page 89: ...copper washer on injector should be replaced with new one The injector holder bolt should be tightened to specified tightening torque as well If not the injection point may be deviated from correct position and it may cause engine disorder Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed 6 To supply the fuel to...

Page 90: ...k the low pressure and high pressure fuel systems before removing the components To run the system properly the electric system must be intact but for the DI engine the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device 2 Hydraulic system ...

Page 91: ...of injector Excessive injector backleak Occurs when the injector control valve is not sealed due to the entry of the foreign materials Example Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector ...

Page 92: ...ssure flow Faulty fuel supply line or damaged or worn pump causes the lack of flow pressure and flow volume Example Air in fuel supply line Excessive load on fuel supply line 400 mBar Burned out and mechanical worn pump High temperature of fuel supply 85 ...

Page 93: ...re Device for low pressure 2 Pre check Check tighten fuel supply line Check fuel level in fuel tank Check air in fuel supply line bubble in fuel supply line or fuel Check fuel supply line for leaks low pressure and high pressure Check that specified fuel is used Check fuel filter for contamination ...

Page 94: ...cedure If several DTCs are output simultaneously check the electric wiring for open or short circuit Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities Carry out the high pressure fuel system check ...

Page 95: ...03 11 2210 01 4 Fuel System Check Procedure ...

Page 96: ...connector and then IMV connector 1 Connect the pressure tester to the fuel rail pressure sensor connector 2 Crank the engine 2 times for 5 seconds 3 Read the highest pressure value displayed on the tester display If the highest pressure value is 1 050 bar or less refer to the section Fuel System Check Process ...

Page 97: ...utton on the tester to check if the message TEST is displayed If the button is pressed again at 4 seconds after starting engine cranking the highest pressure is displayed on the tester 1 2 The fuel rail pressure value can be checked using a diagnostic device ...

Page 98: ... low pressure test and clean it thoroughly to prevent foreign materials from entering 1 2 Disconnect the key connector for fuel filter connection and connect both connectors to the fuel filter and hose 3 Start the engine and check visually for clogged low pressure fuel system excessive air or air entry If the fuel flow is not sufficient or air is in the fuel repair the leak area 4 5 ...

Page 99: ...ector prevent air entry to the low pressure line 2 Disconnect the IMV connector of the high pressure pump and then fuel pressure sensor connector 3 The connector of the injector can be easily contaminated Always keep it clean Crank the engine 2 times for 5 seconds Check the time for flow if injector backleak and confirm that it is within the specified range 4 5 If the value is out of the specified...

Page 100: ...e hose of the container for measuring backleak to the return nipple of the injector Start the engine again and let the engine idle for 30 seconds Perform backleak test of fuel system with a diagnostic device after 30 seconds 3 4 5 This test consists of 4 cycles and the engine rpm reaches 3 500 rpm for 18 seconds in each cycle Check the amount of backleak collected into the container and confirm th...

Page 101: ... rail to the fuel rail for test 3 Disconnect the return hose for HP pump and connect the clear hose and connect its the other end to the return port of the fuel rail for test 4 Connect the digital tester connector to the sensor connector of the fuel rail for test Crank the engine 2 times for 5 seconds after removing the IMV connector and fuel rail pressure sensor connector Read the pressure value ...

Page 102: ...ed to protect the system It reduces the driving force restricts the engine speed rpm and stops engine operation Refer to Diagnosis section in this manual Engine CHECK Warning Lamp 3 The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or major electronic systems of the engine are not working properly As a result the engine s power output may decrease or the engine may sta...

Page 103: ...ains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The below figure shows the clearance between internal operating elements The core elements of fuel system has very ...

Page 104: ...n fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high sp...

Page 105: ...ne low pressure line which supplies low pressure fuel to the low pressure pump including high pressure pump common rail which distributes and accumulates the high pressurized fuel from the fuel pump high pressure line which connected to the injector and the engine control unit ECU which calculates the accelerator pedal position and controls the overall performance of vehicle based on the input sig...

Page 106: ...Engine ECU D20DTR Engine control by various signals Fuel tank Fuel metering by sender HFM sensor Measuring intake air mass and temperature Crankshaft position sensor Measuring engine rpm Injector C3I Pre injection main injection after injection by signals from ECU Camshaft position sensor Determining injection order ...

Page 107: ...ure Distributing the fuel to injectors Fuel filter assembly Supplying clean fuel fuel heating water separation by priming pump Plunger type HP pump 1 800 bar Vane type LP pump 6 bar T MAP sensor Measuring booster pressure and temperature High pressure pump Generating high pressurized fuel and supplying it according to engine rpm required volume required pressure ...

Page 108: ...y the injectors according to the injection signals The injection method is the same with the conventional method Fuel return by backleak which operates the needle valve The major difference is that the fuel return line is connected to the fuel filter inlet port not the HP pump venturi The pressure from the high pressure pump is increased to 1 800 bar from 1 600 bar and the pump is now installed to...

Page 109: ...03 25 2210 01 3 Input Output devices Refer to Chapter Engine Control ...

Page 110: ...accelerator pedal depressed driver s will by receiving the electrical signals from the accelerator pedal sensor The mass air flow sensor detects the volume of intake air and sends the value to the ECU The major function of the ECU is controlling air fuel ratio to reduce the emission level EGR valve control by detecting instantaneous air flow change with the signals from the mass air flow sensor Al...

Page 111: ...Specification Air cleaner element Filter type Dry filter element Initial resistance Max 300 mmAq Service interval EU Clean or change every 20 000 km GEN Clean or change every 15 000 km Air cleaner assembly Operating temperature 30 100 C Intercooler Core material Aluminum Core size 614W x 192H x 30T Tank material Plastic Molding Efficiency 80 ...

Page 112: ...ing the intake hoses and pipes which were disconnected to check the system or replace the air cleaner If the intake system is free of any faults check the EGR and PCV oil separator connected to the intake system The figure may be different from the actual engine Therefore read thoroughly below before replacing the parts 2 Abnormal Noise Caused by Poor Tightness of Intake System When the DI engine ...

Page 113: ...ke system is an open circuit system Therefore any malfunction may occur due to dust and dirt Most of the connections consist of hoses so the system cannot withstand high temperature and pressure Also it can be deformed or loosened easily because it is a clamp mounting system Thus when checking the engine basic inspections such as tightened status check and visual inspection for hose etc should be ...

Page 114: ...r entering to the engine when the ignition switch is turned off Because of this the shape of the intake manifold has been changed and improved HFM sensor is newly adopted to control the intake air volume more precisely 2 COMPONENT 2330 01 Intercooler assembly 2313 15 HFM sensor HFM sensor version 6 For more information refer to Chapter Engine Control 2313 01 Air cleaner assembly ...

Page 115: ...ly in accordance with the engine load and rpm For more information refer to Chapter Engine Control 1719 01 Intake manifold Passage for variable swirl valve and for intake air 1719 16 Electric throttle body For more information refer to Chapter Engine Control ...

Page 116: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM For more information refer to Chapter Engine Control ...

Page 117: ...04 9 1719 00 4 OPERATING PROCESS Work Flow ...

Page 118: ...eates the bowl type squish 2 Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal ...

Page 119: ...efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are dramat...

Page 120: ...05 3 1729 01 1 TROUBLESHOOTING 1 Work Flow ...

Page 121: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 122: ...em purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion 2 LAYOUT Exhaust front pipe assembly Muffler assembly Exhaust tail pipe assembly For more information refer to Chapter Engine Control ...

Page 123: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 124: ... 1 SPECIFICATION Unit Description Specification Turbocharger Max expansion coefficient 4 0 Max turbine speed 226 000rpm Max temperature of turbine housing 790 Weight 6 5kg E VGT actuator Operation duty cycle 250Hz ...

Page 125: ...nute allowing oil to circulate to the turbocharger after the replacement When the engine is stopped abruptly after driving at high speed the turbocharger continues to rotate in condition where the oil pressure is at 0 In such condition an oil film between the journal bearing and the housing shaft journal section gets broken and this causes abrasion of the journal bearing due to the rapid contact T...

Page 126: ...uling the turbocharger Oil Leakage Followings are the reasons for oil leakage condition Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and the rotation speed of turbine wheel Please note this is not a turbocharger problem Oil Drain Pipe Defect In case where oil flow from the turbocharger sensor housing to the crank case is not smooth wou...

Page 127: ...or section as oil pressure within the center housing gets higher than pressure within the compressor housing Overuse of engine break especially in low gear in down hill makes significantly low exhaust gas energy compared to the time where great amount of air is required during idling conditions of the engine Therefore amount of air in the compressor inlet increases but the turbocharge pressure is ...

Page 128: ...erstand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects In case where oil pan oil pipe has been contaminated oil filter is defected and where adhesive of gaskets has been contaminated into the oil line 1 ...

Page 129: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 130: ...06 9 1914 01 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 131: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 132: ...damages as well as checking the condition of connections between pipes In case where the noise of engine is louder than usual there is possibility of dampness in the areas related with air cleaner and engine or engine block and turbocharger And it could affect the smooth supply of engine oil and discharge Check for damp condition in exhaust gas when there is sign of thermal discoloration or discha...

Page 133: ...06 12 2 Work Flow for Troubleshooting ...

Page 134: ...06 13 1914 01 ...

Page 135: ...06 14 ...

Page 136: ...06 15 1914 01 ...

Page 137: ...06 16 ...

Page 138: ...s the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger 1 Overview Diffuser With the meaning of spreading out it is a device that transforms fluid s speed energy into the pressure energy by enlarging the fluid s passage to slow down the flow The E VGT system installed to the D20DTR engine variably controls the passages of the turbine housing to regul...

Page 139: ...F system 1 1 Performance for EURO V Has a faster response time than the conventional vacuum actuator 2 Improved low speed torque high speed power and fuel economy Improved acceleration performance with rapid response time of vane 2 Features Features Benefits Folding and unfolding of the vane is controlled electrically Easy to get low speed air volume Rapid response time Electric control Improved l...

Page 140: ...D20DTR E VGT duty control Accelerator pedal position sensor Transfers driver s will to accelerate to ECU Atmospheric pressure RPM signal HFM sensor Improves the engine power Coolant temperature sensor Operates the VGT according to engine warm up For detailed information about the control logic refer to Chapter Engine Control ...

Page 141: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 142: ...as and running the turbine quickly and powerfully Therefore as VGT can intake more air than normal turbocharger it can give the benefit of the increased output even in a low speed zone Turbocharger lag The turbocharger is at idle speed when there is no load or it is in the normal driving condition During this period the amount of exhaust gas passing through the turbine is not enough to turn the co...

Page 143: ...dant exhaust gas can deliver a more increased energy to the compressor The output will increase in submission to the increase of intake air volume Control range Turbocharger driving mechanism Control method Effect Improved performance At high speed Expands the flow passage for the exhaust gas by unfolding the vanes The flow rate is increased due to the expanded passage Increased turbine impeller s...

Page 144: ...ibed gear Capacity 63 L at 4 000 rpm Relief pressure 5 8 bar 0 3 bar Oil filter Type Full flow Paper element Engine oil Specified oil SAE 5W30 approved by MB SHEET 229 51 Capacity L Min 4 5 L Max 6 0 L Service interval Change every 15 000 km or 12 months But shorten the service interval under severe condition Oil injection nozzle Type Piston Operating pressure 1 5bar Closing pressure 1 0bar Oil fl...

Page 145: ...ficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary 2 Replenishment If the level gets to the lower point open the filler cap on top of the cylinder block and add the genuine oil without exceeding the level of the upper mark Recheck the oil level after 5 minutes Regularly check the engine oil level and add Ssangyong genuine engine oil if ne...

Page 146: ...In other words it creates an oil film on each sliding surface to convert solid friction to liquid friction in order to minimize wear and prevent temperature increasing on the friction part For the D20DTF engine with no oil pressure switch the engine ECU receives the low engine oil level signal from the oil level sensor and communicates with the instrument cluster through the CAN communication to t...

Page 147: ...n provide sufficient flow rate of the engine oil and effective cooling 3 Sealing It helps to seal the space between the pistons and the cylinder walls so that compression is more effective and power is not lost during combustion 4 Anti corrosion As a corrosion inhibitor oil coats internal engine parts to prevent surface rust on the inside of the engine which can be caused by blow by products and w...

Page 148: ...cooling capacity over 68 000 kcal h Antifreeze Type SYC1025 Long life coolant Mixing ratio water antifreeze 50 50 Cooling fan module Type Electric Capacity Ø472 x 400W x 5B Control type PWM type Coolant reservoir Capacity over 1 5 L Circulation Closed roof type Pressure cap Screw type 1 4bar Vacuum valve Screw type 1 4bar Thermostat Type Wax pallet type Opening temperature 90 C Fully open temperat...

Page 149: ... Improper coolant mixture ratio Kinked coolant hose Add coolant Check the coolant concentration Anti freeze Repair or replace the hose Defective thermostat Defective water pump Defective radiator Defective coolant auxiliary tank or tank cap Change the thermostat Change the water pump Change the radiator Change the coolant auxiliary tank or tank cap Cracks on the cylinder block or cylinder head Clo...

Page 150: ... MAX and MIN mark on the coolant reservoir Check the coolant level If the level is below the MIN mark immediately add coolant 1 2 Scalding hot coolant and steam could be blown out under pressure which could cause serious injury Never remove the coolant reservoir cap when the engine and radiator are hot Avoid any direct contact of the coolant to the painted body of the vehicle MAX MIN ...

Page 151: ...n Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank Connect the tester to the tank filler and apply pressure 1 4 bar Check all the coolant hoses pipes and connections for leaks when the pressure of the tester drops and replace or tighten if necessary 2 3 4 3 Thermostat Immerse the thermostat into the water Heat the water and check the valve opening...

Page 152: ...se burns by hot steam or water To open the coolant reservoir cap wrap the cap with a wet towel or thick cloth after the engine is cooled down sufficiently If cool water is added to the heated engine the engine or radiator can be deformed The anti freeze in the coolant can damage the painted surface so avoid the contact of the coolant to the painted body The anti freeze and water should be mixed in...

Page 153: ...en at 100 and lets the coolant flow to the radiator to maintain the engine temperature Water pump The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine Coolant reservoir Long life coolant is used 1 SYSTEM DESCRIPTION 1 Overview Water pump Impeller vane Sealing ...

Page 154: ...xchange heat with the radiator core fin Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core Coolant temperature sensor Measures the coolant temperature and sends the result to the engine ECU ...

Page 155: ...CATION Alternator Crankshaft pulley Alternator pulley 1 2 94 Normal output idling 2200 rpm 70 120 A Regulator voltage 14 6 V Brush Length 12 5 mm Wear limit 7 mm Battery Type MF Capacity 90 AH Unit Description Specification ...

Page 156: ...gear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measur...

Page 157: ...attery Replace the battery Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace the alternator Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace the ignition switch Defective ground of alternator circuit Repa...

Page 158: ...09 6 3 Checking Battery ...

Page 159: ...ixing current load capacity and time and varying voltage Determine battery capacity based on the amount of voltage drop when discharging a fixed load capacity 120 A for 5 seconds Connect the tester to the battery and read the display while applying a load for 5 seconds How to read display Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a batte...

Page 160: ...towing hook 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle whi...

Page 161: ...the terminals are corroded clean them with a wire brush or sandpapers Always disconnect the battery cables with the ignition key removed When disconnecting the battery cables with the ignition key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the...

Page 162: ...supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change 2 System Layout Locations Battery It converts the chemical energy to the electrical energy a...

Page 163: ...09 11 1451 01 2 OPERATING PROCESS 1 Charging Flow ...

Page 164: ...tery charger to the cold battery the amount of current the battery can accept initially is very small As the battery gets warmer it can accept more current Charging capacity Charging a battery with a low capacity charger takes longer time than charging with a high capacity charger Charging status Charging a fully depleted battery takes twice or more as long as charging a half depleted battery Sinc...

Page 165: ...09 13 1451 01 3 CIRCUIT DIAGRAM ...

Page 166: ...ION Description Specification Glow plug Rated voltage 12 V Maximum temperature 1100 C Operating temperature 1080 1100 C Glow plug control unit EMS operating voltage 6 16 V Operating temperature 40 C 110 C Dark current Max 1 mA ...

Page 167: ...g resistor air heater is used to heat the intake air This enables the diesel fuel to be ignited in low temperature condition The ECU receives the information such as engine rpm coolant temperature engine torque etc through CAN communication during pre heating process and the pre heating control unit controls the pre heating heating during cranking and post heating by the PWM control Glow plug Glow...

Page 168: ...10 5 1413 00 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 169: ...10 6 3 Circuit Diagram ...

Page 170: ...ture of the glow plug to 1000 by the pre heating request from the engine ECU before starting Pre heating Coolant temperature 30 C 25 C 20 C 10 C 5 C 0 C 20 C Operating time 28 s 25 s 15 s 5 s 2 s 2 s 0 s Operating conditions IGN ON B below 15 2 V Stop conditions Time out IGN OFF when engine cranking If the input power VB is 11 5 V or less the GCU supplies the battery power for arrival time T1 If t...

Page 171: ...step 1 At cranking The step 3 is started after the step 2 Post glow Step 4 The post heating is for reducing HC CO after the engine is started If the time for post heating exceeds 180 sec the GCU unit cuts off the power to each glow plug even if there is pre heating request from the engine ECU Post heating Operating time approx 20 C 10 C 0 C 20 C 80 C Operating time approx 100 s 50 s 25 s 10 s 10 s...

Page 172: ...Description Specification Capacity 12 V 2 2 kW Engagement Meshed type Rotating direction Clockwise Pinion gear manufacturing Cooled forging Solenoid operating voltage Max 8 V Weight 2 5 kg Bracket manufacturing Aluminum die casting ...

Page 173: ...switch or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replace Loose corroded or damaged battery cable Repair or replace Faulty starter Starter does not stop Faulty starter Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring gear Replace ...

Page 174: ...ne with rotational power by converting the electric energy to the mechanical energy When the engine is cranking the pinion gear meshes with the ring gear If the ring gear overruns the pinion gear clutch overruns to protect the pinion gear 2 OPERATING PROCESS 1 System Layout ...

Page 175: ...11 6 2 Circuit Diagram ...

Page 176: ... vehicle speed must be greater than 36 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Page 177: ...den change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roads yy Do not use in heavy traffic yy Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries The described speed value may vary slightly depending on the road conditions ...

Page 178: ...ne switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an accelerator pedal intervention during the cruise control running 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could result in collision...

Page 179: ...ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 180: ...ruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running Push down the DECEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control syst...

Page 181: ...oward the cruise control lever when the current vehicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 182: ...e cruise control When the brake pedal is depressed When the cruising speed is downed less than 38 km h When the OFF switch is operated by pulling the cruise control lever Type A or by pushing the ON OFF switch of the cruise control lever Type B When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be op...

Page 183: ... Dealer for diagnosis of the cruise control system Abnormal changes of the gear selector lever can damage the yyengine Do not move the gear shift lever to Neutral while driving at the set speed Automatic transmission damage may result The speed that has been set may not be maintained on uphill yyor downhill slopes The speed may drop to less than the set speed on a steep uphill yygrade The accelera...

Page 184: ... EGR valve Motor EGR response time 50 ms Driven by DC motor Valve EGR gas flow rate 120 kg h Cooling capacity 8 3 kW or more Cooling fin type Wavy fin Cooler type U shaped E EGR bypass valve Solenoid valve Drivien by Vacuum Solenoid valve E EGR cooler ...

Page 185: ...pacity reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decresed Benefits of E EGR valve Improved accuracy and response through electr...

Page 186: ...ore warming up the engine 2 Location and Components HFM sensor Used as a main map value to control the EGR The coolant temperature engine rpm engine load intake air temperature HFM decreased at 60 C or more atmospheric pressure atmospheric pressure sensor altitude compensation are used as auxiliary map values EGR pipe Transports the exhaust gas from the EGR cooler and EGR bypass valve to the intak...

Page 187: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 188: ...13 7 1793 00 2 Input Output Devices ...

Page 189: ...he intake air temperature The engine ECU calculates the EGR amount by adding main map value intake air volume and auxiliary map value and directly drives the solenoid valve in the E EGR to regulate the opening extent of the EGR valve and sends the feedback to the potentiometer 1 Operating conditions Intake air temperature between 10 and 50 Atmospheric pressure 0 92 bar or more Engine coolant tempe...

Page 190: ......

Page 191: ...IFICATION Emission Regulation Euro V Front Area 154 06 Size DOC 158 X 124 X 78L DPF 158 X 124 X 254L CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 5 1L Material of Filter SiC ...

Page 192: ...turn off the engine while the vehicle is running Do not shift the gear selector lever to neutral when going downhill Do not use improper engine oil or fuel additives Do not drive for a long time when the warning lamp is illuminated Make sure no flammable material such as dry grass or tissue paper contacts with the catalyst filter while the vehicle is parked For the vehicles used in urban traffic d...

Page 193: ...the exhaust gas The driver may not feel any particular difference from the vehicle Overload of CDPF warning lamp blinking 3 Warning Lamp Related to CDPF CDPF regeneration process warning lamp NOT illuminated If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process the soot is continuously accumulated in the CDPF When this condit...

Page 194: ...sive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp comes on and the engine power is decreased to protect the system To solve this problem blow soot between the engine and exhaust system several times and erase the related DTC Then check if the same DTC is regenerated again If so check...

Page 195: ...h the oxidation process of CO and HC And the DPF Diesel Particulate Filter collects PM Particle Matter and is regenerated to reduce the quantity of particulates HC and CO But there is a limitation in reducing the emission of exhaust gas for each system so the CDPF which combines these two system is applied ...

Page 196: ...ce between before and after the CDPF Engine ECU DCM 3 7 Post injection Throttle valve Regulates the rate of air intake CDPF DOC DPF Front temperature sensor Protects the turbocharger Rear temperature sensor Measures the temperature of fuel combustion 2 COMPONENT For details refer to section Engine Control ...

Page 197: ...emperature exceeds 600 the life of CDPF can be reduced So the amount of fuel post injection is decreased If the temperature drops under 600 the rate of regeneration can be decreased So the amount of fuel post injection is increased Differential pressure sensor This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF Electric throttle va...

Page 198: ...s increased and the post injection is started for regeneration The amount of fuel post injection is controlled by the exhaust gas temperature measured by the rear temperature sensor If the temperature is less than 600 the amount of post injection is increased to increase the regeneration temperature Otherwise the fuel injection amount is decreased or the fuel is not injected When the engine is run...

Page 199: ...temperature of DOC This sensor is located at the rear side of DOC and monitors the overheating of CDPF and post injection volume Engine ECU D20DTR Differential pressure sensor Measures the difference between inlet and outlet pressures of CDPF If the difference is higher than the specified value when collecting the PM this makes the post injection for forced recycling of PM T MAP sensor Intake air ...

Page 200: ...mperature and burns the collected PM at approx 600 C Oxidation DOC When the exhaust gas enters into the CDPF assembly its CO HC and PM are reduced by the redox reaction of the DOC The remaining PM is filtered and collected in CDPF and the temperature of the exhaust gas is increased to between 450 and 500 C 5 OPERATING PROCESS Configuration and principle of operation The exhaust gas passed through ...

Page 201: ... EGT sensor detects whether the DOC can burn oxidize the post injected fuel or not and sends the signal to the ECU to maintain the DOC operating temperature between 300 and 500 The DOC reduces CO and HC of the exhaust gas by redox reaction and also reduces small amount of PM 1 Oxygen adheres to the catalyst materials Less than 180 2 CO and HC are oxidized by the catalyst materials More than 180 ...

Page 202: ...s to the inlet of a channel it is released from the outlet of the adjacent channel through the porous wall because of the closed outlet of the first channel and the PM is collected in the first channel Collecting PM of CDPF Normally when the driving distance becomes approx 600 to 1 200 km enough amount of soot to be burned is filtered and accumulated in the CDPF The ECU increases the amount of fue...

Page 203: ...xhaust temperature intake air mass flow booster pressure etc The regeneration is started when the amount of the collected PM is 28 g or more The ECU commands post injection to increase the temperature of CDPF to 600 When the amount of the collected PM is not enough The DPF works as a filter 1 When enough amount of PM is collected The ECU commands post injection and increase the exhaust gas tempera...

Page 204: ...14 16 4 Fuel Injection During CDPF Regeneration ...

Page 205: ...14 17 2412 02 6 ELECTRIC CIRCUIT DIAGRAM ...

Page 206: ... 0 Full Open to 78 Close Engine torque Nm varies by engine conditions Injection time ms 3 to 5ms Battery voltage V 13 5 V to 14 1 V Accelerator pedal position 1 V 0 4 to 4 8V Accelerator pedal position 2 V 0 2 to 2 4 V Throttle position 1 V 0 3 to 4 6 V Throttle position 2 V 0 3 to 4 6 V Oxygen sensor mV 0 to 5 V A C compressor switch 1 ON 0 OFF Full load 1 ON 0 OFF Gear selection A T 1 ON 0 OFF K...

Page 207: ... 4 Glow plug Differential pressure sensor Camshaft position sensor 1 MAJOR COMPONENTS Rear EGT sensor Oxygen sensor Front EGT sensor HFM air mass temperature Injector C3I Variable swirl valve actuator IMV ...

Page 208: ... rail pressure sensor EGR valve Fuel temperature sensor Electric throttle body Knock sensor 2 ea Coolant temperature sensor T MAP sensor D20DTR ECU E VGT actuator Water sensor GCU Preglow control unit E EGR bypass valve ...

Page 209: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 210: ...ition sensor Camshaft position sensor Coolant temperature sensor Exhaust gas temperature sensor HFM sensor Oxygen sensor T MAP sensor Crankshaft position sensor Accelerator pedal sensor Throttle position sensor Knock sensor Auto cruise switch Rear right wheel speed without ABS Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal Water sensor ...

Page 211: ...ut CAN E EGR cooler bypass valve Instrument cluster TCU Self diagnosis PTC heater Cooling fan E EGR valve Variable swirl valve E VGT actuator IMV valve A C compressor Injector Throttle position sensor Glow plug unit ABS ESP unit GCU ...

Page 212: ...ectives Operating temperature range of ECU is normally 40 to 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circu...

Page 213: ...ot 1 Reduces PM by injecting before main injection After PM control Pilot 2 Reduces NOx and noise by shortening main injection delay due to flammability Post 1 Reduces PM by enabling fuel activation Pre Controls NOx emission level Combustion noise and Stable idle Post 2 Activates CDPF by increasing exhaust gas temperature and supplying reduction material Pilot injection Multi injection ...

Page 214: ...ted fuel volume is changed and stopped according to the coolant temperature and intake air volume Pilot injection is much earlier than main injection due to higher engine rpm Too small injection volume insufficient injection pressure insufficient fuel injection volume in main injection engine braking System failure fuel system engine control system Pilot injection Main injection Combustion pressur...

Page 215: ... etc d Post Injection Injection after main injection Consists of After injection Post 1 Post 2 injection Post injection reduces PM and smoke from exhaust gas No actual output is generated during these injections instead fuel is injected to the unburned gas after main injection to enable fuel activation The PM amount in the emission and smoke can be reduced through these processes Only up to 5 type...

Page 216: ...el pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined according to injected fuel and coolant temperature Open loop determines the ...

Page 217: ... cylinder temperature when EGR ratio increases 5 Main injection timing control The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow The elements are A first correction is made according to the air and coolant temperatures This correction makes it possible to adapt the timing to the operating temperature of the engine When the engine is...

Page 218: ...he ESP system the antagonistic torque engine brake transmitted to the drive wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking The system thus chooses the greater of these 2 values main flow pilot flow in order to prevent any loss of control of the vehicle during a sharp deceleration As soon as the injected fuel becomes higher than the fu...

Page 219: ...hich can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and chooses the smaller of th...

Page 220: ...uced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the fault the system acti...

Page 221: ...e engine speed and the coolant temperature G Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The difference between these two instantaneous speeds is then calculated Finally th...

Page 222: ...bration and noise can be occur for a while This is because the fuel pressure is increased instantaneously and the exact injection value is not input so that the exact engine vibration timing can be detected 6 MDP Learning Control A MDP Learning When the pulse value that the injector starts injection is measured it is called minimum drive pulse MDP Through MDP controls can correct pilot injections ...

Page 223: ... 500 rpm Fuel temperature 0 Fuel temperature 80 Learning 2 times for each cylinder every 5 seconds 2 times for each cylinder every 5 seconds If MDP learning is not properly performed engine vibration and injection could be occurred MDP learning should be performed after replacing ECU reprogramming and replacing injector D Injector characteristic curve for rail pressure ...

Page 224: ...ablish the background noise level of the knocking control signal for each cylinder This window must therefore be positioned at a moment when there cannot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection 1...

Page 225: ...gnaled is a percentage of the maximum possible value of the ratio Because of the severity of the recovery process engine shut down the etection must be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too much Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and...

Page 226: ...trong swirl there are two passages in intake manifold and one of them has the valve to open and close the passage When the valve closes the passage the air flow through the another passage will be faster and the strong swirl will be generated by the internal structure of the passage This swirl makes the better mixture of air and fuel eventually the combustion efficiency in combustion chamber could...

Page 227: ...15 24 B Input Output for variable swirl valve ...

Page 228: ...rol In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal flow and the tangential port generates ...

Page 229: ...ciency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are dramatical...

Page 230: ...y reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decresed B Components E EGR cooler Accelerator pedal module D20DTR ECU Coolant temp...

Page 231: ...15 28 C Input Output of E EGR system ...

Page 232: ...ine rpm Used as the signal for determining EGR operating range Coolant temperature When the coolant temperature is low NOx is decreased but PM could be increased So to reduce PM decrease EGR ratio when the coolant temperature is low Intake air mass and temperature HFM sensor measures the intake air mass to calculate the actual EGR volume If the air mass is larger than programmed value in map EGR r...

Page 233: ...gly the concentration of NOx is decreased The point with highest NOx is immediately after TDC As EGR temperature goes up the concentration of NOx will be higher Thus it is necessary to cool down the exhaust gas However during engine cooled it may cause large amount of PM To prevent this the exhaust gas is bypassed the EGR cooler ...

Page 234: ...g The newly adopted DC motor actuator E actuator controls the E VGT system more precisely and faster To get the high operating power from turbine the ECU reduces the exhaust gas passage In low speed range and increases it in high speed range B Components HFM intake air temperature Front EGT sensor E VGT actuator Accelerator pedal module Crankshaft position sensor Oxygen sensor T MAP sensor Coolant...

Page 235: ...15 32 C Input Output for E VGT system ...

Page 236: ...arger operation and the boost temperature is used for calculating the precise density E VGT provides higher engine power with faster reaction speed compared to conventional VGT Operating wave Vane Control Low speed range In low speed range retract the vane to increase boost pressure The vane has low duty and the unison ring moves to retract the vane in weak PWM signal High speed range The unison r...

Page 237: ... wide band oxygen sensor is used for this kind of engine and this sensor is a little different from the one that used for gasoline engine The combustion in diesel engine is controlled by fuel injection volume Therefore the wide band oxygen sensor should be used in diesel engine This sensor measures the air fuel ratio in very wide range and is also called full range oxygen sensor The wide band oxyg...

Page 238: ...15 35 0000 00 C Input Output for oxygen sensor ...

Page 239: ...ons when there is oxygen concentration difference between exhaust gas and atmosphere If a certain voltage is applied to the sensor the movement of oxygen ions occurs regardless of the oxygen density The current generated through this flow of ions is called pumping current IP and the oxygen sensor measures this value ...

Page 240: ... circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools The heat from automatic transmission is also cooled down through the radiator by circulating the oil through the oil pump ECU controls the electric cooling ...

Page 241: ...15 38 C Input Output for cooling fan and A C compressor ...

Page 242: ... ON HI 18 bar Refrigerant pressure HI 105 Coolant temp 115 HI 115 Coolant temp OFF cut A C compressor OFF conditions Coolant temperature below 20 or over 115 Approx 4 seconds after starting the engine Engine rpm below 650 rpm or over 4500 rpm When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 30 kg then ON below 21 4 kg The output voltage from refrigerant p...

Page 243: ... mounted in the heater air outlet and increase the temperature of air to the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required PTC does not operate during engine cranking while the battery voltage is lower than 11 V or during preheating process of glow plugs B Components HFM intake air temperature Coolant temperature sensor PTC heater PTC 2...

Page 244: ... temperature There are three circuits in PTC heater Only one circuit is connected when PTC1 relay is ON and two circuits are connected when PTC2 relay is ON Operation process reaches at a certain temperature high resistance low current less heat radiation temperature down high resistance high current temperature up ...

Page 245: ...re 10 Coolant temperature 15 65 to 60 intake air temperature 10 to 0 Coolant temperature 15 60 intake air temperature 0 to 5 PTC LO ON Stop A C blower switch OFF Defective ambient air temperature sensor including open or short circuit Engine cranking Low battery voltage below 11V During pre glow process glow indicator ON Operation diagram for PTC heater LO step 2 ...

Page 246: ...rated in the key and the engine control unit have the same code When the ignition key with the integrated transponder is turned to the ON position the ECU Engine Control Unit checks the crypto code of the key and if correct allows the vehicle to start the engine For details refer to Chapter Immobilizer B Components Basic components ignition key system D20DTR ECU Immobilizer antenna Instrument clus...

Page 247: ...CU communicate with the immobilizer key to check if it is valid crypto code If it is valid ECU start to control the engine when turning the ignition switch to START position The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again ...

Page 248: ...oot and burn it again so that the amount of PM in the exhaust gas passed through the DOC Diesel Oxidation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxidation Catalyst and DPF Diesel Particulate Filter For details refer to Chapter CDPF B Components Oxygen sensor Front EGT sensor CDPF DOC DPF Rear EGT sensor Differential pressure sen...

Page 249: ...15 46 C Input Output for CDPF control ...

Page 250: ...as detected by the rear temperature sensor If the temperature is below 600 C the amount of fuel injected is increased to raise the temperature If the temperature is over 600 C the amount of fuel injected is decreased or not controlled When the engine is running in low load range the amount of post injection and the amount of intake air are controlled It is to raise the temperature by increasing th...

Page 251: ...lating Eventually this ashes will block the filter Benefit for specified engine oil Minimized the sulfur content of engine oil which reduces the service life Improved fuel economy and emission level of CO2 with high performance and low viscosity Increased service life of engine oil with high resistance to temperature Problems when using unspecified engine oil The service life of filter may be redu...

Page 252: ...15 49 0000 00 3 Input Output for CAN communication ...

Page 253: ... and lubricate the surfaces on initial operation Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever valve train components are removed for service they should be kept in order They should be installed in the same locations and with the same mating surfaces as when ...

Page 254: ...rminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Any time the air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the engine is started ...

Page 255: ...01 5 1113 01 Front View Rear View 2 G23D ENGINE ASSEMBLY ...

Page 256: ...01 6 LH Side View RH Side View ...

Page 257: ...01 7 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 258: ...tributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan NO FUNCTION NO FUNCTION 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate...

Page 259: ... leak by the drippings on the paper Visually check around the suspected component Check around all the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well Dry the area Operate the vehicle for several miles at...

Page 260: ... the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check for the following conditions and correct them as they may cause a leak Repairing the Leak Gaskets The fluid level pressure is too high The crankcase ventilat...

Page 261: ...essure tester A9912 0012B 001 589 76 21 00 and install it into the spark plug hole Crank the engine approx eight revolutions by using the start motor Compare the measurements of compression pressure tester A9912 0012B 001 589 76 21 00 with the specifications Measure the compression pressure of the other cylinders in the same way If measured value is not within the specifications perform the cylind...

Page 262: ...rmissible Pressure Leakage At Whole Engine Max 25 At Valve and Cylinder Head Gasket Max 10 At Piston and Piston Ring Max 20 OT TDC 1 4 UT BDC 180 2 3 Cylinder Number Cylinder Number Cylinder Pressure Leakage Tester Bosch EFAW210A Sun CLT 228 ...

Page 263: ...and adjust the scale of tester Install the connecting hose to spark plug hole Position the piston of No 1 cylinder at TDC by rotating the crankshaft Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable Perform the pressure test ...

Page 264: ...01 14 5 GENERAL DIAGNOSIS ...

Page 265: ...01 15 1113 01 General Diagnosis Cont d ...

Page 266: ...01 16 General Diagnosis Cont d ...

Page 267: ...01 17 1113 01 General Diagnosis Cont d ...

Page 268: ...01 18 General Diagnosis Cont d ...

Page 269: ...01 19 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 270: ...01 20 2 Fastener Tightening Specifications ...

Page 271: ...01 21 1113 01 Fastener Tightening Specifications Cont d ...

Page 272: ...01 22 2 Performance Curve ...

Page 273: ......

Page 274: ...els containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel system Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly earthed Static electricity bu...

Page 275: ...02 4 Temperature VS Resistance ...

Page 276: ...air absorbs from the heated element MAF sensor is located between the air filter and the throttle valve Under high fuel demands the MAF sensor reads a high mass flow condition such as wide open throttle The ECM uses this information to enrich the mixture thus increasing the fuel injector on time to provide the correct amount of fuel When decelerating the mass flow decreases This mass flow change i...

Page 277: ...ratio based on inputs from the ECT sensor and the MAF sensor The ECM stays in open loop until the following conditions are met The O2 has a varying voltage output showing that it is hot enough to operate properly The ECT sensor is above a specified temperature 22 5 C A specific amount of time has elapsed after starting the engine 4 Closed Loop The specific values for the above conditions vary with...

Page 278: ...llowing methods Increasing the fuel injector pulse width Increasing the idle speed rpm Increasing the ignition dwell time 8 Fuel Cut Off Mode No fuel is delivered by the fuel injectors when the ignition is off This prevents dieseling or engine runon Also the fuel is not delivered if there are no reference pulses received from the CKP sensor This prevents flooding ...

Page 279: ...03 3 1713 08 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 280: ...04 3 2420 01 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 281: ...f anything other than unleaded fuel will damage the catalyst in the catalytic converter 1 2 Catalytic Converter Structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith Washer coat operates first and catalytic met...

Page 282: ...mperature CO purification rate becomes the best near the temperature of 450 C and NOx does so near the temperature of 400 to 500 C Purification of Catalytic Converter Adhesion of soluble organic fraction SOF below 180 C Purification of soluble organic fraction SOF over 180 C Chemical reaction formula SOF HC O2 CO2 H2O 2CO O2 2CO2 2C2H6 7O2 4CO2 6H20 By catalytic action of two primary catalytic con...

Page 283: ...alve can decrease NOx 30 to 35 decrease by making temperature of combustion chamber fall by means of exhaust gas re circulation EGR valve is installed on the diesel engine of Musso Korando Istana and Rexton And micro switch is installed together to control EGR valve The setting method of micro switch is identical with the existing one ...

Page 284: ...earing 12 Connecting Rod 13 Piston 14 Oil Spray Piston Crown Area 15 Non Return Valve Crankcase 16 Oil Supply To Chain Tensioner 17 Camshaft 18 Cam Bearing 19 Valve 20 Oil Gallery Supply Oil to Intake Tappet 21 Oil Gallery Supply Oil to Exhaust Tappet 22 Ball φ 8 mm 23 Camshaft Plug 24 Seal 25 Screw Plug 26 Oil Return Gallery Cylinder Head and Crankcase 27 Oil Return Gallery Crankcase 28 End Cover...

Page 285: ...06 3 2110 01 1 GENERAL SPECIFICATIONS ...

Page 286: ...06 4 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 287: ...1 COMPONENT LOCATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 6 Clamp 7 Clamp 8 Bolt M6 2 piece 9 Radiator 10 Lower Radiator Insulator 11 Plate 12 Clip 13 Upper Radiator Insulator 14 Bracket 15 PWM Electric Fan ...

Page 288: ...el The cooling system for this vehicle has no radiator cap or filler neck The coolant is added to the cooling system through the coolant reservoir 2 Radiator This vehicle has a lightweight tube and fin aluminum radiator Plastic tanks are mounted on the upper and the lower sides of the radiator core On vehicles equipped with automatic transaxles the transaxle fluid cooler lines run through the radi...

Page 289: ...stat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits The wax pellet in the thermostat is hermetically sealed in a metal case The wax element of the thermostat expands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the engine coolant temperature increases When the engine coolant...

Page 290: ... a cooling fan motor relay The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C 203 F and at high speed when the coolant temperature reaches 105 C 221 F The ECM will change the cooling fans from high peed to low speed at 100 C 212 F and will turn the cooling fans off at 90 C 194 F A C On The ECM will turn the cooling fans on at low speed when the A C system ...

Page 291: ...C FAN OPERATION 1 Function The PWM Pulse Width Modulation high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise 2 Mounting Location PWM Fan shroud Electric fan PWM unit ...

Page 292: ...ontrols the time of the output voltage to control the fan motor speed independently Internal functions Motor power shutting off function when overcurrent is applied Adverse voltage prevention function Detection function for the motor lock Temperature detecting function The electric fan operates at FULL speed to cool down the PWM unit when the interior temperature of PWM unit is over 120 150 C Comm...

Page 293: ...er engine starting abrupt acceleration and A C refrigerant pressure sensor detecting the followings A C compressor is turned off when the refrigerant pressure is below 2 0 kg cm2 and then is turned on when the refrigerant pressure is over 2 4 kg cm2 A C compressor is turned off when the refrigerant pressure is over 30 kg cm2 and then is turned on when the refrigerant pressure is below 21 4 kg cm2 ...

Page 294: ...07 3 1452 01 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 295: ...07 4 2 Ignition System Cont d ...

Page 296: ...e in a lighter smaller case The battery has three major functions in the electrical system First the battery provides a source of energy for cranking the engine Second the battery acts as a voltage stabilizer for the electrical system Finally the battery can for a limited time provide energy when the electrical demand exceeds the output of the generator 2 Ratings A battery has two ratings 1 a rese...

Page 297: ...erminals clean and tight or a loose battery hold down clamp Mechanical problems in the electrical system such as shorted or pinched wires 3 Charging Time Required The time required to charge a battery will vary depending upon the following factors Size of Battery A Completely discharged large heavy duty battery required more than twice the recharging time as a completely discharged small passenger...

Page 298: ...able in the field Set the battery charger on the high setting 1 2 Continue to charge the battery until the charge current is measurable Battery chargers vary in the amount of voltage and current provided The time required for the battery to accept a measurable charger current at various voltages may be as follows 3 If the charge current is not measurable at the end of the above charging times the ...

Page 299: ... negative terminal of the discharged battery 6 7 Clamp one end of the second cable to the negative terminal of the booster battery Make the final connection to a solid engine ground such as the engine lift bracket at least 450 millimeters 18 inches from the discharged battery Start the engine of the vehicle with the good battery Run the engine at a moderate speed for several minutes Then start the...

Page 300: ...e may be 90 percent and the off time 10 percent 7 Charging System Generators use a new type of regulator that incorporates a diode trio A Delta stator a rectifier bridge and a rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan are used There is no test hole 8 Starter Wound field starter motors have pole pieces arranged around the armature...

Page 301: ...Diagnostic tables will aid in troubleshooting system faults When a fault is traced to a particular component refer to that component section of the service manual The starting system circuit consists of the battery the starter motor the ignition switch and all the related electrical wiring All of these components are connected electrically ...

Page 302: ... vehicle speed must be greater than 36 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Page 303: ...den change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roads yy Do not use in heavy traffic yy Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries The described speed value may vary slightly depending on the road conditions ...

Page 304: ...ne switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an accelerator pedal intervention during the cruise control running 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could result in collision...

Page 305: ...ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 306: ...ruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running Push down the DECEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control syst...

Page 307: ...oward the cruise control lever when the current vehicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 308: ...e cruise control When the brake pedal is depressed When the cruising speed is downed less than 38 km h When the OFF switch is operated by pulling the cruise control lever Type A or by pushing the ON OFF switch of the cruise control lever Type B When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be op...

Page 309: ... Dealer for diagnosis of the cruise control system Abnormal changes of the gear selector lever can damage the yyengine Do not move the gear shift lever to Neutral while driving at the set speed Automatic transmission damage may result The speed that has been set may not be maintained on uphill yyor downhill slopes The speed may drop to less than the set speed on a steep uphill yygrade The accelera...

Page 310: ...09 3 1521 01 1 ENGINE DATA DISPLAY TABLE ...

Page 311: ...09 4 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 312: ...01 2 1 LOCATIONS OF INTERIOR UNITS AND SENSORS ...

Page 313: ...01 3 0000 00 ...

Page 314: ...01 4 2 LOCATION AND COMPARTMENT OF INTERIOR SWITCHES ...

Page 315: ...01 5 0000 00 ...

Page 316: ...01 6 Ambient temperature sensor 3 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT Receiver drier and horn IWE vacuum solenoid valve 4WD on battery tray ...

Page 317: ...01 7 0000 00 Theft deterrent horn under the battery ESP pressure sensor primary secondary ESP ABS HECU Fuse and relay box ...

Page 318: ...01 8 4 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 319: ...01 9 0000 00 2 Components Locator ...

Page 320: ... pins The REKES key coding should be performed with Scan 100 2 Functions of Terminal Pin no 1 Pin no 2 Pin no 3 STICS Pin no 4 Ground Pin no 5 Signal ground Pin no 6 CAN HIGH Pin no 7 Engine ECU Pin no 8 ABS ESP Pin no 9 Air bag Pin no 10 Pin no 11 TCU Pin no 12 Pin no 13 TCCU Pin no 14 CAN LOW Pin no 15 STICS B21 Pin no 16 Battery ...

Page 321: ...nition switch and other lamp switches before disconnecting or connecting the negative battery cable Otherwise semiconductor parts can be damaged Do not drop or appy excessive impact to sensors and relays If a fuse is blown replace it with a fuse which has the correct amperage rating If you use a fuse with higher capacity than the specification the component can be damaged or catch fire ...

Page 322: ...h a lock press it down to the direction in the below figure When checking voltage or continuity of the connector terminal with a circuit tester connect the tester probe to the terminal at the harness side For a sealed type connector connect the probe to the terminal through the hole in the rubber cap of the wiring Take care not to damage the insulation of the wires Insert the probe until it contac...

Page 323: ...of the STICKS As the ICM box is newly installed the following relays are integrated into the ICM box Door lock relay previously installed to STICKS bracket Windshield de icer relay previously installed next to floor on the driver side Turn signal lamp relay previously installed to passenger side fuse relay box PREVIOUS MODEL NEW MODEL Some relays have been integrated into the ICM box ...

Page 324: ...ock relay windshield de icer relay and turn signal lamp relay There are four fuse relay units 2 FUSE RELAY MOUNTING LOCATION 1 In engine compartment Fuse Relay Box InEngine Compartment Interior Fuse Relay Box On The Driver Side RH 2 In vehicle Interior Fuse Relay Box On The Driver Side LH Mounting Location of ICM ...

Page 325: ...ated Control System is almost the same as that of ACTYON in terms of its function and role Due to the removal of tailgate opening switch and rear wiper and washer system the circuit layout is slightly changed compared to ACTYON Door Lock Relay RK STICS REKES key ...

Page 326: ...haracteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 327: ...03 5 8710 01 Rated Load ...

Page 328: ...03 6 Input Signals ...

Page 329: ...ction does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time from switch in...

Page 330: ... Control System is almost the same as that of ACTYON in terms of its function and role Due to the removal of tailgate opening switch and rear wiper and washer system the circuit layout is slightly changed compared to ACTYON Door Lock Relay RK STICS REKES key ...

Page 331: ...automatically according to the vehicle speed or the amount of rain Continuous wipe slow operation Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position Fast Fast interval Slow Slow interval Continuous wipe fast operation MIST AUTO OFF LO HI Front wiper operati...

Page 332: ...hile holding the switch When releasing the switch it returns to the rear wiper operate position Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch OFF the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times after then the washer fluid is sprayed and the wiper sweeps off 3 times again Rear Washer and Wiper The rear washer and the wip...

Page 333: ...0 1 to 0 59 seconds T2 with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 334: ...ch is turned on for more than 0 6 seconds during the wiper operation by INT switch the operation in step 2 is performed When it is turned on for a certain period of time 0 1 to 0 59 seconds the operation in step 1 is performed 3 ...

Page 335: ...r motor relay output gets ON from the time when the rear washer switch is turned on It gets OFF when the rear washer switch is turned off This control is not available while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation 1 2 3 Rear Washer Motor Control ...

Page 336: ...NT switch OFF the washer motor output gets ON for 1 second If the system recognizes the output signal the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second Then the wiper relay output gets OFF after 3 cycles 1 4 Auto Washer and Wiper Switch AFW ...

Page 337: ... washer operation stops and the auto INT operation is activated 2 3 4 5 Priorities in Washer Operations he rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden during the...

Page 338: ...03 16 5 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 339: ...itch is turned to the ON position again from other positions the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal 1 2 Rain sensing unit AUTO light integrated type A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section ...

Page 340: ...t with the ignition switch ON and the auto INT switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 341: ...s increased while the ignition key is in the ON position the wiper switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 1 ...

Page 342: ... key is in ON position and the wiper switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is fixed to IGN the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal The wiper motor runs only when the rain sensor requires the wiper operation 2 ...

Page 343: ...alfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 1 The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 2 ...

Page 344: ...box It rains but the system does not work in the AUTO position Symptom 2 Check whether the multifunction wiper switch is in the AUTO position Check the power to the sensor Check the conditions of the pin 3 Ground and the pin 4 IGN Check the wiper relay for defective Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sens...

Page 345: ...rates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 346: ...f it rains heavy which requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 2 3 Emitter lense Auto light sensor Vertical A...

Page 347: ...itioned to ON Intermittent interval at 0 km h 3 0 5 19 2 seconds Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 60 km h X 60 sec 637 X 4 PULSE 1 41 km h The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis VOLUME calculation Pause time the dur...

Page 348: ...e intermittent time when turning ON IGN 2 switch OFF INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is ON INT switch ON or Washer switch ON The output stops immediately after turning off the switch The output stops immediate...

Page 349: ... The chime buzzer sounds continuously when opening the driver s door while the ignition key is in ignition switch When removing the ignition key or closing the driver s door during chime buzzer operation the buzzer stops This function is not available when the ignition switch is in ON position 1 2 3 PAS buzzer Chime buzzer ...

Page 350: ...ts UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK the system does not output UNL...

Page 351: ...hen the door is closed during the UNLOCK output the UNLOCK output stops immediately When the ignition key is inserted during the output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does not work if ...

Page 352: ...nition key is removed The chime buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 ...

Page 353: ... goes off when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Page 354: ...ignition switch to the OFF position The chime buzzer stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is ON position 1 2 3 4 Chime buzzer Seat Be...

Page 355: ...vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 The warning light blinks and the chime buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on The warning light goes off and the chime buzzer stops when turning of...

Page 356: ... dimming operation The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and the center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remote control key W...

Page 357: ...s opened and goes off when the door is closed The front and center room lamps come on when pressing the room lamp main switch 3 Center Room Lamp If the switch is at the door coupled position the center room lamp comes on when a door is opened The lamp always comes on while the switch is at the other position Driver s seat Tailgate Center Room Lamp Lamp ON Center Room Lamp Door coupled operation ...

Page 358: ...n key is turned to the ON position The output stops when receiving the lock signal from the remote control key under armed mode 1 2 3 4 20 Ignition Key Hole Illumination Key cylinder with key hole illumination For diesel and gasoline engine equipped vehicle Without immobilizer With key hole illumination For diesel engine equipped vehicle With immobilizer With key hole illumination For gasoline eng...

Page 359: ...ing and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 21 Tail Lamp Auto Cut Battery Saver The front defogger output is ON when turning ON the front defogger switch while the ignition switch is ON with engine running The output stops when turning on the defogger switch again during its operation The output is ON only for 6 minutes when turning ON...

Page 360: ...running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 23 Rear Defogger Timer ...

Page 361: ...ts UNLOCK signal for 0 5 seconds when positioning the driver s or passenger s door lock switch to the unlock position LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK signal by other functions All door lock signals are UNLOCK for 0 5 seconds just for once when receiving the LOCK signal within 0 5 seconds after closing the driver s or passenger s door while the i...

Page 362: ...CK switches in all doors are in UNLOCK position and the vehicle speed is 0 Km h STICS operates the tailgate relay for 0 5 seconds to unlock the tailgate If any LOCK switch is switched to LOCK position or vehicle speed exceeds 3 Km h while operating the tailgate open relay the output of the tailgate relay gets OFF 1 2 ...

Page 363: ...uts LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 364: ...OCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Page 365: ...ates again to over 50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door The door lock system outputs UNLOCK automatically if the LOCK output conditions are es...

Page 366: ... on for remaining period The function is erased when turning OFF the IGN switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or UNLOCK outpu...

Page 367: ... key lock signal armed mode during its extended operation period of 30 seconds 1 2 3 31 Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN Any of all door switches including hood and tailgate is in OPEN position DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 DOOR LOCK Indicates that all door lock switches including tailgate are in LOCK positions DOOR UNLOCK In...

Page 368: ...le any of doors is not closed only the LOCK output can be done and then activates the armed ready mode without theft deterrent horn and hazard warning flasher At this moment if the ignition key is inserted or the door lock switch is unlocked it cancels the armed mode and activates the normal mode When the door is opened or the ignition key is not inserted into ignition switch within 30 seconds aft...

Page 369: ...d warning flasher output is ON for 27 seconds at the interval of 1 second Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation 2 Cancels warning after 27 seconds remaining time while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activated in ar...

Page 370: ...elow 0 5 sec Door unlock and theft deterrent mode is deactivated Press and hold over 2 sec Panic function 1 Door unlock Briefly press If the unlock button on the remote control is pressed the door will be opened and the theft deterrent mode will be activated If the door coupled switch of front room lamp is pressed the lamp will come on for 30 seconds It will turn off immediately after the lock but...

Page 371: ...ch on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 1 2 ...

Page 372: ... when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 36 Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 ...

Page 373: ...03 51 8710 01 1 Power Ground Chime Bell Buzzer Warning Lamp Brake Seat Belt DR Open 3 CIRCUIT DIAGRAM ...

Page 374: ...03 52 2 Central Door Lock Circuit ...

Page 375: ...03 53 8710 01 3 Tail Lamp Hazard Power Window ...

Page 376: ...03 54 4 Defogger ...

Page 377: ...03 55 8710 01 5 Panic Auto Light Rain Sensing Room Lamp ...

Page 378: ...03 56 6 FRT Wiper Washer RR Washer ...

Page 379: ...03 57 8710 01 7 Mirror Fold g Unfold g Fold SW ...

Page 380: ...ized key to start the engine The transponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer Transponder Battery ...

Page 381: ...04 4 2 System Diagram The certification for the immobilizer is performed when turning the ignition switch to the ON position after the CAN communication between the ECU and immobilizer is established ...

Page 382: ...t room lamp is pressed the lamp will come on for 30 seconds It will turn off immediately after the lock button of the remote control is pressed 2 Panic function activated in the theft deterrent mode If you press and hold the door unlock and panic buttons the buzzer will sound for 27 seconds The function is inactivated if any button of remote control is pressed Door Lock Function Briefly press belo...

Page 383: ...ransmits the encrypted code to the transponder Immobilizer Unit The transmitted code is changed to an encrypted signal in the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When the key is cl...

Page 384: ...llenge message to the immobilizer unit to verify whether the key is valid Only when the two signals are identical it recognizes the key as the authorized one and transmits the positive message to the ECU Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or register an extra key let the owner atten...

Page 385: ...ess than 0 5 seconds all doors are locked The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key If the vehicle is locked while all doors including tailgate and engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice 1 2 ...

Page 386: ...n the remote control key for more than 0 5 seconds all doors are unlocked When receiving the DOOR UNLOCK message from the remote control key the door unlock relay is turned on for 0 5 seconds The hazard warning lamps blink once only when the doors are successfully unlocked 1 2 3 ...

Page 387: ...04 10 5 CIRCUIT DIAGRAM ...

Page 388: ...d voltage DC 12V Operating voltage DC 9 V 16 V Checking voltage DC 13 5 V Operating temperature 30 80 Storage temperature 40 85 Illumination color Dial White Pointer Red LCD Red Gear position display in A T Left hand of LCD display P R N D 1 2 3 4 5 and 6 ...

Page 389: ...5 6 7 8 9 10 11 12 13 14 15 Engine hood open warning light Battery charge warning light Water separator warning light Air bag warning light 4WD CHECK warning light 4WD LOW indicator 4WD HIGH indicator Speedometer Turn signal indicator Coolant temperature gauge Brake warning light Door ajar warning light ABS warning light Fuel gauge Low fuel level warning light HDC indicator 16 17 18 19 20 21 22 23...

Page 390: ...05 5 8210 01 B Sub connector gray A Main connector white System Layout Front view Rear view NO 1 NO 10 NO 11 NO 20 NO 1 NO 20 NO 10 NO 11 ...

Page 391: ...Front fog lamp 7 8 Engine CHECK warning light 9 Charge 10 IGN 2 11 12 Air bag 13 Seat belt driver s seat 14 High beam 15 Right turn signal lamp 16 High beam 17 Left turn signal lamp 18 Oil pressure 19 Parking brake signal input STICS 20 1 2 3 4P output 4 Buzzer output 5 Illumination 6 7 Check engine GSL only 8 Door open 9 10 Battery 11 12 Fuel input signal 13 TRIP mode reset switch 14 Manual trans...

Page 392: ...GN ON CAN signal input 5 Front fog lamp indicator LED Fog lamp relay When activating switch 6 Cruise control indicator LED IGN IGN ON CAN signal input 7 Light illumination indicator LED BATT Tail lamp ON 8 High beam indicator LED Headlamp high beam relay When activating switch 9 ABS warning lamp LED IGN IGN ON CAN signal input ABS EBD 10 Glow indicator DSL only LED IGN IGN ON CAN signal input 11 I...

Page 393: ...N IGN ON CAN signal input ESP buzzer activated 16 ESP OFF indicator LED IGN IGN ON CAN signal input 17 Brake warning light LED IGN IGN ON CAN signal input EBD 18 4WD CHECK indicator LED IGN IGN ON CAN signal input 19 Air bag warning lamp LED IGN Signal input 20 Door ajar waning light LED BATT When door opened 21 Charge warning lamp LED IGN Charge system fault 22 Seat belt warning light LED IGN Swi...

Page 394: ...ressure warning lamp LED IGN Signal input 24 Water separator warning light DSL only LED IGN IGN ON CAN signal input 25 Engine coolant overheat warning light LED IGN IGN ON CAN signal input 26 Engine hood open warning lamp LED IGN Switch ground 27 EBD warning light LED IGN CAN signal input 28 HDC indicator LED IGN Switch Input ...

Page 395: ...rt the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive 1 2 3 If the tachometer engine rpm gauge pointer vibrates or stops moving at a certain range or abnormal noises are heard from the tachometer the tachometer may have a malfunction If you have reason to suspect that the reading fro...

Page 396: ...eedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications Perform the speedometer test regarding the tolerance as described However it is not similar simple work in field due to lack of measuring conditions such as test equipment and preciseness Check the allowable tolerance of the speedometer and operat...

Page 397: ...05 12 The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range ...

Page 398: ...and resistance value should be measured at the connector in front of the fuel sender refer to wiring diagram When the power supply and output resistance are normal the float operation by fuel level may be defective if so replace the fuel sender Low fuel warning lamp comes on when The fuel level drops to 9 L or less The lamp goes off if the fuel level reaches 9 5 L or more This table shows the tole...

Page 399: ...tween the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range Temperature ºC 20 60 80 100 120 Resistance Ω 2449Ω 5 589 4kΩ 5 321Ω 5 185 7kΩ 5 112 9kΩ 5 Voltage V 3 615 1 910 1 259 0 819 0 536 When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal operation Al...

Page 400: ...traveled is calculated based on the current fuel level If the DTE is less than 50 km flashes on the display 4 Driving time The driving time from resetting the value 0 00 until now is displayed The value displayed is accumulated while the engine is running even if the vehicle is not driven The display range is 00 00 to 99 59 When measuring the driving time press the TRIP switch for 1 sec or more to...

Page 401: ...to 99 9 km 7 Brightness adjustment The brightness of the illumination can be adjusted in 6 steps by pressing the TRIP switch briefly less than 1 sec The display is changed from ILL1 to ILL6 every time the switch is pressed If you select one level within the range and press and hold the TRIP switch the brightness level is memorized If there is no TRIP switch input for 5 seconds or more the mode is ...

Page 402: ...05 17 8210 01 Shifting Mode TRIP reset switch ...

Page 403: ...ions of LCD display when turning ON OFF tail lamp The illumination for the LCD display comes on when turning on the tail lamp and is adjustable only when the ignition is ON When turning on the tail lamp switch with the ignition OFF the tail lamp comes on but the LCD display is not illuminated Refer to the illustration below IGN ON Comes on regardless of whether the tail lamp switch is turned ON or...

Page 404: ......

Page 405: ...mp comes on if there is any fault in the engine oil system and goes off when a certain amount of time has elapsed after turning ON the ignition switch Door ajar warning light This light comes on when a door or tailgate is either opened or not closed completely Brake warning light This warning light comes on and warning buzzer sounds when the parking brake is applied and or the brake fluid level is...

Page 406: ...n the indicator lamp to indicate the cruise control system is activated Water Separator Warning Light This lamp comes on to warn the driver of water in the fuel tank which causes the loss of engine power When a certain amount of water is accumulated the lamp comes on and a chime sounds Engine CHECK Warning Light This warning light comes on when the ignition switch is turned to ON position and shou...

Page 407: ...f HDC indicator according to the HDC switch operation ON OFF The HDC indicator on the instrument panel has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch When you press it once it starts to operate and when you press it again it stops the operation ...

Page 408: ...stem will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ESP system wil...

Page 409: ...tch at the center switch panel is pushed for over approximately 150 ms while the ESP system is not operating The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ESP system will be resumed after approx 150 ms ...

Page 410: ...a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESP unit resets the ESP OFF switch for approx 3 5 seconds ...

Page 411: ...05 26 ESP Warning Lamp Operation Depending on System Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working ...

Page 412: ...ELF DIAGNOSIS CHECK Self diagnosis OFF If the engine speed increases to 396 rpm or more while the engine is cranking or the ignition key is turned OFF in self diagnosis mode the self diagnosis mode is turned OFF automatically Operating process Speed gauge changes from 0 to 220 km RPM gauge changes from 0 to 6 000 rpm Fuel gauge changes from E to F Temperature gauge changes from C to H Warning Indi...

Page 413: ... ON time OFF time RPAS buzzer output O O 75ms 650ms 1 650ms delay and then 75ms sound Over speed warning O X 500ms 200ms 2 ESP buzzer output O O 100ms 100ms 3 Temp buzzer output O O 500ms 500ms 4 Fuel filter O O 500ms 500ms 5 WKS_KL In NMOT 400 IGN ON lamp on for 6sec ...

Page 414: ...05 29 8210 01 6 CIRCUIT DIAGRAM 1 Gauge Speed RPM Fuel Temp Warning Lamp Fuel Fuel Filter ABS Brake 4WD ...

Page 415: ...05 30 2 Warning Lamp BATT Charge Oil Hood Door ENG Check Air Bag Seat Belt Turn Signal Fog Lamp Hazard ...

Page 416: ...Specification Exterior lamp Headlamp High Low beam 2 H4 60W 55W 2 H4 60W 55W Turn signal lamp 2 PY21W 2 PY21W Position lamp 2 W5W 2 W5W Front fog light 2 H27W 2 H27W Day time running light 2 P21W Side repeater LED LED Rear combina tion lamp Stop tail lamp 4 P21 5W 4 P21 5W Turn signal lamp 2 PY21W 2 PY21W Back up lamp 2 W16W 2 W16W 2 P21W License plate lamp 2 W5W 2 W5W Interior lamp Center room la...

Page 417: ...en the rear fog lamp is turned on only while the front fog lamp is ON ESP OFF Switch If you press the ESP OFF switch the ESP function stops and the indicator lamp in instrument panel comes on Press this switch again to resume the ESP function At this time the indicator lamp goes out Driver s Power Window Switch Driver can controls all door windows Open Close Lock Unlock and doors Lock Unlock with ...

Page 418: ...sired driving distance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO Auto light position Front Wiper and Washer Coupled Operation Pull the lever briefly below 0 6 seconds One wiping cycle Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer fluid will be s...

Page 419: ...Switch POWER MODER SEEK SEEK MUTER VOL Bluetooth Switch Sun roof switch Main room lamp switch Front room lamp spot switch 1 2 3 Passenger s Heated Seat Switch Driver s Heated Seat Switch 4WD Control Switch Head Lamp Leveling Switch VOL ...

Page 420: ...as follows 1 Wiper Function Coupled Auto Washer When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 3 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times 2 Integrated Auto Light Sensor in Rain Sensor Unit The rain sensor unit is installed on a proper location to detect the rain d...

Page 421: ...he front washer fluid reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 422: ...tilize the fluidic movement This is a shape of the inside of nozzle It is designed to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle ...

Page 423: ...nd washer fluid to be sprayed for 1 5 sec with three wiping with no delay of time Front nozzle Installed on both sides of the cowl grille assembly one on each side Sprays washer fluid in fan shape to cover the windshield area as much as possible Washer reservoir tank Tank that supplies washer fluid to front washer system Integrated into the auto light sensor Detects and sends amount of rain drops ...

Page 424: ...m uses the front washer fluid reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone STICS receives the rain sensing data from the rain sensor and controls the wiper and washer systems STICS Installation ...

Page 425: ...08 8 3 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 426: ...ds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch 2 ...

Page 427: ...ion in step 1 is performed 3 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is...

Page 428: ... washer operation stops and the auto INT operation is activated 3 4 5 6 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden during th...

Page 429: ...08 12 4 WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM ...

Page 430: ...witch AUTO and Sensitivity Control A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor refer to the below picture AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto spe...

Page 431: ...de washer MIST AUTO then sends the information to the rain sensor STICS Engine Compartment Fuse Box Wiper relay HI Rear washer relay Front washer relay Wiper relay LO Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the intermediate INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on...

Page 432: ... to operate automatically under the rain sensing mode multifunction switch wiper AUTO mode The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor Followings a...

Page 433: ...nications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper...

Page 434: ...mmunication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the INT auto switch to ON position from OFF position for the first tiime while the ignition key is in ON position When the wiper switch is turned to ON position again from OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain...

Page 435: ...h input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation 1 2 ...

Page 436: ...ion and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 1 stage within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating with the rain se...

Page 437: ...on and the INT switch is in ON position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position 2 The wiper motor runs only whe...

Page 438: ... malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 1 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 2 ...

Page 439: ...est INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 440: ...bstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle 2 Parking Aid Sensor 1 Type Piezo ceramic element 2 Frequency 40 KHz 2 KHz 3 Detecting range 13 5 V Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 cm Min 60 at 50 ...

Page 441: ... operation Always keep the safety precautions Do not press or shock the sensors by hitting or high pressure water gun while washing or the sensors will be damaged If the system is in normal operating condition a short beep sounds when the gear selector lever is moved into R position with the ignition key ON If the system is in abnormal operating condition a beep sounds for 3 seconds when the gear ...

Page 442: ...g noises from heavy commercial vehicles When a high power radio is turned on 3 Narrowed sensing area When the sensing portion is partially covered by snow or mud operates normally after cleaned Surrounding temperature of sensor is too high approx over 80 C or too low approx below 30 C 4 Not defective but may occur improper working When driving on the rough roads gravel road hill and grass When the...

Page 443: ...elements to measure vertical and horizontal distance to obstacles When placing the gear selector lever to R position the designated unit PAS unit in the rear right quarter panel activates the parking aid sensors to measure the distance to obstacles PAS Related Devices Gear Selector Lever R Position PAS buzzer STICS PAS piezoelectric buzzer ...

Page 444: ...10 7 8790 03 Left Right Center Sensor Location Center Sensor Side Sensor PAS Sensor Parking Aid Unit The PAS unit is installed in the rear right section of the rear quarter panel ...

Page 445: ...nges according to the distance as below While reversing if obstacles are within stage 1 the warning beep sounds with long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously ...

Page 446: ...ta on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions conditions for warning beep due to failure 1 2 Sensor failure conditions conditions for warning beep Open in sending circuit Open in receiving circuit Open in power circuit ...

Page 447: ...10 10 4 CIRCUIT DIAGRAM ...

Page 448: ...ical D D Electrical Parking lock system Brake switch signal TGS lever Reverse lock system CAN TGS lever Selected lever indication P R N D Lever position 1 2 3 4 5 CAN Oil temperature sensor Resistance R D 0 5 2 5kΩ Resistance P N 20kΩ TCU EGS 52 Shift solenoid valve 25 Resistance 3 8 0 2Ω Operating distance 0 2mm Operating current 1 5 2A Item W5A330 300 W5A580 400 Input torque 330Nm 1 SPECIFICATIO...

Page 449: ...rating current 1 5 2 0A Operating range 3rd to 5th gears RPM sensor Resistance HALL type Operating voltae 6V Start lockout switch Switch contact ON D position Switch contact OFF P N position Mode switch W Winter S Standard One way clutch F1 F2 Planetary gear set Plain planetary gear 3 number of pinion 3 4 3 4 4 4 Disc clutch Disc C2 C2 C3 Single plate type Disc brake Disc B1 B2 B3 Single plate typ...

Page 450: ...rque converter housing oil pump 20 Transmission rear mounting bracket left right 36 44 Transmission rear mounting bracket center 20 Torque converter mounting bolt 42 Converter housing engine 75 90 Converter housing transmission housing 20 T 45 Valve body 8 T 30 Valve body side cover 4 T 30 Solenoid valve 8 12 point collar nut 200 12 point 30 mm B2 housing bolt 16 T 45 Selector lever unit mounting ...

Page 451: ...oper shifting in relation to engine power This function improves shifting quality significantly And the driver can select S Standard mode or W Winter mode according to the driving conditions This automatic transmission provides two gears even during reverse driving The internal sensors and controls are connected to TCU by cylindrical 13 pin connector DCAG 5 speed automatic transmission offers the ...

Page 452: ...01 7 3650 01 Characteristics ...

Page 453: ...01 8 1 Power Flow Sectional View B1 C1 C2 B3 C3 B2 Shifting elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun 2 POWER FLOW ...

Page 454: ...t planetary gear set M P T V Input shaft Clockwise rotation Front sun gear Locked by F1 and B1 Planetary gear carrier Rotation with reduced speed Rear ring gear Counterclockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Clockwise rotation with reduced speed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with reduced speed Output shaft Clockwise ro...

Page 455: ...ront planetary gear set M P T V Input shaft Clockwise rotation Sun gear and planetary gear carrier Clockwise rotation by C1 activation Rear ring gear Clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Rotation with reduced speed Center ring gear Clockwise rotation Sun gear Locked by B2 Planetary gear carrier Rotation with reduced speed Output shaft Clockwise rotation Gear ...

Page 456: ...r planetary gear set D H L M Impeller Turbine wheel Front planetary gear set P T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Center ring gear Clockwise rotation by clutch 2 activation direct connection Center sun gear Locked by B2 Planetary gear carrier Clockwise rotation with reduced speed Output shaft Clockwise rotation Gear C1 C2 C3 B1 B2 B3 F1 F2 3 ...

Page 457: ...g gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center ring gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring gear direct connection Ou...

Page 458: ...etary gear carrier Rotation with reduced speed Rear planetary gear carrier Clockwise rotation with reduced speed Center ring gear and rear planetary gear carrier Clockwise rotation by clutch C2 activation Rear sun gear Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear increasedspeed Center sun gear Clockwise rotation with increased speed by C3 activation Cen...

Page 459: ...aft Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locked by B3 Center planetary gear carrier Countercloc...

Page 460: ... M P T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Front planetary gear carrier Clockwise rotation by clutch C1 activation direct connection Rear ring gear Clockwise rotation Rear planetary gear carrier and center ring gear Locked by brake B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center planetary gear carrier Counterclockwise rotation r...

Page 461: ...01 16 3 CIRCUIT DIAGRAM Start motor TGS lever CAN line ...

Page 462: ...01 17 3650 01 Solenoid Oil temperature sensor Speed sensor N2 N3 ...

Page 463: ...ition voltage and has three connectors 16 pin TCU receives input signals from certain transmission related sensors gear select lever and inhibitor switch TCU also uses these signals when determining transmission operating strategy TCU uses PCAN to communicate with other units And TCU communicates with engine ECU ESP unit TCCU and instrument cluster through CAN lines to control the gear shifting an...

Page 464: ...n Locked in the P Position If you cannot move the gear select lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt Tip Switch in M Position Manual Gear Shift The shiftable gear can be adjusted by moving this switch to forward and rearward when the gear s...

Page 465: ...re sensor 20 430 7 533 9 kΩ 0 146 8 175 7 kΩ 20 56 74 65 86 kΩ 100 3 201 3 399 kΩ Gear position sensor 1 2 3 D 2 686 kΩ 8 N 5 036 kΩ 8 R 8 953 kΩ 8 P 16 786 kΩ 8 Severe driving conditions Towing a trailer or off road driving Inspect the leak of fl uid at any time occasionlly Taxi patrol service or delivery service extended idling and excessive driving with low speed Frequent stop and go traffi c e...

Page 466: ...02 6 4WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Inhibiter switch Adapter housing 2 Appearance Connector plug Transfer case ...

Page 467: ...02 7 3680 01 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Inhibiter switch Flange for propeller shaft Connector plug Flange for propeller shaft ...

Page 468: ...tional Diagram Fluid pump Clutch pack Double planetary gear set Torque converter Valve body Fluid pump Single planetary gear set Clutch pack Torque converter Valve body Single planetary gear set Double planetary gear set ...

Page 469: ...Output shaft locking nut M24 x 15 100 110 Pump cover to oil pump M8 x 55 24 27 Pump cover to transmission housing M8 x 40 24 34 Pump cover to transmission housing M8 x 58 24 34 Upper valve body to lower valve body M6 x 30 15 17 Detent spring M8 x 16 20 25 Variable bleed solenoid and speed sensor M4 x 12 2 8 3 2 Transmission oil level plug 30 35 Front cooling lines to transmission cooler 25 35 Rear...

Page 470: ...02 10 4 SHIFT PATTERN DIAGRAM ...

Page 471: ... applications The transmission contains fully synthetic automatic transmission fluid ATF and is filled for life therefore it does not require periodic servicing Engine power reaches the transmission via a torque converter with integral converter lock up clutch The six forward gears and one reverse gear are obtained from a single planetary set followed by a double planetary set This type of gear se...

Page 472: ...ted on the transmission system as there is sufficient engine strategy to protect the system However reverse gear engagement is prevented until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12 and vehicle speed is less than 10 km h Converter Clutch Lock Up In All Gears The transmission features converter clutch lock up in all gears This feature provides improved...

Page 473: ...led by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change Coastdown downshifts occur at 0 accelerator pedal when the vehicle is coasting down to a stop To reduce the shift shock and to improve the shift feeling during downshift TCU electronically controls the t...

Page 474: ...t lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt 1 Gear Position 4 P R N D 4 Mode Switch 3 W S 3 Selection of Manual Automatic Shift Function M D 2 D M 2 Automatic shift according to the driving condition Manual shift Winter mode Start off the vehi...

Page 475: ...sition 5th gear position 6th gear position Use on a rugged road mountain path and steep hill Engine braking effect on steep hill is available Use on a long and gentle slope 2 1 automatic kickdown shift is available Engine braking effect is available Use on a long and gentle slope 3 2 and 2 1 automatic kickdown shift is available Engine braking effect is available Use on a long and gentle slope 4 3...

Page 476: ...to OBD II regulation 1 2 3 4 In case of overheated transmission The TCU enters the limp home mode when the batter voltage drops below 8 V If the transmission is overheated the shift pattern is changed to the hot mode to cool the transmission more efficiently While the transmission is overheated the selector lever symbol and engine temperature warning lamp on the instrument cluster blink until the ...

Page 477: ...Unit TCU The transmission control unit TCU is mounted under the driver s seat and controls the operation of the transmission TCU processes the analog information from the internal sensors and the digital information through CAN communication lines TCU monitors all the input and output signals If there is any failure TCU changes the system to Limp Home Mode and alerts to the driver through the warn...

Page 478: ...02 18 2 CAN Input Output TCU receives and sends the data among the units through P CAN communication CAN Input Output Data between Engine ECU and TCU ...

Page 479: ...02 19 3680 01 CAN Input Output Data between ABS ESP and TCU CAN Input Output Data between TCCU and TCU CAN Input Output Data between ICM and TCU ...

Page 480: ...be locked up properly If it is failed TCU releases the torque converter clutch to activate the fail safe operation 4 Shift Energy Management This function involves reducing or increasing the engine output torque during shifting This reduces the energy which is dissipated in the friction elements of the transmission during up shift This is done by reducing the engine torque during the gear ratio ch...

Page 481: ... shift operation 5 Shift Mode Selection by TCU The driver can select Standard S or Winter mode W with the mode switch TCU automatically changes the shift mode according to the transmission oil temperature uphill or downhill gradient and altitude to keep the good driving conditions Standard Mode S Uphii and Downhill Mode Altitude Mode Standard Mode is selected when setting the mode switch in Standa...

Page 482: ...ion oil temperature is below 20 C The torque converter cannot be locked up below 20 C to provide the warming up process of transmission Hot Mode If the transmission oil temperature is between 110 C and 145 C the system provides the cooling and reduces the load to the transmission This is called Hot Mode Above 110 C Above 130 C Above 145 C In Hot Mode any of shift mode is not available Cruise Contr...

Page 483: ...r Gear ratio Engaged element clutch band C1 C2 C3 B1 B2 1 2OWC M1 3 53 ON ON 1st 3 53 ON ON 2nd 2 14 ON ON 3rd 1 48 ON ON 4th 1 16 ON ON 5th 0 87 ON ON 6th 0 68 ON ON Reverse 3 09 ON ON Gear S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A M1 ON 1 0 1 1st ON 1 0 0 1 2nd ON ON 1 0 1 0 1 3rd ON ON 1 0 1 0 1 4th 0 0 0 1 5th ON 0 1 1 0 1 6th ON ON 0 1 1 0 1 Reverse ON ON ON 1 1 1 0 1 Gear Selection and Enga...

Page 484: ...02 24 Hydraulic Circuit Diagram ...

Page 485: ...d be ON C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON ON Power Flow Diagram Manual 1st gear is not en...

Page 486: ...02 26 1st Gear M 3 53 1 ...

Page 487: ...lve moved to the left end C1 clutch not engaged C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON Power Flo...

Page 488: ...02 28 1st Gear D 3 53 1 ...

Page 489: ...S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 S4 ON B1 shift valve moved to the left end B1 band operated Drive oil for B1 band engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 ...

Page 490: ...02 30 2nd Gear D 2 14 1 ...

Page 491: ...cting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON ON 1 0 0 1 0 1 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 2 14 ON ON Power Flow Diagram ...

Page 492: ...02 32 2nd Gear D Lock Up ...

Page 493: ...not engaged C2 shift valve open S2 OFF C2 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 48 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 48 ON ON Power Flow Diagram C3 clutch c...

Page 494: ...02 34 3rd Gear D 1 48 1 ...

Page 495: ...h engaged by drive oil C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C1 and C2 engagement is regulated by VBS S6 and S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 16 0 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 16 ON ON Power Flow Diagram 4th gear is...

Page 496: ...02 36 4th gear D 4th gear D in Limp home mode 1 16 1 ...

Page 497: ...end C2 clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 87 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 87 ON ON Power Flow Diagr...

Page 498: ...02 38 5th gear D 0 87 1 ...

Page 499: ...eft end C2 clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S4 ON B1 shift valve moved to the left end B1 Band engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 68 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 68 ON ON Power Flow Diagram ...

Page 500: ...02 40 6th gear D 0 68 1 ...

Page 501: ...o B2 Band directly through manual valve S3 ON Pressure to C3 increased or regulated S1 and S2 ON C1 not engaged in any case Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 ON ON ON 1 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Page 502: ...02 42 Reverse gear R 3 09 1 ...

Page 503: ...de Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 0 0 0 0 0 0 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Page 504: ...02 44 Reverse R Limp Home Mode ...

Page 505: ... Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Page 506: ...02 46 Park ...

Page 507: ...cting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Page 508: ...02 48 Neutral ...

Page 509: ...is used to prevent incorrect shifting To improve the shifting performance 3 piece triple cone is used for 1 2 shift 2 3 The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 4 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement The clutch rel...

Page 510: ...03 4 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 511: ...03 5 3170 01 2 Tightening Torque ...

Page 512: ...03 6 Inside N Switch 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch 0 5 mm 0 5 mm ...

Page 513: ...he gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm When the gear has been...

Page 514: ... information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Neutral Signal Input None Wire CAN Wire Actyon Kyron models with manual transmission New Rexton model ...

Page 515: ......

Page 516: ...ive interval Inspect and replenish every 60000 km or 3 years under severe driving conditions change every 120 000 km 1 SPECIFICATION Reversing High force type What s the severe conditions Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly Taxi patrol service or delivery service extended idling and excessive driving with low speed Frequent stop and go traffic ext...

Page 517: ... 2 SPECIAL SERVICE TOOLS Install the main shaft reverse sleeve and bearing Install the main drive pinion assembly front ball bearing Install the main shaft double angular ball bearing Install the 3rd 4th synchronizer hub Install the main shaft 5th gear Install the main shaft 6th gear Install the main shaft 1st gear sleeve Install the drive pinion assembly front ball bearing Install the main shaft ...

Page 518: ... No SSM00203 001 Name Counter shaft bearing installer Install the counter shaft front roller bearing Part No T88310011A 9 Name Bearing support Support the counter shaft when removing the roller bearing with a puller Special service tool Supplier Tool Tech ...

Page 519: ... 41 1 1EA Loctite 4 Reverse shift fork retainer bolt 53 9 67 6 2EA Loctite 5 Backup lamp switch 29 4 34 3 1EA Loctite 6 Oil drain plug 58 8 78 4 1EA Loctite 7 Interlock bolt 14 7 21 5 1EA 8 Neutral switch 29 4 34 3 1EA Loctite 9 Oil filler plug 58 8 78 4 1EA Loctite 10 Extension housing bolt 42 1 53 9 12EA 11 Concentric slave cylinder bolt 9 8 15 6 3EA 12 Front bearing retainer bolt 19 6 24 5 8EA ...

Page 520: ...Bolt Seal 19 6 24 5 Nm Seal Oil Bushing Spacer Gasket Plug 58 8 78 4 Nm Gasket Plug 2 3 4 5 6 7 8 9 10 11 Breather Air Pulg Seal 53 9 67 6 Nm Cylinder assembly Concentric slave Plunger Rolling Boot Guide Oil Spring Guide Bolt Flange 42 1 53 9 Nm 12 13 14 15 16 17 18 19 ...

Page 521: ...04 8 3162 00 Main shaft ...

Page 522: ...b Synchronizer Sleeeve Synchronizer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Ring assembly Triple cone Gear assembly 1st speed Sleeve 1st gear Bearing Double angular ball Ring Snap Gear Main shaft 5th Spacer Gear Main shaft 6th Sleeve Reverse gear Bearing Needle roller Gear assembly Reverse speed Ring assembly Triple cone Hub Synchronizer Sleeeve Synchronizer Stopper Synchronizer key Bearin...

Page 523: ... Bearing Needle roller Gear assembly 5th speed Key assembly Synchronizer Ring assembly Triple cone 1 2 3 4 5 6 7 8 9 10 Hub Synchronizer Sleeeve Synchronizer Ring Synchronizer Sleeve Speed gear Bearing Needle roller Gear assembly 6th speed Gear Counter shaft Nut Locking 156 9 186 3 Nm Bearing Needle roller 11 12 13 14 15 16 17 18 19 ...

Page 524: ...Adapter assembly Plate Intermediate Guide Oil Bolt 7 8 9 8 Nm Pin Dowel Retainer Bearing Magnet 1 2 3 4 5 6 Bolt Seal 19 6 26 4 Nm Shaft Reverse idler gear Bearing Needle roller Gear Reverse idler Spacer Reverse 7 8 9 10 11 ...

Page 525: ...er ball Pin Spring Rail sub assembly Shaft 1st 2nd Bushing Rail sub assembly Shaft 3rd 4th Lug Shaft 5th 6th 1 2 3 4 5 6 7 8 Lug _ Reverse shaft Fork Reverse shaft Rail Shaft 5th 6th Fork Shaft 5th 6th Pin Spring Lever assembly Shaft 5th 6th Bolt Flange 14 7 21 5 Nm 9 10 11 12 13 14 15 ...

Page 526: ...TGS mounting Pin Spring Pin Spring Adapter Case 1 3 4 5 6 7 8 9 10 13 14 15 16 17 20 Bolt Flange 42 1 53 9 Nm Seal Oil Seal Oil Pin Dowel Switch Neutral 29 4 34 3 Nm Gasket Bolt Interlock 14 7 21 5 Nm Pin Detent Switch Backup lamp 29 4 34 3 Nm Bolt Fork hinge 53 9 67 6 Nm Bearing Poppet ball 29 4 41 1 Nm Bolt Guide 14 7 21 5 Nm Bolt 2 9 4 9 Nm Bracket Wiring 21 22 23 24 25 26 27 28 29 30 31 32 33 ...

Page 527: ... the improper gear shift semi remote control system has been introduced To prevent the gears from engaging improperly the synchronizer mechanisms and independent interlock systems are installed on 1 2 gears 3 4 gears 5 6 gears and reverse gear The High Force system for reverse gear shift has been introduced The synchronizer has three types Triple 1 2 3 R Double 5 Single 4 6 6 speed M T ...

Page 528: ...smission housing Extension housing Main shaft Counter shaft Main drive gear Intermediate plate Gear Teeth Final gear ratio Input Output 1st 13 38 4 489 2nd 23 35 2 337 3rd 33 29 1 350 4th 28 43 1 000 5th 47 24 0 784 6th 52 23 0 679 R 13 36 4 253 Idle 25 ...

Page 529: ...04 16 2nd speed 1st speed 2 POWER FLOW ...

Page 530: ...04 17 3170 01 4th speed 3rd speed ...

Page 531: ...04 18 6th speed 5th speed ...

Page 532: ...04 19 3170 01 Reverse gear ...

Page 533: ...04 20 3 SHIFTING MECHANISM High Force mechanism for reverse gear shift 3rd 4th 1st 2nd R 5th 6th Neutral switch Backup lamp switch Control shaft Control finger Lug arrangement ...

Page 534: ... Sometimes the vehicles gears can be changed unexpectedly or unintentionally by various factors Therefore two tip switches are installed to prevent such changes from happening For instance when a vehicle is running on a severely curved road the driver must hold the steering wheel with two hands Shifting gears or using the engine brake while driving on the road will be dangerous So one tip switch i...

Page 535: ...vehicle When towing the is vehicle the towing speed should be 50 km h or less and the towing distance should not exceed 50 kilometers It is more recommended to load this vehicle on a flat bed towing vehicle 4 D 1 6 Gears This position is for normal driving on paved roads or high speed driving The gear ratio of the 6th gear is 0 68 1 5 M Manual Mode This allows the driver to define the highest poss...

Page 536: ...strument cluster 4 3 4 2 and 4 1 automatic kick down shifts are available 4th gear has engine braking available 9 3 3 gears only available in the M position The 3rd gear state will display on the instrument cluster 3 2 and 3 1 automatic kick down shifts are available 3rd gear has engine braking available 10 2 2 gears only available in the M position The 2nd gear state will display on the instrumen...

Page 537: ...osition to the M mode the M mode sensor detects this change and sends a signal to the TCU and the TUC shifts down one or two gears without any jerking This means the newly engaged gear in the M mode is the one level lower gear from the D position For example when the selector lever is pushed from the D position to the M mode the transmission will automatically switch the 3rd gear to the 2nd gear T...

Page 538: ... s smooth driving off With the Winter mode 2WD and AWD models have fast up shifts and slow down shifts to increase gas mileage When these models use the full throttle the Winter mode automatically switches to the Standard mode However in case of 4WD models the Winter mode will stay on even with the full throttle In spite of the Winter mode being selected the transmission will use only the 1st gear...

Page 539: ...05 8 2 Electric Circuit ...

Page 540: ... lever unit so that the system detects the brake switch operation signal for allowing shift from the P to other positions This system is a safety measure to prevent the selector lever from moving unless the brake pedal is depressed 1 Selector Lever 2 Shift Pattern Display 3 Selector Lever Handle 4 Parking Lock Release Flap 5 Selector Lever Control Unit Internally Installed 6 Mode Switch 2 Electric...

Page 541: ...05 10 3 Shift Lock Solenoid Function ...

Page 542: ...edal is pressed the Selector Lever Unit does not activate the P Locking solenoid and the Selector Lever 1 stays locked In this situation the lock lever 4 is engaged to the P Lock position and the Locking Lever Tap 3 holds the Lock Lever 2 Therefore the Selector Lever cannot be shifted to other positions ...

Page 543: ...e apply the following instruction Apply the parking brake firmly and turn the ignition off Depress the brake pedal and push down the shift lock release lever with a stick such as a pen Then shift the lever to other positions 1 2 Do not push down the shift lock release lever excessively The internal parts could be damaged Shift lever lock release ...

Page 544: ...06 3 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE ...

Page 545: ...h freeplay according to the wear of clutch disc 2 Operation description Internal Components of Clutch Cover Disc wear Free play Diaphragm spring 1 Adjusting equipment 2 3 Pressure plate 4 Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear ...

Page 546: ...haft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by us...

Page 547: ...06 6 Components of Clutch Assembly Concentric Slave Cylinder Clutch Assembly 3 Functions Adapter Pipe Assembly ...

Page 548: ...06 7 3010 01 Cross Sectional View of Clutch Assembly 1 Transmission housing 4 Bolt 2 Clutch disc assembly 5 Washer 3 Clutch disc cover assembly 6 Bolt ...

Page 549: ... x Dia mm A T 552 3 Φ63 5 Compressed M T 603 8 Φ63 5 Compressed Dimension of front propeller shaft Length x Dia mm 2WD Front 1136 0 Φ63 5 Rear 743 Φ63 5 Compressed 4WD M T Front 785 1 Φ63 5 Rear 743 Φ63 5 Compressed 4WD A T Front 836 8 Φ63 5 Rear 743 Φ63 5 Compressed 2 TIGHTENING TORQUE Fastener Tightening torque Mounting bolts for front rear axle 66 7 73 5Nm Mounting bolts for T M and T C 79 4 87...

Page 550: ...propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration Function of propeller shaft Transmits driving torque Compensates the angle change universal joint CV joint Compensates ...

Page 551: ...cation Axle shaft type Semi floating type Axle housing type Build up type Differential Type Conventional Gear type Hypoid Final gear ratio DSL Eng A T M T 3 54 4 27 GSL Eng A T M T 4 89 4 55 Oil Capacity Specification SAE 80W 90 API GL 5 Capacity Front 1 4 L Rear 2 0 L DSL Eng A T M T GSL Eng A T M T ...

Page 552: ... axle Rear axle Specification M T A T M T A T Gear ratio 4 55R 5MT 4 27R 6MT 3 54R 5AT 4 89R 6AT 4 55R 5MT 4 27R 6MT 3 54R 5AT 4 89R 6AT Gear Type Hypoid Size Φ 182 8 mm Φ 218 4 mm Offset 28 58 mm DYMOS 35 mm 38 1 mm Housing Steel Steel casting steel aluminum cover Oil Specification SAE 80W 90 API GL5 SAE 80W 90 API GL5 Capacity 1 4L 1 4L 2 0L Length 448 0 mm 469 0 mm Width 681 9 mm 1717 7 mm Weig...

Page 553: ...08 5 4120 01 1 OVERVIEW OF AXLE 1 Front Axle 2 Rear Axle ...

Page 554: ...on to the conventional part time transfer case but the changes in comparison to the conventional transfer case are as follows No additional coding is required when replacing TCCU Delete the devices tone wheel speed sensor wiring etc related to the speed sensor in the transfer case This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 through the CA...

Page 555: ...9 4 1 STRUCTURE Front axle Front locking hub system IWE Power steering assembly Front propeller shaft MB5th DSI6th gear automatic transmission Part time transfer case TCCU Rear propeller shaft Rear axle ...

Page 556: ...main connector Shift motor connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper ...

Page 557: ...09 6 2 SYSTEM LAYOUT AND OPERATION 1 System Layout ...

Page 558: ...cuum locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear To atmosphere Electrical signal Booster Locking hub actuator Locking hub...

Page 559: ...de the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve Hub actuator LH 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released from the hub actua...

Page 560: ...09 9 4116 01 4 POWER FLOW 1 Components of Power Flow Part time transfer case Transfer case Engine Rear 2WD Rear wheel side Front 4WD Front wheel side ...

Page 561: ...09 10 2 Flow Layout ...

Page 562: ...09 11 3240 01 3 2H Mode Rear Wheel Drive 1 Layout ...

Page 563: ...09 12 4 4H Mode 4 Wheel Drive High speed 1 Layout ...

Page 564: ...09 13 0000 00 4 4L Mode 4 Wheel Drive Low speed 1 Layout ...

Page 565: ...er type Cylindrical double tube gas type Stabilizer type Torsion bar Height H When tightening upper arm lower arm shock absorber yoke nut 86 5 5 mm Description Specification Toe in 2 2 mm 0 13 0 13 deg Camber 0 14 0 25 LH The difference between both ends is should be below 0 5 0 34 0 25 RH Caster 4 4 0 4 LH The difference between both ends is should be below 0 5 4 5 0 4 RH ...

Page 566: ...d Above 28 8 cm2 Pad wear indicator Mechanical type Brake booster Type Vacuum assist type Size 8 9 Tandem Master cylinder Type Tandem type integrated level sensor Inner diameter of cylinder Ø26 99 mm Brake pedal Maximum operating stroke 150 mm Pedal ratio 4 1 Free play 3 to 10 mm Parking brake Type Mechanically expanded rear lining Operating type Hand operated type Inner diameter of drum Ø190 mm B...

Page 567: ...riction causes the disc and attached wheel to slow or stop Brake master cylinder The brake master cylinder is a control device that converts non hydraulic pressure commonly from a driver s foot into hydraulic pressure in order to move other device s which are located at the other end of the hydraulic system such as one or more slave cylinders As piston s move along the bore of the master cylinder ...

Page 568: ...nsor cluster Yaw rate sensor lateral longitudinal G sensor Not applied Applied ESP indicator ESP OFF switch and warning lamp Steering wheel angle sensor 4 Components ABS ESP ARP 2WD 4WD 2WD 4WD Whhel speed sensor 4 4 4 4 Sensor cluster N A N A Applied Applied G sensor N A Applied N A N A 2H G sensor Operating 4H G sensor Operating 4L G sensor Operating 2H sensor cluster Operating Operating 4H sens...

Page 569: ... function is failed ESP indicator Blinking when ESP function is operating ESP OFF indicator ON when the ESP OFF switch is pressed ESP warning lamp ON when ESP function is failed ESP buzzer Sound when ESP function is operating HDC indicator Red HDC operating Green HDC switched ON 5 Indicators and Warning Lamps for ABS ESP ...

Page 570: ...ssing Repair Loosened suspension mounting bolt Retighten Pulls to one side when braking Unbalanced tire pressure between left and right Adjust Poor contact of brake pad Repair Oil or grease on brake pad Replace Scratch uneven wear distortion of brake disc Replace Improperly installed brake caliper Repair Improper operation of auto adjuster Repair Crack or distortion of brake pad Replace Poor braki...

Page 571: ...ncorrectly adjusted free play of brake pedal Adjust Faulty master cylinder Replace Lack of lubrication in sliding parts Lubricate Faulty brake booster vacuum leak Repair Wear hardening or poor contact of brake pad Replace Oil or water on lining Repair or replace Fixed or broken parking brake cable Replace Excessive stroke of brake lever Adjust notch Faulty auto clearance adjuster Repair Poor parki...

Page 572: ...ly foot brake during downhill driving Driving with foot on brake pedal Get off the foot from pedal Foreign materials such as dirt or sand in brake system Replace caliper wheel cylinder master cylinder return spring Broken return spring in shoe assembly Replace Incorrectly adjusted parking brake cable Adjust Incorrect wheel or wheel cover generating the heat Replace ...

Page 573: ...ke system Symptom 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disc and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is in complete contact with the pad s frictio...

Page 574: ...m the brake line with the order in the figure 3 Fill the reservoir with the brake fluid as much as it bleeded and continue to bleeding operation Never reuse the used brake fluid Use only specifies brake fluid DOT 4 Add brake fluid between MAX and MIN lines on the reservoir 0 7 to 0 8 liters Be careful not to splash the brake fluid on painted area or body Make sure that any foreign material does no...

Page 575: ... brake 4 Repeat the air bleeding procedures until clear brake fluid comes out of air bleed screw 6 Check for oil leaks from the brake lines 7 Air in brake fluid Deteriorated fluid Air bleed screw at front brake Air bleed screw at rear brake Air bleeding completed ...

Page 576: ...t of the specified value adjust the length 1 2 3 4 Specified value A 150mm 5 BRAKE SYSTEM CHECK Over the specified value Cause Action Worn brake pad Replace Worn brake shoe Replace Improper stroke of hand brake Adjust Air in brake line Air bleeding Oil leak Repair or replace Brake booster push rod Replace or adjust Improperly adjusted stopper bolt Adjust Below the specified value Cause Action Brak...

Page 577: ...amp switch connector Unscrew the lock nut and remove the stop lamp switch assembly Loosen the lock nut on the pedal push rod Turn the pedal push rod to adjust the pedal height Tighten the lock nut Install the stop lamp switch assembly Connect the stop lamp switch connector Check if the stop lamps come on when pressing the brake pedal around 5 mm If the stop lamp dpes not come on adjust the stop la...

Page 578: ...ay with below procedures Stop the engine Depress the brake pedal several times to discharge the vacuum pressure of the brake booster Depress the brake pedal until you feel the resistance and measure the movement A 1 2 3 Below the specified value Check if the distance between the outer case of stop lamp switch and the brake pedal Over the specified value It may be caused by bigger clearance between...

Page 579: ...brake goes down when starting engine with pedal depressed the system is normal If not the system is defective Depress the brake pedal when the engine is running If the pedal height is not changed for 30 seconds after stopping the engine the system is normal If not the system is defective 1 2 3 If the above three checks are OK the system is normal If any condition is not met check the valve vacuum ...

Page 580: ...e vapor lock frequently Water content in fluid around 3 after 18 months around 7 10 after few years The water ib fluid makes the corrosion in the brake lines deforms and deteriorates the rubber components brake calipers and pistons DOT4 Brake fluid for premium vehicle Lower water absorbing rate AND higher boiling point than DOT3 Brake Fluid Level Check The brake fluid level should be between MAX a...

Page 581: ... measured points is below the wear limit replace the brake disc with new one New disc Wear limit 28 mm 25 4 mm Disc Run Out 3 Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when braking Limit 0 03 mm before install...

Page 582: ...nts and visually check the followings Damage and tear on boot 4 Uneven wear and oil contamination 5 Damage crack and wear on cylinder body A and guide pin B 6 Wear rust and damage on the cylinder and piston Scratch and bending on disc plate 7 8 ...

Page 583: ...replace the brake disc with new one 1 2 New pad Wear limit 10 mm 2mm New disc Wear limit 10 4mm 8 5mm Disc Run Out Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when braking 1 2 Limit 0 03 mm before installation 0...

Page 584: ...ified value with the parking brake adjusting nut Check the parking brake force after adjustment 1 2 3 Specified notches 5 If the parking brake force is not enough check the parking brake lever and cable Replace the components if needed 4 Never park the vehicle only with the parking brake on the stiff hill It may cause roll down of the vehicle due to release of the parking brake Place the wheel cho...

Page 585: ...ssembly Brake master cylinder Nut 12 8 16 7 Nm Booster mounting seal O ring Brake pedal assembly Brake pedal Brake pedal return spring 1 2 3 6 7 8 11 12 13 Nut Brake pedal Stop lamp switch Stopper Clevis pin Snap pin Bolt Brake pedal assembly 17 6 21 6 Nm Nut Brake booster 17 6 21 6 Nm 17 18 19 20 21 22 23 ...

Page 586: ...e hose assembly Front brake hose mounting holder Flexible hose clip Caliper eye bolt 19 6 29 4 Nm Brake tube mounting clip 1 2 3 4 5 7 8 9 11 12 Brake tube mounting clip Brake tube mounting holder Brake tube 2 way connector Screw Rear hose 2 way connector 3 way connector hose tube assembly Rear brake hose assembly Rear brake hose assembly Bolt 9 8 11 8 Nm 13 14 20 21 22 24 25 26 27 ...

Page 587: ...er mounting bolt 25 5 30 4 Nm Caliper clip set 21 22 23 24 25 Rear brake caliper assembly Rear brake pad Washer Bolt 52 9 63 7 Nm Rear brake disc Rear disc brake dust shield Bolt Rear drum brake assembly Parking brake shoe Parking brake repair kit Rear axle shaft grommet 1 2 3 4 5 6 7 12 15 16 17 ...

Page 588: ...Parking brake lever assembly Equalizer Nut 9 8 12 7 Nm Front brake mounting bracket Bolt Parking brake rear cable assembly Parking brake rear cable assembly Bolt 9 8 12 7 Nm Parking brake cable retaining ring 1 3 4 5 6 10 11 12 13 ...

Page 589: ...er cylinder booster pedal and supply lines pipes and hoses Hydraulic Brake Brake Pedal This system uses the leverage effect and Pascal s principle When depressing the brake pedal the pedal pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure The hydraulic pressure generated by the master cylinder is delivered to the brake caliper through the brake pip...

Page 590: ...ad until you bring your vehicle to a complete stop This is called as stopping distance What is braking distance Tire slip occurs until the vehicle stops completely when the the brake is applied This slip is what we call a braking distance What is free running distance The free running distance is the time from the driver sees the obstacles and begins to prepare for depressing the brake pedal until...

Page 591: ...11 28 Front Brake Assembly Front Wheel Speed Sensor 4WD HECU 2 SYSTEM LAYOUT Master Cylinder and Booster Brake Pedal ...

Page 592: ...11 29 4850 01 Rear Wheel Speed Sensor 4WD Rear Brake Assembly ABS EBD Indicators Parking Brake Lever Parking Brake ...

Page 593: ... Front Disc Brake Brake caliper Brake hub Brake disc Air breather Drive shaft Lower arm ball joint Brake pad Upper arm connection 2 way piston Brake caliper Tie rod end connection Knuckle Backing plate Lower arm connection ...

Page 594: ...11 31 4850 01 Rear Disc Brake Brake caliper Rear shock absorber Brake disc Air breather Brake hub Brake pad Brake hose one way piston Brake caliper Air breather Backing plate ...

Page 595: ...DRAULIC CIRCUIT Brake booster Brake fluid reservoir and master cylinder HECU Hydraulic Electric Control Unit 1 2 3 Front disc brake and caliper Rear disc brake and caliper 3 way connector ESP ONLY 4 5 6 with ABS ...

Page 596: ...11 33 4850 01 5 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 597: ...r between ABS ESP system equipped vehicle and non ABS ESP equipped vehicle The drum type brake is installed on non ABS equipped vehicle while the solid disc thickness approx 10 4 mm is installed on ABS ESP equipped vehicle 3 Parking Brake Ventilated disc type Solid disc type Front Ventilated Disc and Caliper 2 internal Cylinders Piston Rear Disc and Caliper 1 Internal Cylinder For the parking brak...

Page 598: ...12 4 2 SECTIONAL DRAWING 1 Front Disc Brake 2 Rear Disc Brake ...

Page 599: ...the vehicle speed to the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication 1 Location of the wheel speed sensor rear right wheel Connector Appearance In vehicle without ...

Page 600: ...12 6 3 SPECIFICATIONS Description Item NON ABS ABS ESP Brake pedal Brake master cylinder Brake booster Front brake Rear brake Parking brake Brake fluid ...

Page 601: ...mply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disc and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is in comple...

Page 602: ...r comfortable driving When the vehicle exceeds its physical limits it cannot be controlled Do not rely on the system Keep on the safe driving Feeling when ESP is working When the ESP system activates the feeling can be different depending on vehicle driving conditions For example you will feel differently when the ESP system is activated during the ABS is operating with the brakes applied and when...

Page 603: ...e rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 ESP HECU Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Brake Force Distribution 3 ABD Automatic Braki...

Page 604: ...ing lamp comes on ESP is activated by pressing the switch again ESP warning lamp goes off HDC is activated by pressing the switch Green HDC indicator comes on HDC is deactivated by pressing the switch again Green HDC indicator goes off Detects the angle of the steering wheel and sends it to HECU Detects lateral acceleration longitudinal acceleration and yaw rate ...

Page 605: ...eel Speed Sensor FOR 4WD Rear Wheel Speed Sensor LH RH HECU Receives the signals from wheel speed sensor steering wheel angle sensor sensor cluster and pressure sensor and perform the vehicle stability control function ...

Page 606: ...ing by controlling the vehicle stability using the input values from the sensors and applying the brakes independently to the corresponding wheels The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering is when the steering wheel is steered to a certain angle during driving and th...

Page 607: ... during driving and the rear tires slip outward losing traction When compared with under steering vehicles the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases 2 Over steering ...

Page 608: ...e as he or she intends 2 ESP Control As the single track vehicle model used for the calculations is only valid for a vehicle moving forward ESP intervention never takes place during backup The ESP system includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the brakes are applied during cornering at the speed of ...

Page 609: ...12 15 4892 01 The following figure shows the operating range according to driving conditions Operating range Turning Turning ...

Page 610: ...stem under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 611: ...ired under emergency The BAS System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the brake pre...

Page 612: ...cy braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions Pressure over 20 bar Pressure changes over 1500 bar sec...

Page 613: ...e must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns T...

Page 614: ...ehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off however the ARP function is also deactivated when the ESP function is not operatable due to system malfunction ...

Page 615: ...allows the vehicle to automatically decelerate to about 7 km h by 0 1G on steep roads slope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation When you press the HDC switch the green HDC indicator comes on and when the HDC operates the green HDC indictor flashes...

Page 616: ...d is the speed that the HDC is not terminated even after the vehicle speed reaches 7 km h but is converted to the stand by mode When the vehicle speed increases again as a result of the increase of the road steepness etc the HDC goes into operation Forward driving 7 km h Reverse driving 7 km h automatic transmission 8 5 km h manual transmission The vehicles with manual transmission do not have a s...

Page 617: ...during the HDC operation When depressing the accelerator pedal or brake pedal HDC system is changed to stand by mode When releasing the pedal HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by depressing and releasing the pedal When the slope level exceeds 20 during the HDC operation When depressing the accelerator pedal HDC system is changed to st...

Page 618: ...ring downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden When the internal temperature of HDC system goes over 450 C due to long downhill driving on a steep hill with HDC operated 5 There is no specific temperature sensor in the system but a programmed logic inside the HECU predicts the temperature based on the operating times and conditions of HDC When...

Page 619: ...25 4892 01 4 Input Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function ...

Page 620: ...peration ON OFF and operation conditions The HDC indicator on the instrument panel has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Initial ignition ON HDC system error occurs Brake system overheat ...

Page 621: ...eration The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the HDC may su...

Page 622: ...r Active Wheel Speed Sensor 7 Components and Locations There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system However the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied ...

Page 623: ...12 29 4892 01 Steering Wheel Angle Sensor HDC Switch Sensor Cluster Yaw Rate Lateral Sensor Longitudinal Sensor 1 Comparison with ABS System ESP OFF Switch ABS ESP HDC Indicator ...

Page 624: ...12 30 7 INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input Output of ESP System ...

Page 625: ...12 31 4892 01 8 HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ...

Page 626: ...rcuit and in secondary circuit When the vehicle brakes are not applied during engine running or when applying the non ABS operating brakes the normally open separation valve and the inlet valve are open whereas the normally closed shuttle valve and the outlet valve are closed When the ESP system is operating the normally open separation valve will be closed by the solenoid valve operation and the ...

Page 627: ...ed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve The pressure decreases just before the wheel speed drops and the wheels are locked The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump oper...

Page 628: ...es the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until jus...

Page 629: ...nding on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the wheel starts ...

Page 630: ...nsor for 4WD 11 COMPONENTS OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor Valve body B Plunger C Cam bushing Motor pump EBD warning lamp two indicators come on ...

Page 631: ...12 37 4892 01 1 Input and Output Diagram Of ABS System ...

Page 632: ...at are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 633: ... the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This procedure helps the wheel to maintain a stable hydraulic pressure 2 3 Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable the wheel can be locked as the wheel speed decreases This is when the ABS ECU detects the wheel speed and the...

Page 634: ...heel by the pump no pressure increase in wheel Therefore when depressing the brake pedal the pressure generated in the master cylinder is transferred to the disc and then the outlet valve decreases this pressure intermittently This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels When the ABS hydraulic pressure control takes place there may be some v...

Page 635: ...mp to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydraulic pressure cannot be generated a driver can steer the vehicle without power assist but it needs very high steering force In this case the operating force ...

Page 636: ...13 4 1 SYSTEM LAYOUT ...

Page 637: ...13 5 4610 01 ...

Page 638: ...13 6 2 COMPONENTS ...

Page 639: ...13 7 4610 01 ...

Page 640: ...32psi 2 21bar Temporary 60psi 4 13bar Wheel 16 inch 6 5J x 16 18 inch 7 5J x 18 Balance weight 16 inch Inner Attachment type Outer Clip type 18 inch Inner Attachment type Outer Attachment type Tightening torquse of wheel bolt 120 140 Nm Temporary tire 175 90R 16 Tire inflation pressure Full Size 32psi 2 21bar Temporary 60psi 4 13bar ...

Page 641: ...terval Incorrect toe adjustmen Adjust Incorrect wheel bearing preload adjustment Adjust Malfunction of brake syste Adjust Tire squeal vibration Too low tire pressure Adjust Unbalanced wheel or tire Adjust Heavy vibration of wheel or tire Uneven tire wear Uneven tire wear Check and adjust Premature tire wear Too high tire pressure Adjust Fast driving with low pressure tire Adjust Overload Adjust ...

Page 642: ...nflation pressure Excessive wear in the outer side of the tread than in the inner side Excessive camber or deflection of knuckle arm Excessive wear in the inner side of the tread than in the outer side Insufficient camber or deflection of knuckle arm 1 Appearance Check 3 INSPECTION Inside Outside Inside Outside Inside Outside Inside Outside ...

Page 643: ...ce in tie rod length between left and right sides Blade type wear from inner side toward outer side of the tread Excessive toe in Deflection of knuckle arm Difference in tie rod length between left and right sides Corrugation wear of tread Poor wheel balance Loose wheel bearing poor wheel alignment Inside Outside Inside Outside Inside Outside ...

Page 644: ...the groove at the point with mark which is the indicator of the tread wear limit The limit of the tread wear for all season tires are 1 6 mm which is the same as the general tires but the wear limit mark is indicated as Wear limit 1 6 mm Higher than recommended pressure can cause hard ride tire bruising or damage and rapid tread wear at the center of the tire Excessive tire wear over the limit of ...

Page 645: ...n the tire tread Specified value 2 03 mm If any measurement exceeds the above specifications replace the applicable tires or wheels Tire inflation pressure 3 Specified value 32 psi 2 21 bar Maintaining the specified tire ressure is essential for comfortable riding driving safety and long tire life Incorrect inflation pressures will increase tire wear and will impair safety vehicle handling comfort...

Page 646: ...balance weights for aluminum wheels Weight balance can be added by 5 g There are two types of weight balance tape type and adhesion type Make sure to read the manual of the manufacturer thoroughly before using wheel balance tester Change tire location To avoid uneven wear of tires and to prolong tire life inspect and rotate your tires every 5 000 km 6 Mixing tires could cause to lose control while...

Page 647: ...14 10 4 COMPONENTS Alloy wheel Alloy wheel Steel wheel Cap assembly wheel Cap assembly wheel Nut 120 140 Nm Tire 1 2 3 6 7 8 9 ...

Page 648: ...he power to propel brake and steer on the road It also functions to maintain a vehicle s movement In order to complete such tasks a tire must be structured to be a resilient vessel of air There is wear limit mark on the tire which protrudes as a strip shape located approximately 1 6 mm from the groove bottom This wear limit mark is not seen from the outside so there is additional mark on the shoul...

Page 649: ...14 12 OVM Tools Location Spare tire Jack connection Jack ...

Page 650: ...r and bead the flexible sidewall protects the carcass and enhances the ride A tire s type size structure pattern manufacturing company product name and various characters are indicated here Bead The bead attaches the tire to the rim and wraps the end of the cord fabric Comprised of the bead wire core flipper and other parts the bead is generally designed to be slightly tight around the rim so that...

Page 651: ...s the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly resulting in increased life The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire is excessive so a lot of heat is generated and the tire is worn ...

Page 652: ... be blown out in a short period of time If the standing wave symptom occurs on the tire rubber on the tread comes off and eventually the tire can be blown out which is very dangerous When driving at high speed the inflation pressure should be increased to decrease heat generation due to extension and contraction motion to decrease hydroplaning and to prevent standing wave To prevent this symptom i...

Page 653: ...ith the road surface but rotate floating on a thin film of water It causes brake failure lower traction force and losing the steering performance To prevent this increase the tire inflation pressure use tires with leaf shape tread which is not worn However it is a best measure to drive slowly Hydro Planing ...

Page 654: ...e 1 add the balance weight of a weight corresponding to unbalanced weight from B to A to maintain the static balance If the static balance is not maintained tramping up and down vibration of the wheels occurs Dynamic Balance The static unbalance of the wheel creates the vibration in the vertical direction but the dynamic unbalance creates the vibration in the lateral direction As shown in the figu...

Page 655: ...UT AND COMPONENTS This sensor is installed at the front bottom of engine compartment Manual air conditioner FATCFATC Ambient temperature sensor It changes sun load coming through front windshield into current to input to FATC controller Type Air Conditioner Controller FATC Manual air conditioner ...

Page 656: ...r filter Thermo AMP Main wiring connector Power transistor Blower Unit Side Heater Unit Side Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condition to control the air conditioner A sensor that detects coolant temperature and transmits it to engine ECU Condenser Installed in front of vehi...

Page 657: ...01 4 2 VENTILATION SYSTEM 1 Locations of Vents 2 Air Duct ...

Page 658: ...MP Power transistor Blower motor Air source door actuator Coolant temperature sensor Air mix door actuator Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Thermo AMP Air mix door actuator Main wire connector Active incar sensor interior temperature sensor Mode door actuator ...

Page 659: ...mo AMP Coolant Temperature Sensor Mode Door Actuator Power Transistor Blower Motor Air Conditioner Filter Air Source Door Actuator 3 AIR CONDITIONER MODULE AND SENSORS 1 Locations Active incar sensor Power transistor Blower motor Air mix door actuator ...

Page 660: ...01 7 6810 01 2 Components ...

Page 661: ...01 8 3 PTC Heater Layout 1 PTC Heater Assembly Layout ...

Page 662: ...e ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below 20 C Coolant temperature over 115 C For approx 4 seconds after starting the engine When engine speed is below 650 rpm When engine speed is over 4 500...

Page 663: ......

Page 664: ...at belt pretensioners of the driver s and passenger s seat belts retract seat belts 1 2 Curtain air bag G sensors These are located inside the left and right B pillar panel bottoms When a collision occurs the air bag at the side of collision deploys accordingly Please pay attention to that in the case of the curtain air bag only the air bag at the side of collision deploys not both 1 Once an air b...

Page 665: ...g the air bag deployment signal at the vehicle speed 3 km h or higher it sends out the door UNLOCK signal for 5 seconds Inflator Gas guide Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner 1 LOCATIONS AND RELATED COMPONENTS Curtain air bag DAB Driver Air Bag ...

Page 666: ...d passenger s air bags and or the driver s and passenger s seat belt retensioners When the front collision G sensor sends out only the air bag deployment signal the signal deploys the two front air bags and ctivates their seat belt pretensioners LH RH Connector Inflator Gas guide Curtain air bag Gas guide Inflator Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner ...

Page 667: ...verall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyoung Motors 1 Air Bag System Block Diagram Functions and Roles Included ...

Page 668: ...02 7 8810 03 ...

Page 669: ...ollision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver Rear View 1 Components Air bag cover Air bag housing Air bag cushion approx 50 liters Inflator approx 190 Kpa Retainer ring H...

Page 670: ...e together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and inflates the air bag cushions curtain air bags independently operate in case of the side collisions Rear View Front View 1 Compon...

Page 671: ...n air bag is slightly different from the one of the front air bag including pretensioner but it is the same as the conventional side air bag A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B pillar The signal is transmitted to the air bag unit The air bag unit instantly inflates the necessary air bag necessary by sending a high current...

Page 672: ...02 11 8810 03 1 Components ...

Page 673: ...ir bags deploy When a collision occurs or when brakes are applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat Belt Pretensioner Driver Side Belt Pretensioner Passenger Side Belt pretensioner LH Curtain air bag G sensor Belt pretensioner RH ...

Page 674: ...reel assembly Reel bracket Upper stay D ring Bending tongue Tongue stopper Lower anchor D bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D bolt Label D bolt Spacer Bush Lower anchor cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 675: ...02 14 5 Air Bag Unit Air Bag Unit Connector The sensor that detects collision is integrated into the air bag unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 676: ...s that is around the pretensioner reel The body panel has guiding holes to ensure its correct installation But incorrect tightening torque may break the sensor or make it insecure As a result the sensor may have inaccurate judgment and have the air bag deployed inaccurately Connector Driver s Side Passenger s Side Signal terminal Ground ...

Page 677: ...onator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for firing Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag related components...

Page 678: ...he middle of the unlock signal being sent out the unlock signal continues for the remaining time This function cancels when the ignition key is withdrawn 1 2 3 4 Reminder for door lock unlock control The unlock function by the air bag signal takes priority over any other lock unlock operations While or after the automatic unlock is made by the air bag system any lock or unlock request by other fun...

Page 679: ...times the air bag warning lamp will turn off if no malfunction have been detected 2 When the Air Bag Unit Detects Any Malfunctions in Unit When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second Then the waning lamp stays on 3 When the Air Bag Unit Receives Any Malfunction Signals from the O...

Page 680: ...02 19 8810 03 10 Electrical Wiring Diagram ...

Page 681: ...F SEAT 1 Driver Seat Reclining Motor Seat Cushion Rear Area Up Down Motor Seat Cushion Front Area Up Down Motor Lumbar Support Lever Seat cushion rear area up down bar Sliding rail Seat cushion front area up down bar Sliding motor Sliding rail ...

Page 682: ...03 4 2 Passenger Seat Reclining Motor Power Seat Switch Sliding rail Sliding rail Sliding motor Reclining Switch Sliding lever No seat height control function ...

Page 683: ... or down 2 Seat Cushion Angle Adjustment When moving the front side of the seat cushion switch up or down the front side of the seat cushion moves up or down When moving the rear side of the switch up or down the rear side of the seat cushion moves up or down 3 Seatback Reclining Adjustment When moving the upper side of the reclining switch forward or rearward the seatback moves forward or rearwar...

Page 684: ...l it up without pressing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down To change the seatback angle push the lever rearward Then release the lever at the desired position The seat is locked at the position Seatback Reclining Lever Seatback Reclining Lever ...

Page 685: ...s Seat Belt in Front Seats 3 point type Seat Belt Seat belt anchor Seat belt height adjustment lever Seat belt D ring Pre tensioner Seat belt anchor Seat Belt Seat belt D ring Buckle for 3 point rear center 2 point type seat belt Buckle of 3 point type seat belt Buckle for 3 point rear center Buckle for 3 point rear side Buckle of 3 point type seat belt Buckle of 2 point type seat belt Buckle for ...

Page 686: ...03 8 4 CIRCUIT DIAGRAM 1 Power Seat Driver ...

Page 687: ...03 9 7410 01 2 Power Seat Passenger ...

Page 688: ...04 3 7340 01 1 COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Front Drain Hose Rear Drain Hose ...

Page 689: ...OPEN direction for less than 0 5 seconds the sunroof slides back and opens until it reaches at the 1st stop position 330 mm Then if you continue to rotate the switch to its stop the sunroof is pull opened 420 mm To stop the operation while moving operate the sunroof switch to any direction 2 Close To fully close the sunroof briefly for approx 0 5 sec rotate the sunroof switch counterclockwise CLOS...

Page 690: ...nd the sunroof goes back to the original position However if the force against the sunroof is less than the specified value or the continuous resistance is detected the Anti Trap function doesn t operate Therefore make sure that there is no obstacle such as hand head or part of body before operating the sunroof 4 Hazard Manual Operation The sunroof can be operated by rotating the screw in motor op...

Page 691: ...04 6 6 Circuit Diagram of Sunroof ...

Page 692: ...CATIONS Instrument Panel Instrument Lower Panel Driver Side Glove Box and Instrument Lower Panel Passenger Side Sun Visor A Pillar B Pillar D Pillar C Pillar Quarter Panel C Pillar D Pillar and Rear Quarter Panel Center Console Assembly ...

Page 693: ...05 3 7610 01 Interior Room Lamp Sun Visor Front Room Lamp A Pillar B Pillar Door Trim Front Door Rear Door Trim Headlining Assembly Roof Wiring Rear Washer Hose ...

Page 694: ...06 3 7870 00 Hood Assembly Front Fender Assembly 1 COMPOSITION OF BODY EXTERIOR Front Door Assembly Front Bumper Assembly ...

Page 695: ...06 4 Rear Door Assembly Tailgate Assembly Rear Bumper Assembly Side sill garnish ...

Page 696: ...07 3 4110 01 1 DIMENSIONS Unit mm Top view Side view Front view Rear view ...

Page 697: ...07 4 2 JACK UP POINTS ...

Page 698: ...d Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision ...

Page 699: ...and NVH According to the Introducing of Front Floor and Rear Floor 3 Applied the Door Outer Panel Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 700: ...07 7 4110 01 4 Applied BPR Body Panel Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise ...

Page 701: ...07 8 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 702: ......

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