SSANGYONG Actyon Sports II 2012.01 Manual Download

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12-13

4610-01

Oil Pump Pressure Check

▶

Unscrew the pressure line fitting in power

steering pump.

Install the pressure gauge between the

power steering pump and the power

steering oil pressure line.

Place the shift lever to neutral position.

Apply the parking brake.

Open the valve in pressure gauge. Start

the engine and let it run at idle speed.

Turn the steering wheel several times so

that the oil temperature reaches to normal

operating level.

Before checking the pressure, check the oil

level and belt tension. Prepare the empty

container to collect the spilled oil during the

service.

Check the oil pump pressure to locate any

defect in oil pump.

Fully close the valve in pressure gauge and

measure the oil pressure.

Relief pressure

90 ± 3 bar

Oil pump

Steering gear box

To prevent internal damage, do not close

the gauge valve over 10 seconds.

Keep the oil temperature at proper range.

Summary of Contents for Actyon Sports II 2012.01

Page 1: ...GENERAL INFORMATION 1 DIMENSIONS 2 SPECIFICATION 3 7 ...

Page 2: ......

Page 3: ...01 3 0000 00 1 DIMENSIONS Unit mm 1910 1790 3060 4990 5070 1570 1570 Top view Side view Front view Rear view ...

Page 4: ... 4 Detailed Dimensions Unit mm Headlamp Front fog lamp Side repeater Tun signal lamp front Position lamp 1 2 3 4 5 Stop Tail lamp Back up lamp License plate lamp Turn signal lamp rear Reflector 6 7 8 9 10 ...

Page 5: ...01 5 0000 00 Unit mm ...

Page 6: ...mped on the frame behind the front right tire Engine number The engine number is stamped on the cylinder block behind the A C compressor 2 Vehicle Identification Chassis number The chassis number is stamped on the frame behind the front right tire ...

Page 7: ...01 7 0000 00 2 SPECIFICATION 1 Specifications in Unit Optional item Vehicle weight and gross vehicle weight may vary according to the options and vehicle types ...

Page 8: ...01 8 ...

Page 9: ...nded 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 10: ...01 10 3 Scheduled Maintenance Services Diesel Engine ...

Page 11: ...01 11 0000 00 ...

Page 12: ...01 12 ...

Page 13: ...01 13 0000 00 4 Scheduled Maintenance Services General Diesel Engine ...

Page 14: ...01 14 ...

Page 15: ...01 15 0000 00 ...

Page 16: ...01 16 5 Scheduled Maintenance Services Gasoline Engine ...

Page 17: ...01 17 0000 00 ...

Page 18: ...01 18 ...

Page 19: ...MODIFIED ITEMS 1 EXTERIOR 2 INTERIOR 3 MAJOR CHANGES IN ENGINE RH 4 MAJOR CHANGES IN ENGINE LH 5 MAJOR CHANGES IN CHASSIS 2 4 6 8 10 ...

Page 20: ...Headlamp Tailgate garnish Tailgate Reflector Front bumper Hood Radiator grille Old New Old New Emblem Old New Position Turn signal lamp High Low beam Turn signal lamp Old New Old New 6410 02 Hinge with spring High Low beam Position lamp Fog lamp 7950 08 Emblem DRL ...

Page 21: ... combination lamp Side view Sun roof sun shade panel roller type Deck side panel Front fender Wheel Side sill Old New Old New Old New Old New Stop Tail lamp Turn signal lamp Back up lamp Stop Tail lamp Turn signal lamp Back up lamp 7820 22 Washer nozzle ...

Page 22: ...30 01 Clutch pedal Add clutch ECU switch 2130 07 Coolant reservoir Changed the appearance and capacity 2 8 L 8410 02 Fuse box in engine compartment Changed the layout of relays 2 INTERIOR Old New Old New Old New Old New Interlock switch 7410 12 Seat logo Old New ...

Page 23: ...02 5 0000 00 3710 01 Gear shift lever M T Old New 8210 01 Instrument cluster 3722 02 Gear selector lever A T Old New Old New 7610 01 Instrument panel Old New ...

Page 24: ...9 Intake duct and bracket Changed intake duct air intake direction location of T MAP sensor D20DTF Korando C 3 MAJOR CHANGES IN ENGINE RH Old New Old New Old New T MAP sensor T MAP sensor 1533 30 Oil level sensor oil pressure switch Old New Old New Oil pressure switch Oil level sensor 1225 01 Cylinder head cover PCV valve Changed the location of blow by hose and PCV valve ...

Page 25: ...d New Old New Power steering pump Old New 1533 30 Coolant outlet pipe Old New Coolant temperature sensor hole EGR cooler outlet Coolant temperature sensor hole EGR cooler outlet Coolant outlet pipe 1520 21 Coolant outlet port Changed the location of coolant temperature sensor and deleted the coolant outlet port from turbocharger 1793 23 EGR cooler coolant outlet hose ...

Page 26: ...ing type water cooling air cooling 1729 01 Exhaust manifold Changed the location of mounting flange and exhaust gas temperature sensor mounting hole 1127 01 Cylinder block D20DTF Korando C 4 MAJOR CHANGES IN ENGINE LH Old New Old New Old New Exhaust gas temperature Old New Old New Plug screw Pipe screw Ladder frame ...

Page 27: ... Reduced weight Deleted ring gear 1130 18 Drive plate assembly A T Changed the location of torque converter mounting hole 1130 13 Dual mass flywheel Deleted centering sleeve 1115 02 Engine mounting bracket D20DTR Actyon Sports Old New Old New Old New Old New Old New with center bearing without center bearing ...

Page 28: ...module Introduced ESP system 4420 01 Stabilizer bar Introduced dual peak bush 4411 01 Shock absorber spring Spring height and rate changed Height 345 7 4WD 341 7 2WD 5 MAJOR CHANGES IN CHASSIS Old New Old New Dual peak bush ...

Page 29: ... transmission 3680 01 Automatic transmission Changed the torque conver torque converter housing due to new engine Old New Old New 2412 02 CDPF Introduced CDPF to meet EURO 5 regulation 2411 01 DOC Introduced DOC to meet EURO III or EURO IV regulation G23D D20DTR ...

Page 30: ......

Page 31: ...YOUT 2 MAJOR COMPONENTS 3 ENGINE COMPARTMENT LAYOUT 4 CAUTION WHEN SERVICING THE ENGINE 5 STANDARD BOLTS SPECIFICATIONS 6 CODING AND INITIALIZATION SPECIAL SERVICE TOOLS 1 SPECIAL SERVICE TOOLS 2 NORMAL EQUIPMENTS 3 4 6 8 10 11 12 17 ...

Page 32: ......

Page 33: ...01 3 0000 00 Left view Right view Rear view Front view 1 ENGINE LAYOUT ...

Page 34: ... steering pump pulley Water pump pulley Alternator pulley Idler pulley No 2 A C compressor pulley Auto tensioner Idler pulley No 1 Isolation damper Rear view E EGR valve Fuel temperature sensor Fuel HP pump assembly Coolant temperature sensor IMV valve Crankshaft position sensor Oil pressure switch ...

Page 35: ...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 36: ...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 Power steering fluid reservoir Brake fluid reservoir Fuse relay Engine oil dipstick gauge Washer fluid reservoir cap Engine oil filler cap Air cleaner Operating vehicle with insuffi cient amount of oil can damage the engine Make sure the engine oi...

Page 37: ...on Daily inspection Weekly inspection Service interval Engine oil oil filter Inspection EU Change every 20 000 km or 12 months The service interval should be shortened under severe conditions General Change every 15 000 km or 12 months The service interval should be shortened under severe conditions Coolant Inspection Change every 200 000 km or 5 years Air cleaner element Inspection Diesel EU Chan...

Page 38: ...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 39: ...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 40: ...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 41: ...atically Select 5 speed A T DC 5 AT 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 h...

Page 42: ...r T99410010A Name Belt tension adjuster Use to release tension without removing belt when replacing pulley or pump How to use on engine Part number T9941 0010A Name Flywheel fixing device Use to fix flywheel or drive shaft to prevent engine from rotating when removing crankshaft pulley ...

Page 43: ...Name Valve spring complete Use Used to compress the valve spring Y9922 082B W99110230A Part number Y9922 018 Name Remover Use to remove the valve stem seal Part number Y9922 008 Name Installer Use to install the valve stem seal Name Part number Tool How to use ...

Page 44: ... Used to measure the protrusion of piston Part number Y9922 0172B Name Piston install guide Use Used to slide the piston into cylinder Part number W9911 0120A Name Inserting guide Use Used to install the rear crankshaft oil seal Part number T9918 0010A Name Injector remover Euro V ...

Page 45: ...01 15 0000 00 No 부품명 수량 사진 6 Main nut A 1 7 Main bolt A 1 No Part name Amount Tool 1 Injector remover set 1 2 Main bar 1 3 Cross bar 2 4 Main bolt holder 1 5 Ball bearing 1 Components ...

Page 46: ...01 16 No Part name Amount Tool 8 Injector holder A 1 9 Injector B 1 10 Injector holder cover 1 11 Bar holder assembly 2 12 Support mounting bolt 4 13 Main support 4 ...

Page 47: ...e gauge Use to angle tighten correctly after torque tightening Name Part number Tool How to use Name Engine stand 1 tone or more Use to fix the removed engine or engine with transmission Name Engine crane 1 tone or more Use to move the engine module including transmission to working space or engine stand 2 NORMAL EQUIPMENTS ...

Page 48: ...rt number Tool How to use Name High pressure pump gear nut remover Use to remove install the high pressure pump sprocket Name Adapter gauge Use to measure the compression pressure by inserting it into glow plug hole ...

Page 49: ...play Intake 0 1 to 0 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 Approx 0 7 mm Exhaust Approx 0 8 mm Valve recess Intake 0 1 to 0 7 mm Exhaust Cylinder block Piston protrusion 0 541 to 0 649 mm Piston ring TOP ring end gap 0 20 to 0 35 mm 2nd ring end gap 0 35 to 0 50 mm...

Page 50: ...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 51: ...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 52: ...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 53: ... 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 54: ...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 55: ...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 0 541 to 0 649 mm Measure it at both ends of crankshaft ...

Page 56: ...to 0 7 mm Exhaust valve 0 1 to 0 7 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 1 to 0 7 mm 2 Cylinder head pressur...

Page 57: ...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 58: ... 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 59: ... 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 60: ...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 61: ... 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 62: ...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 63: ...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 64: ...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 65: ... 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 66: ...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 67: ...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 68: ...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 69: ... 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 70: ...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 71: ...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 72: ...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 73: ...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 74: ... 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 75: ...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 76: ...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 77: ... 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 78: ...02 32 Screw plug Oil seal Timing gear case cover 5 Timing gear case cover Timing gear case cover TGCC ...

Page 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ... 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 90: ... 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 91: ...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 92: ...ck 1 Overview The major dimensions in D20DTR are similar to D20DT 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 93: ...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 94: ... 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 95: ...ery 15 000 km Water accumulating capacity 200 cc Heater capacity 250W 13 5V Injector System pressure 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...

Page 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...03 11 2210 01 4 Fuel System Check Procedure ...

Page 104: ...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 105: ...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 106: ... 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 107: ...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 108: ...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 109: ... 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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...03 25 2210 01 3 Input Output devices Refer to Chapter Engine Control ...

Page 118: ...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 119: ...leaner 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 Weight 103 9 kg Operating temperature 30 100 C Intercooler Core material Aluminum Size 614W x 192H x 30T Core size 614W x 192H x 30T Tank material Plastic Molding Efficiency 80 ...

Page 120: ...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 121: ...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 122: ...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 123: ...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 124: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM For more information refer to Chapter Engine Control ...

Page 125: ...04 9 1719 00 4 OPERATING PROCESS Work Flow ...

Page 126: ...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 127: ...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 128: ...05 3 1729 01 1 TROUBLESHOOTING 1 Work Flow ...

Page 129: ... 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 130: ...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 131: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 132: ... 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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 138: ...06 9 1914 01 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 139: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 140: ...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 141: ...06 12 2 Work Flow for Troubleshooting ...

Page 142: ...06 13 1914 01 ...

Page 143: ...06 14 ...

Page 144: ...06 15 1914 01 ...

Page 145: ...06 16 ...

Page 146: ...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 147: ...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 148: ...e power 2 COMPONENTS Engine ECU 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 세부제어로직은 엔진제어편 참조 ...

Page 149: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...Min cooling capacity over 68 000 kcal h Antifreeze Type 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 temperature ...

Page 156: ... 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 157: ... 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 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...09 6 3 Checking Battery ...

Page 166: ...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 167: ...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 168: ...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 169: ...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 170: ...09 11 1451 01 2 OPERATING PROCESS 1 Charging Flow ...

Page 171: ...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 172: ...09 13 1451 01 3 CIRCUIT DIAGRAM ...

Page 173: ...ption Specification Glow plug Rated voltage 12 V Operating voltage 6 16 V Maximum temperature 1300 C Operating temperature 1100 C Glow plug control unit EMS operating voltage 6 16 V Operating temperature 40 C 110 C Dark current Max 1 mA ...

Page 174: ...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 175: ...10 5 1413 00 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 176: ...10 6 3 Circuit Diagram ...

Page 177: ...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 178: ...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 179: ...Description Specification Capacity 12 V 2 3 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 180: ...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 181: ...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 182: ...11 6 2 Circuit Diagram ...

Page 183: ...pedal The vehicle speed must be greater than 38 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 184: ...torways or highways where there is no sudden 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 roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 185: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 186: ...12 6 2 Configuration ...

Page 187: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 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...

Page 188: ... 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 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Page 189: ...ntil the desired speed is reached while the vehicle speed is over 36 km h 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 To decrease the vehicle speed in stages while the cruise control system is runnin...

Page 190: ...hicle 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 But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Page 191: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Page 192: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Page 193: ... 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 194: ...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 195: ...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 196: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 197: ...13 7 1793 00 2 Input Output Devices ...

Page 198: ...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 199: ......

Page 200: ...ission Regulation Euro V Front Area 154 06 Size DOC 158 X 124 X 78L DPF 158 X 124 X 195L CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 4 2L Material of Filter AT Aluminum Titanium Alloy ...

Page 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ... 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 211: ...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 212: ...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 213: ...14 16 4 Fuel Injection During CDPF Regeneration ...

Page 214: ...14 17 2412 02 6 ELECTRIC CIRCUIT DIAGRAM ...

Page 215: ... 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 216: ... 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 217: ... 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 218: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ... 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 225: ...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 226: ... 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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ... 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 233: ...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 234: ...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 235: ...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 236: ...15 24 B Input Output for variable swirl valve ...

Page 237: ...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 238: ...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 239: ...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 240: ...15 28 C Input Output of E EGR system ...

Page 241: ...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 242: ...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 243: ...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 244: ...15 32 C Input Output for E VGT system ...

Page 245: ...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 246: ... 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 247: ...15 35 0000 00 C Input Output for oxygen sensor ...

Page 248: ...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 249: ... 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 250: ...15 38 C Input Output for cooling fan and A C compressor ...

Page 251: ... 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 252: ...nted 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 rel...

Page 253: ... 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 254: ...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 255: ...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 256: ...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 257: ...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 258: ...15 46 C Input Output for CDPF control ...

Page 259: ...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 260: ...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 261: ...15 49 0000 00 3 Input Output for CAN communication ...

Page 262: ... 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 263: ...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 264: ...01 5 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 265: ...01 6 LH Side View RH Side View ...

Page 266: ...01 7 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 267: ...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 268: ... 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 269: ... 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 270: ...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 271: ...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 272: ...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 273: ...01 14 5 GENERAL DIAGNOSIS ...

Page 274: ...01 15 1113 01 General Diagnosis Cont d ...

Page 275: ...01 16 General Diagnosis Cont d ...

Page 276: ...01 17 1113 01 General Diagnosis Cont d ...

Page 277: ...01 18 General Diagnosis Cont d ...

Page 278: ...01 19 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 279: ...01 20 2 Fastener Tightening Specifications ...

Page 280: ...01 21 1113 01 Fastener Tightening Specifications Cont d ...

Page 281: ...01 22 2 Performance Curve ...

Page 282: ......

Page 283: ...02 3 1713 08 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 284: ...03 3 2420 01 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 285: ...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 286: ...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 287: ...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 288: ...04 3 2110 01 1 GENERAL SPECIFICATIONS ...

Page 289: ...04 4 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 290: ...CATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 4 Outlet Hose 5 3 way 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 291: ...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 292: ...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 293: ... 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 294: ...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 295: ...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 296: ...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 297: ...CEDURE OVERVIEW AND OPERATION PROCESS 1 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION 1452 01 GENERATOR REPAIR INSTRUCTIONS 1462 01 STARTER REPAIR INSTRUCTIONS 2610 01 BATTERY REPAIR INSTRUCTIONS 1440 01 SPARK PLUG AND IGNITION COIL REPAIR INSTRUCTIONS 3 5 11 12 13 14 ...

Page 298: ...05 2 ...

Page 299: ...05 3 1452 01 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 300: ...05 4 2 Ignition System Cont d ...

Page 301: ...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 302: ...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 303: ...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 304: ... 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 305: ...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 306: ...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 307: ...pedal The vehicle speed must be greater than 38 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 308: ...torways or highways where there is no sudden 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 roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 309: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 310: ...12 6 2 Configuration ...

Page 311: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 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...

Page 312: ... 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 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Page 313: ...ntil the desired speed is reached while the vehicle speed is over 36 km h 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 To decrease the vehicle speed in stages while the cruise control system is runnin...

Page 314: ...hicle 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 But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Page 315: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Page 316: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Page 317: ... Fuse Relay Box In Engine Compartment 1 OVERVIEW The ICM Integrated Control Module mounted to the back of the STICS is integrated with the door lock unlock relay windshield de icer relay and turn signal lamp relay There are four fuse relay units Interior Fuse Relay Box LH Mounting Location of ICM ...

Page 318: ...TMENT The label attached on each fuse box indicates only major fuses and relays Therefore there are more fuses and relays than indicated For details about the connection of fuses and relays refer to the power distribution circuit diagram on the following pages ...

Page 319: ...01 5 8410 02 4 CAPACITY AND NAME OF INTERIOR FUSE AND RELAY 1 Interior Fuse and Relay Box on Driver Side ...

Page 320: ...01 6 2 Interior Fuse and Relay Box on Passenger Side ...

Page 321: ...shield de icer relay Turn signal lamp relay 1 Overview 2 Mounting Location Door lock unlock relay Turn signal lamp relay Windshield de icer relay Inner view of ICM PCB PAS buzzer Chime ICM box STICS The relays in the ICM box cannot be replaced respectively so if the any of the components on the PCB are defective they should be replaced as an assembly ...

Page 322: ... No 12 terminal The STICS activates and or controls the door lock relay connected to the ICM No 15 terminal using the STICS No B3 terminal depending on the operating conditions The activated door lock relay supplies the No 30 terminal with the B power which is standby on the No 87 terminal and supplies each door actuator with the B power The supplied power flows to the G201 ground connected to the...

Page 323: ...o 6 terminal using the STICS No A1 terminal depending on the operating conditions The activated door unlock relay supplies the No 30 terminal with the B power which is standby on the No 87 terminal and supplies each door actuator with the B power The supplied power flows to the G201 ground connected to the ICM No 14 terminal via the No 30 and 87a door lock relays for corresponding load ...

Page 324: ...amp relay terminals via the ICM No 18 terminal The STICS activates and or controls the hazard warning lamp relay using the No A26 terminal depending on the operating conditions The activated relay supplies the No 87 and 87a terminals with the power which is on standby on the No 30 hazard warning lamp relay terminal The supplied power flows to the corresponding circuit via the No 7 and 16 ICM termi...

Page 325: ...lay terminals via the ICM No 10 terminal The STICS activates and or controls the windshield de icer relay using the No A4 terminal depending on the operating conditions The activated relay supplies the No 87 terminal with the power which is on standby on the No 30 windshield de icer lamp relay terminal The supplied power flows to the windshield de icer circuit via the No 1 ICM terminal ...

Page 326: ...2V 200 mA Inductive load 9 Door unlock relay DC 12V 200 mA Inductive load 10 Horn relay DC 12V 260 mA 11 Tail lamp relay DC 12V 200 mA Inductive load 12 Hazard warning lamp relay DC 12V 200 mA Inductive load 13 Power window relay DC 12V 200 mA Inductive load 14 Rear defogger relay DC 12V 200 mA Inductive load 15 Wiper LOW relay DC 12V 200 mA Inductive load 16 Wiper HIGH relay DC 12V 200 mA Inducti...

Page 327: ...UNLOCK one of rear doors GND LOCK all rear doors OPEN 12 Tailgate lock unlock switch LOCK OPEN UNLOCK GND 13 Rear defogger switch ON GND OFF OPEN 14 Seat belt switch Unfastened GND Fastened OPEN 15 Sunroof open switch ON GND OFF OPEN 16 Parking brake switch ON GND OFF OPEN 17 Air bag collision sensor ON 200 ms output LOW OFF OPEN 18 Wiper motor parking switch STOP BAT VOLTAGE ROTATING GND 19 Washe...

Page 328: ...door lock switch ON GND OFF OPEN 28 Multifunction auto light switch ON GND OFF OPEN 29 Turn signal lamp switch ON BAT GND OFF OPEN approx 5 1 V 9 2 V 30 Rain sensor ON GND DATA OFF BAT 31 Telematics ON GND DATA OFF BAT 32 Diagnosis ON GND DATA OFF BAT KWP2000 ...

Page 329: ... SPORTS called as RKSTICS REKES STICS Super Time Integrated Control System is almost the same as that of ACTYON SPORTS in terms of its function and role Chime STICS unit PAS buzzer ICM relay box Inside of Lower IP Cover on Drive Side ...

Page 330: ...he lever for more than 0 6 seconds Three wiping cycles with washer spray Front Auto Washer Switch AFW When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times MIST OFF AUTO LO HI Previous model Pressing the switch makes washer flui...

Page 331: ...ed on for 0 1 to 0 59 seconds with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off The wiper relay is turned on at 0 3 seconds after from the time when the washer switch is turned on for more than 0 6 seconds with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch ...

Page 332: ...switch 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 ...

Page 333: ...th the ignition switch ON and the INT 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 ...

Page 334: ...overridden during the auto washer coupled wiper operation The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation When the auto INT switch input is received during the auto washer operation the auto washer operation stops and the auto INT operation is activated ...

Page 335: ...02 12 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 336: ...when turning the INT AUTO switch from the OFF to ON position the LOW relay operates to drive the wiper motor for 1 cycle only if data from the rain sensor indicates rain drops Multifunction wiper switch 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...

Page 337: ... with the ignition switch and the INT AUTO switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However a washer input is overridden if there is an output for continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation ...

Page 338: ...ased ex sensitivity 0 1 while the ignition switch and the INT 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 ...

Page 339: ...n switch is in ON position and the INT switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 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 ...

Page 340: ...alfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 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 ...

Page 341: ... the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF However the wiper operates up to 5 minutes after rain stops If this function does not occur check No 8 pin If the pin is normal check the wiper relay related terminals 1 2 Symptom 3 The wiper operates 3 or 4 times at high speed abruptly Check whether the variable resistance knob on the multifunction wiper switch is...

Page 342: ...nding the pins 1 and 2 Symptom 5 The wiper does not operate at high speed even in heavy rain Symptom 6 The wiper responses are too fast or slow Check whether the variable resistance knob on the multifunction 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 343: ...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 in comparison with daytime i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level Enlarged auto light sensor Emitterlens The LED emitting the infrared rays is installed on the bott...

Page 344: ...o 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 VOLUME calculation The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis Pause time calculation Pause time means the duration that wipers are stopped at ...

Page 345: ...time when turning ON IGN switch OFF INT switch ON Resume the intermittent time when turning ON 1 2 3 2 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 wiper relay is ON INT switch ON or washer switch ON The output stops immediately after turning off the switch Pause time of vehicle speed sensit...

Page 346: ...ile 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 does not work when the IGN1 switch is in ON position The function has priority over the TAILLAMP ON WARNING Chime Buzzer PAS buzzer ICM relay box STICS ...

Page 347: ...utputs UNLOCK signal for 5 seconds 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 UN...

Page 348: ... is closed during the UNLOCK output for approx 5 seconds the UNLOCK output stops immediately When the ignition key is inserted during the 5 seconds 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 functio...

Page 349: ...nd the ignition key is removed The c 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 does not work when the IGN1 switch is in ON position ...

Page 350: ...le 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 Since the luggage room tailgate does not have the door switch the door ajar warning light does no...

Page 351: ...tch to the OFF position during the warning operation The chime buzzer stops and the seat belt warning light stays on for the remainig time when fastening the seat belt 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 The seat belt warning light blinks and the ...

Page 352: ... is applied and the vehicle speed is below 10 km h The warning light goes off when releasing the parking brake under step 2 The warning light blinks and the chime buzzer sounds for 2 5 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 is applied The warning light goes off and the chime buzzer stops when releasing the parking br...

Page 353: ...m lamp output should stop immediately after turning on the ignition key during the 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 k...

Page 354: ... 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 whenever a door is opened The lamp always comes on while the switch is at the other position Driver s seat Tailgate Center Room Lamp Door coupled operation Center Room Lamp Lamp ON...

Page 355: ...ut stops when the ignition key is turned to the ON position The output stops when receiving the lock signal from the remote control key and entering armed mode 1 2 3 4 Key cylinder with key hole illumination With diesel and gasoline engine With diesel engine With gasoline engine Without immobilizer rechargeable With key hole illumination With immobilizer rechargeable With key hole illumination Wit...

Page 356: ... lamp relay is turned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp The tail lamp relay is turned on when inserting the ignition key into the ignition switch The tail lamp relay is turned off auto cut when opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 ...

Page 357: ...02 34 STICS Circuit for Front Rear Defogger Timer ...

Page 358: ...ding de icer activates the corresponding switch and the STICS controls the operating time Tailgate and outside rearview mirror heated glass switch Pressing switch activates tailgate and outside rearview mirror heated glass for approx 12 minutes Windshield heated glass de icer switch Pressing switch activates windshield heated glass for approx 12 minutes ...

Page 359: ...arted IGN ON The output stops when turning on the front defogger switch again during its operation The output is ON only for 6 minutes when turning on the front defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the ignition switch is OFF 1 2 3 4 ...

Page 360: ... started IGN ON The output stops when turning on the rear defogger switch again during its operation 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 ignition switch is OFF 1 2 3 4 ...

Page 361: ...he escort signal is received again during this time the operation is extended once for 20 seconds However only when the system is in armed mode when receiving the escort signal from the remote control key the power supply and output is turned on The headlamp relay output is turned off immediately after receiving the lock signal from the remote control key during its operation However signals other...

Page 362: ...s UNLOCK signal for 0 5 seconds when positioning the driver s or passenger s door lock knob to the unlock from lock 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 whil...

Page 363: ...is activated LOCK UNLOCK output is performed However if the driver s passenger s lock switch is previously locked UNLOCK output is performed and if the driver s passenger s lock switch is unlocked LOCK output is performed The input of the central door lock switch is overridden in armed mode 1 2 ...

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

Page 365: ...ess 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 switch The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this function or the...

Page 366: ...en turning OFF the ignition switch 1 2 3 4 Cautions for door lock unlock control 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 output is ig...

Page 367: ...ndow relay output is ON for 30 seconds when turning off the ignition switch The power window relay output is OFF when opening the driver s door or the passenger s door The power window relay is turned OFF when receiving the remote control key lock signal armed mode during its extended operation period of 30 seconds 1 2 3 ...

Page 368: ... does not affect the engine hood OPEN CLOSE of the dech tailgate does not affect entering the armed mode In other words when the hood and front rear door are closed even if the dech tailgate is open the vehicle can enter the armed mode DOOR LOCK DOOR UNLOCK DOOR LOCK Indicates that driver s passenger s and rear door and tailgate lock switches are in LOCK positions DOOR UNLOCK Indicates that driver...

Page 369: ...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 370: ... completion of warning 27 seconds a b c The theft deterrent horn and hazard warning flasher output is ON for 27 seconds at the interval of 1 second a Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC ESCORT during warning operation Cancels warning after 27 seconds remaining time while the ignition key is turned to ON position If the ignition switch is turned to ON p...

Page 371: ...eactivated when receiving PANIC signal from the remote control key during theft deterrent warning The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning PANIC output is OFF The PANIC warning output is ON when receiving the PANIC signal from the remote control key in Armed Ready Armed Warning Completion Relock Ready mode maintaining the the...

Page 372: ...is in the ON position If the ignition key is turned to the OFF position during this function is activated this function is immediately deactivated If the system receives signals for the turn signal lamp operation during this function is activated this function is immediately deactivated While the turn signal lamp signals are already inputted pressing the automatic hazard warning lamp switch does n...

Page 373: ...r the lock button of the remote control is pressed Panic function activated in the theft deterrent mode 2 If you press and hold the door unlock and panic buttons the buzzer will sound for 27 seconds and the hazard warning flasher blinks The function is inactivated if any button of remote control is pressed For the previous model only the theft deterrent horn has been activated LED flasher Briefly ...

Page 374: ...02 51 8710 01 Battery Replacement Key type Immobilizer charging key REKES key Specification Lithium ion PD2032 CR2032 Amount 1 EA 1 EA REKES key Battery Immobilizer charging key ...

Page 375: ...tion Connect the device to the diagnostic terminal The code can be registered only by the panic signal from the transmitter Other switches LOCK UNLOCK ESCORT can t code a b c Remote Door Lock All doors are locked when briefly pressing the door LOCK burron on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote con...

Page 376: ...the door switch on the remote control key for longer than 0 5 seconds The door unlock relay is ON for 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked successfuly 1 2 3 ...

Page 377: ...K and PANIC button more than 2 seconds on the remote control key the panic function is activated The vehicle activates the panic alarm by using the horn and hazard warning lamp for 27 seconds when receiving the panic message from the remote control key 1 2 ...

Page 378: ...r 20 seconds and goes off automatically when the escort message is received from the remote control key 1 2 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 RELOCK function 1 ...

Page 379: ...itch input folds the mirror If you turn the ignition switch to the OFF from ON position operating time is extended by 60 seconds Unlikely the previous model opening the front door does not affect the extension time i e opening closing the front door is irrelevant If the unfolding input is received from the switch during folding output or the folding input is received during unfolding output the ex...

Page 380: ...peration in step 2 the chime buzzer will not sound again If you turn the ignition swtich to the ON position again and the operating contions in step 1 are met the chime buzzer sounds again If the operating condtions for door ajar warning and sunroof open warning are met at the same time the sunroof open warning is activated preferentially 1 2 3 4 In order to prevent the driver from getting off the...

Page 381: ...02 58 Circuit Diagram for Wiper 4 CIRCUIT DIAGRAM ...

Page 382: ...02 59 8710 01 Circuit Diagram for Door Lock Control The door ajar warning lamp in the instrument cluster does not come on even though the tailgate is opened ...

Page 383: ... received code during registration The remote control key should be coded using the diagnostic device a b c 1 Operating requirements You should remove the ignition key 2 Code registration requirement You can register the code only using the diagnostic device 3 Transmitter code registration 5 REKES Key Coding ...

Page 384: ...iagnostic device maximum 5 Connect the diagnostic device to the vehilce and select the vehicle type and system RK STICS When the following screen is displayed select REMOCON CODING 1 Remove the remote control key from the ignition key box and press Next Press the door UNLOCK PANIC button on the remote control key once for approx 2 seconds or longer 2 ...

Page 385: ... one The first key coding completion screen is displayed with beep sound as follows Press Next and perform the second remote control key coding in the same way 3 When the second key coding is completed the following screen is displayed Finish the remote control key coding by pressing Previous 4 Exit the diagnostic screen remove the device from the diagnostic connector and perform the function test...

Page 386: ...nto the key cylinder and turn it to the ON position Select the vehicle type and system immobilizer on the diagnosis program Select the Transponder registration menu and enter the password initial value is 0000 Select Next 1 2 3 Press Next with the first key in key box 4 ...

Page 387: ...02 64 Check the progress 5 If another key should be registered additionally insert the second key into the key cylinder and press Next within 10 seconds since the first transponder coding is complete 6 ...

Page 388: ...02 65 0000 00 Press OK button when the registration is complete 7 If the registration fails press Previous button and perform the registration procedures again ...

Page 389: ...ice Fuction For Each Terminal Pin No Function Pin No Function 1 FFH diagnosis 9 Air bag 2 FFH forced driving 10 3 STICS 11 TCU 4 Ground 12 5 Signal ground 13 TCCU 6 CAN HIGH 14 CAN LOW 7 15 REKES key coding 8 16 Battery The REKESkey coding is not performed by connecting the REKEScoding terminal No 15 of the diagnostic connector to the jump wire between the ground terminals possible only diagnostic...

Page 390: ...03 3 7010 06 ECU REKES key Diagnostic connector 1 SYSTEM CONFIGURATION 1 Components and Locations Immobilizer warning lamp in instrument panel Immobilizer unit ...

Page 391: ...03 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 392: ... immobilizer and the rechargeable key are controlled by the immobilizer rechargeable unit Both functions are used in this system This immobilizer rechargeable unit starts the engine by communicating with the engine control unit and increases the life of the existing REKESbattery by charging the battery of the remote control key Immobilizer rechargeable unit Rechargeable Key VS RKSTICS Key Recharge...

Page 393: ...oom 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 When pressing the door UNLOCK and PANIC button for approx 2 seconds or longer the warning alarm sounds and the hazard warning lamp blinks for approx 27 seconds The function is inactivated if any button of...

Page 394: ......

Page 395: ...ted code to transponder 2 Sends an encrypted signal to unit as a response 3 Randomly transmitted code is changed to an encrypted signal in immobilizer rechargeable unit 4 System compares signal from transponder and encrypted signal in immobilizer rechargeable unit 5 When two or more immobilizer keys come into contact with each other s When the key is close to any device sending or receiving electr...

Page 396: ...nd transmits the positive message to the ECU 6 The ECU enable the engine to be started 7 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 please attend on the site In any cases the immobilizer system can not be removed from the vehicle If you attempt to remove it and dama...

Page 397: ...oil in the transmitter according to the change of magnetic field For details see the below Primary magnetic induction coil Secondary magnetic induction coil The single coil has both immobilizer function and recharge function For the immobilizer function if the transponder confirms the key as the startable key by communicating with the ECU it induces a magnetic induction in the primary coil by pass...

Page 398: ...econdary coil a magnetic field is formed as above Primary magnetic induction coil for charging battery Secondary magnetic induction coil The magnetic field occurred in the secondary coil interrupts the magnetic field in the primary coil 2 The magnetic field induced in the primary coil in this way creates the electromotive force by letting the current flow through the coil 3 ...

Page 399: ...03 12 3 Circuit Diagram ...

Page 400: ...l key for less 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 engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice 1 2 ...

Page 401: ... remote control key for less 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 all the doors unlocked successfuly 1 2 3 ...

Page 402: ... goes off automatically when the escort message is received from the remote control key 1 2 4 Remote Panic When pressing and holding the PANIC button on the remote control key for more than 2 seconds the panic function is activated The vehicle activates the panic alarm by using the horn for 27 seconds when receiving the panic message from the remote control key 1 2 ...

Page 403: ...voltage DC 13 5 V 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 404: ...ode indicator 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Engine hood open warning light Battery charge warning light Hazard Indicator 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 l...

Page 405: ...04 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 406: ...seat 4 5 6 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 8 Door open 9 10 Battery 11 12 Fuel input signal 13 TRIP mode reset switch 14 Manual transmission N n...

Page 407: ...GN IGN 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 LED IGN IGN ON CAN signal input 11 Immobi...

Page 408: ...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 409: ...pressure warning lamp LED IGN Signal input 24 Water separator warning light 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 ...

Page 410: ...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 411: ...n speedometer However these symptomsalso could be occured when the tirehas unevenwear differenttireinflationpressuresor differenttirespecifications 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 operations ...

Page 412: ...04 12 The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range ...

Page 413: ...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 414: ...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 415: ...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 416: ...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 417: ...04 17 8210 01 Shifting Mode TRIP reset switch ...

Page 418: ...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 419: ......

Page 420: ...ine Oil Pressure Warning Ligh This lamp 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 ap...

Page 421: ...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 422: ...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 Indicato...

Page 423: ...04 23 8210 01 5 CIRCUIT DIAGRAM ...

Page 424: ...04 24 ...

Page 425: ...amp 2 PY21W Back up lamp 1 2 P21W 1 P21W 2 Rear fog light 1 P21W License plate lamp 2 W5W Interior lamp Front room lamp 2 8W Glove box lamp 1 5W Center room lamp 2 10W Door courtesy lamp 2 5W Description The surface of lamps can get foggy when raining or washing the vehicle This is normal and is a result of the temperature difference between inner and outer surface of lamp cover However if water g...

Page 426: ...O 0 22 A relay load LOCK Max 28 A motor load Max 0 25 V Auto washer 0 1 A Wiper 4 5 A motor load 20 A Lock Min Max 0 8 V INT 25 mA MIST 5 A motor load Max 0 25 V Hazard warning flasher bezel switch Item Rated load Hazard warning flasher switch 12 V 10 A Rear heated glass switch 12 V 0 1 A Windshield heated glass switch 12 V 0 1 A TRIP switch 12 V 0 1 A Outside rearview mirror control bezel switch ...

Page 427: ...the driver seat Tailgate and outside rearview mirror heated glass switch Pressing switch activates tailgate and outside rearview mirror heated glass for approx 12 minutes Driver power window switch ESP ON OFF switch Pressing this switch deactivates the ESP Electronic Stability Program system and turns on the ESP OFF indicator on the instrument cluster Pressing this switch again turns off the ESP O...

Page 428: ...ill be sprayed again and the wiper will automatically operate 3 times Auto light switch Front wiper and washer coupled operation Pull the lever briefly below 0 6 seconds Wiping without washer spray Pull and hold the lever for more than 0 6 seconds Three wiping cylces with washer spray 4WD control switch Driver s heated seat switch Passenger s heated seat switch Audio remote control switch Gear shi...

Page 429: ...ey OFF and INT AUTO switch OFF sprays the washer fluid for 2 sec and operates the wiper 4 times and then immediately sprays the washer fluid for 1 5 sec and operates the wiper 3 times 2 Integrated Auto Light Sensor in Rain Sensor Unit The rain sensor unit is installed on the best location to detect the rain drops and the lighting intensity And an auto light sensor is newly integrated into the rain...

Page 430: ...he 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 Washer fluid inlet Spray passage Counter current Passage Washer fluid outlet Whirlwind ...

Page 431: ...for 1 5 sec with three wiping with no delay of time Frontnozzle 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 to STICS STICS Front nozzle ass...

Page 432: ...t operation Continuous wipe slow operation Front Auto Washer Switch AFW When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times Wiper and Washer Coupled Operation Pull the lever briefly for less than 0 6 seconds One wiping cycle w...

Page 433: ... 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 at 0 3 seconds after from the time when the washer switch is turned on for more than 0 6 seconds with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 434: ... 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 4 ...

Page 435: ...07 9 7810 01 4 CIRCUIT DIAGRAM ...

Page 436: ...ving 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 speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly E...

Page 437: ... Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the highest INT speed almost LOW 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 in comparison with daytime i e the AUTO wiper ...

Page 438: ...INT AUTO switch from the OFF to ON position with the ignition switch in the ON mode the LOW relay operates to drive the wiper motor for 1 cycle regardless of the rain sensor communication After that when turning the INT AUTO switch from the OFF to ON position the LOW relay operates to drive the wiper motor for 1 cycle only if data from the rain sensor indicates rain drops 2 2 FUNCTIONS OF RAIN SEN...

Page 439: ...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 a washer input is overridden if there is an output for continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 440: ...e 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 sensor while...

Page 441: ...ng terminal is grounded while the ignition key is in ON position and the INT switch is in ON position 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 442: ...lfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 2 The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 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 1 ...

Page 443: ...e ON position The wipers are operated in vehicle speed sensitive mode as soon as turning the INT auto switch to the ON position with the ignition key ON or turning the ignition key to the ON position with the INT auto switch ON This applies to the vehicle without the rain sensor Controls the wiper intermittent operation by the values from the vehicle speed and the setting value ...

Page 444: ...urned off during its operation IGN switch ON INT switch OFF Resume the intermittent time when turning ON IGN switch ON INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective 2 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is ON i e with the INT switch ON or washer switch ON Th...

Page 445: ...y 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 in comparison with daytime i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 3 OPERATION MODE OF RAIN SENSING WIPER SYSTEM ...

Page 446: ...rasonic wave Piezo ceramic element Calculates the distance between the sensor and the object by calculating the return time of the emitted the ultrasonic wave Frequency used 50 KHz 1 KHz Detection distance 30 cm 120 cm based on lineal distance between sensor and obstacle Tolerance 10 cm Sensor detection range at 6 dB LH RH sensor Center sensor Item Value Item Value Rated voltage DC 12 V Operating ...

Page 447: ...ic waves Obstacles lower than the bumper ex drain ditch or mud puddle 2 Not defective but improperly working When the sensing portion is frozen operates normally after thawed When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned When receiving other ultrasonic signals metal sound or air braking noises from heavy commercial vehicles When a high power ra...

Page 448: ...en reverse parking to notify the driver of the distance to obstacle When placing the gear selector lever to R position this unit activates the sensor to measure the distance between the object and the bumper The existing PAS unit displays the malfunctions using the LED when there are any defects in sending receiving signal or the open circuit to sensor On the other hand the PAS unit of KORANDO SPO...

Page 449: ...ls and if within stage 3 the warning beep sounds continuously 1 Sensing Distance and Range Sensor detection range Within 20 cm from the ground Intrinsically supersonic wave sensors may not detect obstacles within 20 cm from the ground Area 1 Obstacles may not be detected within 80 cm from the sensor Area 2 Sensor may not detect zone within 30 cm from the rear bumper Area 3 ...

Page 450: ...will be diagnosed once If any malfunction due to an open circuit in sensor or an error in sending receiving signals the system warns the driver with audible buzzer sound If it is normal the warning buzzer sounds for 65 ms 2 Troubleshooting When the sensor failed in self diagnostics PAS buzzer STICS ...

Page 451: ...09 8 3 CIRCUIT DIAGRAM ...

Page 452: ...8 16 0 V Operating temperature 20 C 70 C Storage temperature 40 C 80 C Radio Frequency range FM 87 5 108 MHz 50 kHz STEP MW 522 1620 kHZ 9 kHz STEP LW 144 290 kHz 1 kHz STEP Channels FM1 6 FM2 6 MW 6 LW 6 Performance Speaker output 45 W CH 4Ω Speaket impedence 4Ω Current consumption below 5 A max 10 A Parasitic current below 3 mA Bluetooth Performance HFP A2DP AVRCP Configuration MD 5XR Technology...

Page 453: ...10 4 Remote contro switches on steering wheel USB AUX module Front door speaker Handsfree microphone 1 LAYOUT ...

Page 454: ...10 5 8910 00 Micro pole antanna Rear door speaker Audio ...

Page 455: ...all 4 USB AUX CD selection 5 Power ON OFF Mute Volume 6 Preset key 1 Intro SCAN 7 Preset key 2 RPT 8 Preset key 3 Random 9 Preset key 4 folder down 10 Preset key 5 folder up 11 Preset key 6 File guide 12 AST SCAN TUNE UP DOWN 13 Eject 14 End call 15 Set 16 Band 17 LCD window ...

Page 456: ...e and has three connectors 16 pin 12 pin 20 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 ...

Page 457: ... 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 se...

Page 458: ...rature 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...

Page 459: ...01 6 4WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Inhibiter switch Adapter housing 2 Appearance Connector plug Transfer case ...

Page 460: ...01 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 461: ...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 462: ...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 463: ...01 10 4 SHIFT PATTERN DIAGRAM ...

Page 464: ... 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 465: ...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 466: ...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 467: ...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 468: ...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 469: ...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 470: ...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 471: ...01 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 472: ...01 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 473: ...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 474: ... 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 475: ...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 476: ...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 477: ...01 24 Hydraulic Circuit Diagram ...

Page 478: ...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 479: ...01 26 1st Gear M 3 53 1 ...

Page 480: ...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 481: ...01 28 1st Gear D 3 53 1 ...

Page 482: ...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 483: ...01 30 2nd Gear D 2 14 1 ...

Page 484: ...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 485: ...01 32 2nd Gear D Lock Up ...

Page 486: ...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 487: ...01 34 3rd Gear D 1 48 1 ...

Page 488: ...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 489: ...01 36 4th gear D 4th gear D in Limp home mode 1 16 1 ...

Page 490: ...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 491: ...01 38 5th gear D 0 87 1 ...

Page 492: ...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 493: ...01 40 6th gear D 0 68 1 ...

Page 494: ...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 495: ...01 42 Reverse gear R 3 09 1 ...

Page 496: ...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 497: ...01 44 Reverse R Limp Home Mode ...

Page 498: ... 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 499: ...01 46 Park ...

Page 500: ...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 501: ...01 48 Neutral ...

Page 502: ...e 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 exten...

Page 503: ... 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 504: ...nce Description Part 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 ...

Page 505: ... 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 506: ...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 507: ...02 8 3162 00 Main shaft ...

Page 508: ...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 509: ... 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 510: ...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 511: ...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 512: ...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 513: ... 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 514: ...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 515: ...02 16 2nd speed 1st speed 2 POWER FLOW ...

Page 516: ...02 17 3170 01 4th speed 3rd speed ...

Page 517: ...02 18 6th speed 5th speed ...

Page 518: ...02 19 3170 01 Reverse gear ...

Page 519: ...02 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 520: ...is used to prevent incorrect shifting To improve the shifting performance 3 piece double 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 521: ...03 4 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 522: ...03 5 3170 01 2 Tightening Torque ...

Page 523: ...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 524: ...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 sm...

Page 525: ...ormation 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 with...

Page 526: ......

Page 527: ...disc Type Dry type single diaphragm Diameter of facing Outer Ø250 mm Inner Ø160 mm Numbers of disc 2 Thickness of disc Free 8 7 0 3 mm When loaded 8 0 0 2 mm Setting load of clutch cover assembly At least 7 800 N Clutch master cylinder Operating travel 27mm Inner diameter Ø17 46 mm Concentric slave cylinder Maximum operating travel Max 20 mm Operating pressure Max 2 200 N Clutch fluid Type DOT 3 o...

Page 528: ...ch pipe and hose Concentric slave cylinder Pressure plate Flywheel If a driver depress the clutch pedal the hydraulic pressure is generated in the master cylinder It is transmitted to the concentric slave cylinder through the pipe resulting in the cylinder being forced out At this time the clutch disc is forced against the cylinder by pushing the cover This in turn remove the flywheel from the pre...

Page 529: ...unction which activates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out Unlike SAT type SATIC type does not need SST for clutch cover removal Operation 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 Disc wear Free play Diaphr...

Page 530: ...ft 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 usin...

Page 531: ...04 7 3010 01 3 Layout Clutch disc Clutch cover assembly Dual mass flywheel DMF Concentric slave cylinder Centering pin ...

Page 532: ...ion The divided dual masses are connected to the coil spring and damping system internally The DMF has the following benefits Reducing fuel consumption by lowering engine speed Reducing rattling noise and vehicle vibration in all driving ranges Reducing synchronization wear Facilitating gear change Protecting power train parts by preventing excessive load from being delivered Primary flywheel Seco...

Page 533: ... 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 534: ...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 535: ...to transmission Torque Gear ratio 4 55R 3 91R 4 55R 3 91R Gear Type Hypoid Size Ø182 8 mm Ø228 6 mm Offset 28 58 mm DYMOS 35 mm Tongil 30 mm Housing Steel Steel casting Oil Type SAE 80W 90 GL5 SAE 80W 90 GL5 Capacity 1 4 L 1 4 L GSL 1 9 L DSL 2 0 L Length 448 0 mm 469 0 mm Witdh 681 9 mm 1 717 7 mm Weight 45 kg 90 kg ...

Page 536: ...me transfer case Total length 343 mm Mating surface of front flange 40 mm Weight 32 4 kg including oil Oil capacity 1 4 L Oil type ATF DEXRON III Location Transfer case Major element Housing Part time TOD Bolt 11 ea M8 x 1 25 Input shaft A T outer spline M T inner spline ...

Page 537: ...ing 4WD HIGH and 2 48 of reduction gear ratio when selecting 4WD LOW The silent chain in transfer case transfers the output power to front wheels The simple operation of switches on instrument panel allows to shift between 2H and 4H easily while driving for 4L stop vehicle first The warning lamp warns the driver when the system is defective Front Rear ...

Page 538: ...rive train when the 4WD system is properly working Mode change 2H 4H 2 Wheel drive 4 Wheel drive Shifting is possible while driving at the speed of 70 km h or less 2H 4H 4L 2 Wheel drive 4 Wheel drive high speed 4 Wheel drive low speed For Automatic Transmission For Manual Transmission Stop the vehicle on level ground and move the gear selector lever into the N position Turn the switch to the desi...

Page 539: ...07 6 2 LAYOUT Front axle Front locking hub system IWE Front propeller shaft DSI 6 speed automatic transmission Part time transfer case Rear propeller shaft Rear axle ...

Page 540: ...power supply connector for 1 pin Transfer case main connector Shift motor connector Rear propeller shaft Oil filler plug Tightening torque 19 30 Nm Transfer case assembly Front propeller shaft T C motor Oil drain plug Tightening torque 19 30 Nm Damper ...

Page 541: ...ndicators 4H 4WD HIGH indicator ON 4L 4WD LOW indicator ON 2H Indicator OFF System failure 4WD CHECK warning lamp ON 4WD mode switch 4H 4 Wheel drive high speed 4L 4 Wheel drive low speed 2H 2 Wheel drive TCCU Solenoid valve ...

Page 542: ... section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Locking hub actuator Locking hub actuator Vacuum solenoid valve for IWE Vacuum pump Booster Electric signal To atmosphere TCCU Operating Process Vacuum generation process in front hub actuator Hub actuator FR Hub actuator FL Vacuum pump TCCU to atmosphere to atmosphere Vacu...

Page 543: ...gear 22WD 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 The vacuum pressure is released from the hub actuator At this time the front hub end gear is engaged tmosphere in 4WD mode Hub actuator LH Hub actuator RH In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump ...

Page 544: ...3240 01 5 POWER FLOW Switching 2H 4H 4L Vacuum solenoid Locking hub operation Released internal vacuum Front propeller shaft TCCU Front axle Front wheel Rear propeller shaft Rear axle Rear wheel Transfer case ...

Page 545: ...07 12 1 2H Mode 2 Wheel Drive Power Flow Output shaft of transmission Rear propeller shaft Rear wheel Rear axle Rear wheel Input shaft of transfer case Output shaft of transfer case ...

Page 546: ...07 13 3240 01 2 4H Mode 4 Wheel Drive High Speed Power Flow ...

Page 547: ...07 14 3 4L Mode 4 Wheel Drive Low Speed Power Flow ...

Page 548: ...sorber type Reciprocating cylindrical type gas type Stabilizer bar type Torsion bar type Rear Suspension Suspension type 5 link type Spring type Coil spring Shock absorber type Reciprocating cylindrical type gas type Stabilizer bar type Torsion bar type Front Wheel Alignment Toe in 2 2 mm 0 4mm Camber LH 0 19 0 25 RH 0 29 0 25 Caster LH 4 4 0 4 RH 4 5 0 4 ...

Page 549: ... Front axle shaft assembly Steering gear box assembly Lower arm assembly Shock absorber yoke Knuckle assembly Stabilizer bar assembly Front View Upper arm on knuckle nut Tightening torque 140 160 Nm Lower arm on knuckle nut Tightening torque 140 160 Nm Shock absorber to yoke bolt Tightening torque 125 145 Nm ...

Page 550: ...link upper nut Tightening torque 30 50 Nm Upper arm frame side bolt nut Tightening torque 110 130 Nm Stabilizer bar clamp bolt Tightening torque 40 60 Nm Lower arm end yoke bolt Tightening torque 70 80 Nm Lower arm shock absorber yoke side nut Tightening torque 150 170 Nm Lower arm frame side bolt nut Tightening torque 210 230 Nm Top View ...

Page 551: ...8 6 4 SYSTEM LAYOUT AND TIGHTENING TORQUE OF REAR SUSPENSION Lower arm link Stabilizer bar link Stabilizer bar Shock absorber Coil spring seat upper side Lateral rod Axle housing Upper arm link Top View ...

Page 552: ...ck absorber lower bolt nut Tightening torque 80 100 Nm Upper arm bolt nut Tightening torque 150 180 Nm Lower arm bolt nut Tightening torque 150 180 Nm Stabilizer bar link lower Tightening torque 60 80 Nm Stabilizer bar mounting bracket Tightening torque 40 60 Nm Stabilizer bar link upper Tightening torque 30 45 Nm ...

Page 553: ...ed torque Bent or broken coil spring Replace Damaged tire Replace Worn bushing Replace Vehicle pulls to one side Deformed arm assembly Replace Worn bushing Replace Bent or broken coil spring Replace Hard steering Excessive resistance of lower arm ball joint Replace Insufficient tire pressure Replace Faulty power steering Replace Unstable steering Worn or loosened lower arm bushing Retighten or rep...

Page 554: ...smission Rear suspension 1 SUSPENSION The suspension is the device to connect the axle and vehicle It absorbs the vibrations and impacts from road surface which enhances the comforts driving force braking force and drivability Front suspension ...

Page 555: ... Disadvantage The disadvantage is that it is slightly more complex than other systems like a MacPherson strut Due to the increased number of components within the suspension setup it takes much longer to service and is heavier than an equivalent MacPherson design 1 2 Double wishbone suspension is an independent suspension design using two occasionally parallel wishbone shaped arms to locate the wh...

Page 556: ...and drivability by reducing the coil spring weight Also it increases the space for passenger compartment by lowering the floor This type of suspension consists of multiple links such as coil spring shock absorber upper and lower arms lateral rod and stabilizer bar Shock absorber Stabilizer bar Rear coil spring Lower arm Upper arm Lateral rod ...

Page 557: ...s of the tires A and the rear ends of the tires B along the same axle when viewed the wheels from the top Toe in 2 2 mm 0 4 mm When viewed from the top the distance between the tire centers is smaller in the front than in the rear Side slip protection Parallel front wheels rotation straight ahead driving is ensured by toe in to prevent the wheels from tilting outwards by the camber while driving P...

Page 558: ... case the shock absorber contracts and the restoration force is applied to the steering wheel Disadvantages Cornering force decreases as the positive camber increases when the vehicle makes turn The hub bearing is worn unevenly if camber is excessive Zero camber When the tire center line is perpendicular to the ground level Negative camber Advantages Better traction force due to wide load area app...

Page 559: ...ter Top of the king pin is tilted backward from the vertical line of the wheel center when viewed the tires from the side Advantages Directional force to go straight following control Restoring force of the wheel restored to the straight ahead direction Prevention of wheel shimmy wheels wobble left and right Negative caster Top of the king pin is tilted forward from the vertical line of the wheel ...

Page 560: ...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 561: ...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 562: ...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 563: ...rning lamp ON when EBD function is failed ABS warning lamp ON when ABS 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 ...

Page 564: ...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 565: ...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 566: ...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 567: ...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 568: ...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 569: ... 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 570: ...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 571: ...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 572: ...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 573: ...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 574: ...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 575: ... 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 576: ...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 577: ...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 578: ...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 579: ...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 580: ...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 581: ...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 582: ...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 583: ...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 584: ...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 585: ...09 28 Front Brake Assembly Front Wheel Speed Sensor 4WD HECU 2 SYSTEM LAYOUT Master Cylinder and Booster Brake Pedal ...

Page 586: ...09 29 4850 01 Rear Wheel Speed Sensor 4WD Rear Brake Assembly ABS EBD Indicators Parking Brake Lever Parking Brake ...

Page 587: ... 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 588: ...09 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 589: ...09 32 4 HYDRAULIC CIRCUIT Brake booster Brake fluid reservoir and master cylinder Front disc brake and caliper 1 2 3 HECU Hydraulic Electric Control Unit Rear disc brake and caliper 4 5 ...

Page 590: ...09 33 4850 01 5 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 591: ...ng voltage 4 75 5 25V None functions in sensor cluster Installed in IP panel behind audio only for 4WD Operating temperature 30 85 Operating range 1 5 1 5g Output voltage 0 5 4 5V Wheel speed sensor Supplying voltage 4 5 16V Output current approx 2 7 km h of vehicle speed 7mA Lo 14mA 20 Operating temperature 40 150 Operating frequency 1 2500Hz ...

Page 592: ...10 4 2 OPERATING FREQUENCY 1 Hydraulic and Electronic Control Unit HECU Hydraulic and Electronic Control Unit HECU 1 FL wheel RR wheel RL wheel FR wheel Master cylinder ...

Page 593: ...10 5 4892 01 2 ABS System Sensor front wheel speed Sensor rear wheel speed Screw 7 8 11 8 Nm Clip cable holder Clip sensor cable mounting rear Plug blind G sensor Nut 9 8 10 8 Nm 1 2 3 4 5 6 9 11 ...

Page 594: ...fety beyond its physical limit ABS in this vehicle contains EBD function In normal driving conditions the brake system operates without ABS function 2 What is EBD Electronic Brake force Distribution EBD is an automobile brake technology that automatically varies the amount of force applied to each of a vehicle s brakes based on road conditions speed loading etc Always coupled with anti lock brakin...

Page 595: ......

Page 596: ...ensor 4WD Located at both ends of rear axle Rear disc Rear caliper assembly 2WD 4WD Located on the knuckle ABS warning lamp G sensor Located on the floor under center fascia 2 COMPONENT EBD warning lamp two indicators come on ...

Page 597: ... Front wheel speed sensor 4WD Located on the hub assembly Front disc Front caliper assembly 2WD 4WD Located on the knuckle ABS hydraulic device and control unit Located near the brake booster in engine compartment ...

Page 598: ...ng the speed information from 4 wheel speed sensors when the vehicle is being driven For example when the comparison of the reference speed with front right wheel speed shows a slip the control signal is determined according to whether it s deceleration or acceleration If the control conditions are met the brake for the front right wheel will be got under control ...

Page 599: ...is OK initialization mode When the system is defective the warning lamp comes on When disengaging the connector the warning lamp comes on ABS is not available during lamp ON In this condition Only the conventional brake system without ABS function is available When the communication between warning lamp CAN modules in meter cluster is failed the warning lamp comes on A B C D E ABS warning lamp 2 B...

Page 600: ...or self diagnosis and goes off if the system is OK initialization mode When applying the parking brake the brake warning lamp comes on When the brake fluid is not sufficient the brake warning lamp comes on When disengaging the connector the warning lamp comes on When the system is defective ABS warning lamp and the brake warning lamp come on simultaneously A B C D E When the solenoid valve is defe...

Page 601: ...10 13 4892 01 5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Page 602: ...process cannot be described sufficiently accurately with the brake forces calculated The values calculated only apply if the wheel is not locked In the case of a locking wheel the static friction turns into lower sliding friction with the result that the stopping distance is increased This loss of friction is termed slip in specialist literature The stopping distance depends on the vehicle weight ...

Page 603: ...nly special feature is shown by the curve for freshly fallen snow for this curve increases at 100 slip In a vehicle without ABS the wheel locks on braking and therefore pushes a wedge before it This wedge of loose surface or freshly fallen snow means and increased resistance and as a result the stopping distance is shorter This reduction in stopping distance is not possible with a vehicle with ABS...

Page 604: ...he circle the vehicle is stable to drive If a force exceeds the circle the vehicle leaves the road Brake force When depressing the brake pedal the brake force increases to the maximum then the brake force decreases until the wheel locks Cornering force The cornering force is a maximum when the wheel is turning freely with zero slip When braking the cornering force falls to zero if the wheel locks ...

Page 605: ...ed is the mean I e average speed of all wheel speeds determined by simple approximation Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the prev...

Page 606: ...each wheel speed Firstly it is determined whether the vehicle is in the deceleration or acceleration state using the wheel speed change ratio Then a signal is transmitted to the valve Finally the brake pressure is adjusted via the signal V Vehicle speed Vref Vehicle speed reference Vw Wheel speed ...

Page 607: ...d rear axles This is called Electronic Brake Distribution In an unloading car condition the brake efficiency is comparable to the conventional system but for a fully loaded vehicle the efficiency of the EBD system is higher due to the better use of rear axle braking capability Advantages Elimination of conventional proportioning valve EBD utilizes the existing rear axle wheel speed sensor to monit...

Page 608: ...he master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve At this moment the normally closed outlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Open OFF Outlet valve Normal close NC valve Close ...

Page 609: ...ls In order to prevent the hydraulic pressure from increasing the inlet valve will be closed the outlet valve will be opened and the oil will flow into the low pressure chamber In addition the ABS HECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some Solenoid valve Valve Open Close Pump mot...

Page 610: ...ve modulator operates the inlet valve control solenoid to stop increasing the hydraulic pressure by closing the inlet valve At this moment the outlet valve is closed This procedure helps the wheel to maintain a constant hydraulic pressure Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Close OFF Outlet valve Normal close NC valve Close ...

Page 611: ...he hydraulic pressure to the wheel increases the wheel speed will reduce This operation continues repetitively until there are no signs that the ABS HECU tends to lock the wheels Since the ABS hydraulic pressure control process takes place repeatedly for a short time there may be some vibration and noises at the brake pedal Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valv...

Page 612: ...10 24 7 CIRCUIT DIAGRAM ...

Page 613: ... 2 500Hz Unit Description Specification ABS ESP HECU Clock frequency 32 MHz Clock frequency 50 MHz Memory 128 KB Memory 256 KB Wheel speed sensor Active type Active type Output 7 14 mA Steering wheel angle sensor None Max detection angle speed 1500 Sec Pulse duty 50 10 Operating voltage 9 to 12 V Sensor cluster None Yaw rate sensor lateral G sensor longitudinal G sensor 4WD Mounting direction shou...

Page 614: ...n angle speed 100 Sec Operating temperature 30 to 75 Supplying voltage 9 to 16 V battery voltage Output voltage HI approx 3 50 V 3 0 to 4 1 V Output voltage LO approx 1 50 V 1 3 to 2 0 V Pulses rev 45 pulses rev Description Specification Supplying voltage approx 12 V 8 to 16 V Current consumption below 250 mA Operating range Yaw rate sensor 75 Sec Lateral longitudinal sensor 14 7m Sec ...

Page 615: ... System Sensor front wheel speed Sensor rear wheel speed Screw 7 8 11 8 Nm Clip cable holder Clip sensor cable mounting rear Plug blind HECU Sensor cluster Nut 9 8 10 8 Nm ESP OFF switch Steering wheel sensor 1 2 3 4 5 6 9 10 11 12 13 ...

Page 616: ...11 6 HECU Hydraulic Electronic Control Unit to FL wheel to RR wheel to RL wheel to FR wheel Hydraulic Electronic Control Unit HECU 1 to master cylinder ...

Page 617: ... steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer understeer or cornering The ESP ECU controls against oversteer or understeer during cornering by controlling the vehicle stability using input values from these sensors and applying the braking force to the corresponding wheels independently The system also controls the engine power right be...

Page 618: ...nds of rear axle Front wheel speed sensor Located on the hub assembly Sensor cluster Located at the bottom of center fascia panel Steering wheel angle sensor Located on column shaft with contact coil HECU assembly Located near the brake booster in engine compartment and contains the pressure sensor 2 COMPONENTS ...

Page 619: ...plied and when the brakes are not applied on a curve If the ESP system operates when the brake is applied the brake pressure will be increased on the corresponding wheel which already has braking pressure for the ESP controls ARP Operation During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle spee...

Page 620: ...is OK initialization mode When the system is defective the warning lamp comes on When disengaging the connector the warning lamp comes on ABS is not available during lamp ON In this condition Only normal brake system without ABS function is available When the communication between warning lamp CAN module in meter cluster the warning lamp comes on 1 2 3 4 5 ABS warning lamp Brake warning lamp ESP O...

Page 621: ...age is abnormal When valve relay is defective a b c d e When the communication between warning lamp CAN module in meter cluster the warning lamp comes on 6 3 ESP OFF Indicator ESP OFF indicator ON When turning the ignition switch to ON position ESP warning lamp comes on for 3 seconds for self diagnosis and goes off if the system is OK initialization mode When the ESP OFF switch is pressed to turn ...

Page 622: ...11 12 5 SYSTEM DESCRIPTION 1 Block Diagram of ESP HECU ...

Page 623: ...corresponding wheels independently The system also controls the engine power right before the wheel spin synchronized with the ASR function to decelerate the vehicle automatically in order to maintain the vehicle stable during cornering 1 Under steering What is understeering Understeer is a term for a condition in which the steering wheel is steered to a certain angle during driving and the front ...

Page 624: ...ering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction Compared to understeering vehicles it is hard to control the vehicle during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases ESP controls during oversteer The ESP system recognizes the directional angle with the steeri...

Page 625: ...rake pedal is depressed or not depressed during cornering when the ABS is operating and when braking without the ABS It also includes the vehicle conditions when the TCS a part of the ESP system is operating Condition Understeer control Oversteer control Only ESP in operation No braking by driver ESP Normal braking no ABS operation ESP ABS brake ESP ASR ...

Page 626: ...uring initial braking according to pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels 2 Operation The b...

Page 627: ... 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 Lateral sensor In sensor cluster Vehicle speed Brake force Radius The vehicle driving condition is controlled by the internally programmed logic according to the input...

Page 628: ...11 18 6 HYDRAULIC CIRCUIT OF ESP MCP Master Cylinder Primary MCS Master Cylinder Secondary ESV Electric Shuttle Valve NO Normal Open NC Normal Close LPA Low Pressure Accumulator ...

Page 629: ...not control the vehicle over the physical limit Do not solely rely on the system but be advised to drive the vehicle safely Drive feeling during ESP operation When the ESP system activates the driving feeling can be different depending on vehicle driving conditions For example it will feel different when the ESP system is activated while the ABS is operated by depressing the brake pedal and when t...

Page 630: ...e separation valve and the inlet valve are open normal open the electrically operated shuttle valve and the outlet valve are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve ...

Page 631: ...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 operates to allow fast oil drainage The shuttle valve and the separation valve do not operate while decompression ...

Page 632: ...be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves 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 ...

Page 633: ...ve 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 just before the corresponding wheel gets locked ...

Page 634: ...essure 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 to lock the HBA...

Page 635: ......

Page 636: ...11 26 7 CIRCUIT DIAGRAM Only ABS ...

Page 637: ...11 27 4890 10 Only ESP ...

Page 638: ...o 40 245 Steering angle Inner 37 59 Outer 33 48 Oil pump Type Vane type Maximum pressure kgf cm2 90 3 Pulley size mm Ø115 Operating temperature 40 150 Minimum turning radius m 5 95 Steering oil Type ATF Dexron II or III TOTAL FLUIDE DA Extreme cold condition only Capacity L Approx 1 0 Service interval Daily check and add if necessary ...

Page 639: ...ly steering wheel Damper steering wheel Screw Lid Bolt Column shaft assembly tilt Shaft assembly lower Nut 39 2 58 5 Nm 1 2 3 4 5 6 7 8 Washer Bolt 19 6 24 5 Nm Bolt 19 6 24 5 Nm Nut Bolt joint 17 6 24 5 Nm Washer Blanking cover cruise switch 9 10 11 12 13 14 15 ...

Page 640: ...inkage assembly gear operation ball joint Bolt 100 130 Nm Nut 100 130 Nm Bolt 100 130 Nm Nut 100 130 Nm Bolt 100 130 Nm 1 2 3 4 5 6 Pin Nut End assembly tie rod Boot kit power steering gear box Clamp mounting Rubber mounting 7 8 9 10 14 15 ...

Page 641: ...12 6 3 Pipe Lines Hose assembly pump to gear Tube hose assembly return Clamp pipe Nut well Screw Bolt Hose return Hose return 1 2 4 5 6 7 8 9 ...

Page 642: ... drive belt Adjust or replace Clogging of fluid line Repair or replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace Steering wheel pulls to one side Damaged steering linkage Replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace Defective brake system Repair or replace Excessive free play of steering wheel Worn steering gear Replace...

Page 643: ...tive steering gear Replace the gear assembly Interference between steering column and parts Repair Looseness of steering linkage Retighten Loosened or damaged oil pump drive belt Adjust or replace Looseness of oil pump bracket Replace Looseness of oil pump Replace Air insertion into system Bleed air Defective oil pump Replace Abnormal noise when turning steering wheel Looseness of steering column ...

Page 644: ...th a lift Unscrew the adjusting plug lock nut Measure the torque of the adjusting plug 1 2 3 4 If the torque is excessive or too low adjust to the specified torque 5 Place the rack gear to the center position Tighten the adjusting plug to 10 2 Nm Turn the pinion gear so that the rack gear is turned to lock to lock 5 times Unscrew the adjusting plug Tighten the adjusting plug to 4 6 to 5 6 Nm Unscr...

Page 645: ...tool Turn the steering wheel to the its both ends and measure the maximum steering angle 1 2 If the steering angle is out of the specified value check and adjust the toe in Steering angle Inner 37 59 Outer 33 48 Free Play Check Start the engine and place the wheels at straight ahead direction Turn the steering wheel until the tires starts to move and measure the distance on the circumference of th...

Page 646: ...oil temperature reaches to normal operating level 75 85 C Place the steering wheel at straight ahead direction Check the oil level in the power steering oil reservoir Adjust the oil level between MAX and MIN 1 2 3 4 If the difference between two measurements is below 5 mm and the level is between MAX and MIN level it s normal If it is over 5 mm bleed air from the system Check the fluid level on a ...

Page 647: ...Start the engine Turn the steering wheel to its both ends until any bubble can be found in the steering oil reservoir Perform the test drive and check the steering wheel for normal operation and noise If the oil level abruptly goes up bleed the air from the system again 1 2 3 4 5 6 7 8 The air bleeding should be done after servicing the power steering system and when the difference between two mea...

Page 648: ...rn the steering wheel several times so that the oil temperature reaches to normal operating level 1 2 3 4 5 Before checking the pressure check the oil level and belt tension Prepare the empty container to collect the spilled oil during the service Check the oil pump pressure to locate any defect in oil pump Fully close the valve in pressure gauge and measure the oil pressure 6 Relief pressure 90 3...

Page 649: ...n specified range the pump is normal If not replace the power steering pump 8 Turn the steering wheel righ or left until it stops with the engine idling ans valve fully open 9 Oil pressure 78 to 83 bar To prevent the internal damage do not close the gauge valve for over 10 seconds Keep the oil temperature at proper range ...

Page 650: ...essure relief valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump 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 hydra...

Page 651: ...il from the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Steering pump Steering return pipe Steering cylinder Return line High pressure line Return hose tube Steering pump reservoir High pressure hose Linkage gear box Steering wheel Lower shaft Column shaft ...

Page 652: ...12 17 4610 01 Oil Flows during Right Turn Steering pump To piston pipe in From piston pipe Piston pipe Piston Oil reservoir ...

Page 653: ...25 75R 16 18 inch 255 60R 18 Tire inflation pressure Front 32 psi Rear 32 psi 44 psi when the vehicle is fully laden with luggage 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 127 4 156 8 Nm ...

Page 654: ...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 655: ...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 4 INSPECTION Inside Outside Inside Outside Inside Outside Inside Outside ...

Page 656: ...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 657: ...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 658: ...out on 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 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 comfortable...

Page 659: ...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 660: ...13 10 5 COMPONENTS Alloy wheel Alloy wheel Steel wheel Cap assembly wheel Cap assembly wheel Nut 127 4 156 8 Nm Tire 1 2 3 6 7 8 9 ...

Page 661: ...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 662: ...13 12 OVM Tools Location Valve insert Spare tire Jack pantograph jack Wheel wrench Jack connection Driver Spanner 1 2 3 4 5 ...

Page 663: ...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 664: ...e 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 out ...

Page 665: ... can 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 sympt...

Page 666: ...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 667: ...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 668: ...ed power W 240 10 Max at12V Fan speed rpm 2900 200 Supply voltage V 12 0 PTC Supply power W 900 1 050 Compressor Capacity cc rev 170 Diameter of pulley mm 120 Max speed rpm 8 000 Supply voltage V 12 0 Power consumption A 2 2 Discharge pressure kgf cm G 8 10 Power transistor Supply voltage V 12 0 Operating temperature 30 60 Resistance Hi Low Ω 2 0 Ω 10 Hi ML Ω 0 9 Ω 10 Hi MH Ω 0 4 Ω 10 ...

Page 669: ...ssembly Resistor Expansion valve assembly Wiring assembly Heater evaporator Heater assembly 1 2 3 4 5 6 7 9 10 Actuator assembly Temperature Actuator assembly Mode Heater assembly PTC Control assembly Heater and A C control Bulb Insert assembly Ventilation Sensor assembly Humid and Incar Sensor assembly Intake 11 12 15 20 21 22 23 24 ...

Page 670: ...t O ring O ring Pipe assembly Liquid No 1 Pipe assembly Liquid No 2 1 2 3 4 5 7 8 9 10 11 12 13 14 15 O ring Pipe assembly Liquid No 3 Hose assembly Liquid Receiver drier and bracket assembly Nut Nut Bracket assembly A C compressor Bolt Bracket assembly A C compressor sub Bolt Hose Drain Sensor assembly Receiver drier Cap Charge valve 16 17 18 19 20 21 22 23 25 26 27 30 50 ...

Page 671: ...01 5 6810 01 Duct assembly Console front Screw Duct assembly Console rear Duct assembly Console foot Duct assembly Foot 1 4 8 9 10 ...

Page 672: ... step of the self diagnosis The 6 steps of the self diagnosis are Step 1 Step 2 Step 3 Step 4 The VFD and all LED segments are checked for proper illumination The sensors and air mix door are checked for proper operation The position and condition of the air source door and mode door are checked The actuator door position fan speed and compressor operation are checked Pressing the defroster switch...

Page 673: ...e by up to 3 degrees from the temperature set on the A C controller You can check that the temperature value from each temperature sensor is displayed properly in this step Pressing the defroster switch changes the temperature value that appears on the display in the order as follows 2 Self diagnosis step 1 Step 1 Turn the ignition ON and press the OFF switch for 5 sec or more within 10 sec Then t...

Page 674: ...r the meaning of the rest of the numbers refer to the description below 1 Turn temperature dial lightly toward right to enter step 2 10 to 20 sec System starts sensor check after 2 is displayed 2 Fault code for sensor appears and blinks 3 Fault code no 1 ambient temperature sensor blinks twice Fault code no 5 sun sensor blinks twice fault codes appears sequentially If is displayed before 2 it mean...

Page 675: ...t takes several tens of seconds to finish the check If there is no fault code 30 is displayed And if there is a malfunction the corresponding fault code is added as described in the step 2 Turn temperature dial lightly toward right to enter step 3 1 System starts sensor check after 3 is displayed 2 Fault code for sensor appears and blinks 30 is displayed when there is no fault 3 Refer to the follo...

Page 676: ...ss the defroster switch to change the diagnosis mode 4 Step 4 Press Press Press Press Press Press Turn temperature dial lightly toward right to enter step 4 1 Below table describes the detailed diagnosis items performed for each number Check the corresponding component for proper operation according to the table The voltage values listed in the table are the output voltage to operate the blower mo...

Page 677: ...e temperature value each time the defroster switch is pressed 1 Turn temperature dial lightly toward right to enter step 5 Press Press Press Ambient temperature display Interior temperature display Intake air temperature display 6 Step 6 You can increase or decrease by up to 3 degrees from the set temperature When entering the step 6 from 5 turn the fan speed dial Step 6 starts Decrease by up to 3...

Page 678: ...nosis Turn the AUTO switch ON or turn OFF the ignition key 8 When A C system is faulty Initial auto diagnosis The fault code for the faulty sensor is not displayed Therefore you should start the self diagnosis to check the system ...

Page 679: ...yed check as follows Turn the ignition switch to ON position Measure the voltage between the terminals of the blower motor while changing the fan speed from the lowest level to the highest level The specified voltage value in each stage A B C If the voltage is out of specified value check the wiring for open circuit If the wiring is intact replace the power transistor D 3 Thermo AMP Sensor Intake ...

Page 680: ... is lower than the measured value in the sunlight the sensor is intact Turn the ignition switch to the ON position Measure the voltage between the terminals of the sun sensor at the FATC connector approx 2 5 V under sunlight and approx 4 8 V under shade If the voltage cannot be measured check the wiring for open circuit If the result is not as specified replace the FATC controller A B C D E ...

Page 681: ...01 15 6810 01 1 SYSTEM LAYOUT EXTERIOR Receiver drier A C compressor Line and port Ambient temperature sensor A C condenser Electric fan ...

Page 682: ...01 16 2 SYSTEM LAYOUT INTERIOR Sun load sensor A C controller A C Module assembly Mode door actuator Air mix door actuator ...

Page 683: ...01 17 6810 01 Air source mode actuator Duct temperature sensor Thermo AMP PTC Power transistor Blower motor assembly A C filter ...

Page 684: ...01 18 3 VENTILATION SYSTEM 1 Vent Ports Location Interior 2 Configuration of Air Duct ...

Page 685: ...ator PTC heater assembly Duct temperature sensor Air mix door actuator Air source door actuator A C antibacterial filter Blower motor 1 2 3 4 5 6 7 Power transistor Thermo AMP Mode door Heater core Air mix door Evaporator Air source door 8 9 10 11 12 13 14 ...

Page 686: ...otor assembly Power Transistor A C cable assembly Thermo AMP Heater unit right case Air mix door actuator Lower duct Mode door link assembly Mode door actuator Heater unit left case Mode door Heater core Duct temperature sensor Evaporator Blower unit lower case Air source door actuator ...

Page 687: ...Mode door actuator Duct temperature sensor Air source door actuator Power transistor Blower motor Thermo AMP Air mix door actuator A C controller unit Interior temperature sensor Main wiring connector 3 Wiring Layout ...

Page 688: ......

Page 689: ...refrigerant pressure ambient temperature and condenser temperature to protect the A C circuits However for the vehicles equipped with DI engine the engine ECU turns off the A C compressor under below conditions including those above Coolant temperature 20 or less Coolant temperature 115 or more For approx 4 sec after starting the engine Engine speed 650 rpm or less Engine speed 4 500 rpm or more D...

Page 690: ...Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure 3 Receiver drier Condition Gas Liquid Function Keeps the refrigerant free from moisture by separating collecting the moisture from it 4 Expansion valve Condition Liquid Liquefied gas Function Performs adiabatic expansion and flow control for easier evaporation 5 Evaporator Condition Liquefied gas Gas Functio...

Page 691: ...akes place before the liquid refrigerant is sent to the evaporator is called Adiabatic Expansion During adiabatic expansion the expansion valve lowers the pressure of the refrigerant and determines the correct amount of refrigerant going into the air conditioning evaporator That is the amount of heat which is needed to stop the evaporation is determined according to the cooling load The expansion ...

Page 692: ...01 26 7 A C CIRCUIT DIAGRAM 1 A C AUTO PWM Motor Compressor Air Mix Motor Sun Load Sensor Intake Air Temperature Sensor Thermo AMP ...

Page 693: ...01 27 6810 01 2 A C AUTO Blower motor mode air source Inside air Humid sensor Outside air temperature sensor ...

Page 694: ...y cable 1 2 3 4 Collision sensors a kind of impact G acceleration sensor detect the lateral and longitudinal collisions and determine whether or not to deploy air bags The roles of each collision sensor are as follows FrontG sensors insidethe air bag unit Send signals to the front air bags driver and passenger air bags and the driver s and front passenger s seat belt pretensioners When the front c...

Page 695: ...e air bag is deployed in the event of frontal collisions while drving But there are exceptional cases as follows Situation Condition May operate or not Never operate Seldom oeprate Underbody impact from the road surface impact against the curb at a very high speed or dropping impact onto the road surface with a large angle occurs The vehicle rolls over or tips over sideward by severe impact A coll...

Page 696: ...t get severely injured by sudden deployment of the air bag The air bag contains explosive materials so handle it carefully when disposing or replacing it The air bag components will be very hot immediately after deployment Do not touch them until they cool down Once the air bag seat belt pretentioner is triggered it will not deploy again even if an additional impact is applied to it Once triggered...

Page 697: ...inflates at a very fast speed by gas with high temperature which might cause injury such as an abrasion bruise and burn depending on the accident conditions Normal inflation of the air bag could make a loud noise and smoke non toxic gas A minor collision which occupants can be protected only by seat belts will not activate the air bag system It is because that air bag inflation at a minor collisio...

Page 698: ...r bags and activates their seat belt pretensioners Once an air bag deploys its repair parts vary according to the deployment situation and damage to the vehicle from collision Needed repairs also slightly vary between the front air bags and the curtain air bags The following are the differences Replacementpartswhenthe frontair bags deploy Air bag unit and its wiring including connector seat belt p...

Page 699: ...eiving the air bag deployment signal at the vehicle speed 3 km h or higher it sends out the door UNLOCK signal for 5 seconds Driver side pretensioner Air Bag Warning Lamp 2 CONFIGURATION Seat belt pretensioner Driver Air Bag DAB ...

Page 700: ...stalled inside this And it sends out signals to deploy the front air bags driver and passenger air bags and or the driver and passenger 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 activates their seat belt pretensioners ...

Page 701: ...SS The overall 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 ...

Page 702: ...02 11 8810 01 ...

Page 703: ...sh unlock unlock when colliding The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to ON position After this period the door lock system outputs UNLOCK for all doors for 5 seconds from 40 ms after receiving the air bag collision signal Even though the key is turned to OFF position during the output of UNLOCK the output continues on for remaining p...

Page 704: ...en the ignition switch is OFF LOCK or UNLOCK output is ignored if LOCK or UNLOCK output is required while performing the output of LOCK or UNLOCK However UNLOCK by air bag signal and operation by the remote control key are valid If the door lock system outputs LOCK and UNLOCK simultaneously only the LOCK output can be activated 1 2 3 4 Cautions for Door Lock Unlock Control ING KEY SW 1 Deployment ...

Page 705: ...ction have been detected When the Air Bag Unit Detects Any Malfunctions in Unit When the Air Bag Unit Detects Any Intermittent Failure 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 When due to an error from outside the system the intermittent failure s...

Page 706: ...02 15 8810 01 6 CIRCUIT DIAGRAM ...

Page 707: ...ng the sunroof repeatedly with the engine turned off will run down the battery Operate the sunroof while the engine is running When the sunroof operation is completed release the switch Keeping pressing the switch can result in malfunction Especially in winter never operate the sunroof if operation areas are iced Wait until melted Make sure that the sunroof is completely closed when leaving the ve...

Page 708: ...04 4 TILT OPEN Sunroof switch 1 SYSTEM LAYOUT Sunroof assembly Sunroof motor control unit ...

Page 709: ...in use The sunroof glass can be open automatically and can be tilted by the switch operation The sunroof switches are included in the overhead console switches and consists of the TILT CLOSE and OPEN switches CLOSE OPEN Sun shade blind Sunroof glass Sunroof operation switch Closes the sunroof Opens the sunroof Sunroof glass Roller blind ...

Page 710: ...g turn of the switch to the OPEN position with the sunroof closed it is tilted up 2nd step opens by itself from tilted up condition When making a long turn of the switch to the OPEN position with the sunroof tilted up it opens only whilst turning the switch Closing sunroof Sliding close Manual close While turning the switch to the CLOSE position the sunroof is closed Release the switch at the desi...

Page 711: ...NO DATA ...

Page 712: ...NO DATA ...

Page 713: ...07 3 4110 01 1 DIMENSIONS Unit mm 1910 1790 3060 4990 5070 1570 1570 Major Dimensions Top view Side view Front view Rear view ...

Page 714: ...4 Detailed Dimensions Unit mm Headlamp Front fog lamp Side repeater Front turn signal lamp Position lamp 1 2 3 4 5 Stop Tail lamp Back up lamp License plate lamp Rear turn signal lamp Reflector 6 7 8 9 10 ...

Page 715: ...07 5 4110 01 Unit mm with trailer hitch ...

Page 716: ...07 6 2 LIFTING POINTS Lifting point Lifting point ...

Page 717: ... Dash Panel and Engine Tunnel with Foaming Pad 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 Reinforcement for Front Floor and Rear Floor ...

Page 718: ...07 8 2 Applied BPR Body Panel Reinforcement Sealer to the Door Outer Panel Foaming pad Foaming pad Foaming pad ...

Page 719: ...07 9 4110 01 3 Applying the Asphalt Sheet to the Body Panel Improved Anti Vibration ...

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SSANGYONG Actyon Sports II 2012.01, Manual

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Summary of Contents for Actyon Sports II 2012.01

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