SSANGYONG Korando 2010 Manual Download

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01-5

VEHICLE GENERAL

korando 2010.10

0000-00

2. SPECIFICATION

Descriptions

Diesel 2.0 Engine

(4WD)

Diesel 2.0 Engine

(2WD)

General

Overall length (mm)

4,410

←

Overall width (mm)

1,830

←

Overall height (mm)

1,675 (1,710: including

roof rack)

←

Gross vehicle weight (kg)

2,260

2,180

Curb vehicle
weight (kg)

A/T

1,692

1,611

M/T

1,672

1,591

Fuel

Diesel

←

Fuel tank capacity (ℓ)

←

Engine

D20DTF

←

Number of cylinders/
Compression ratio

4 / 16.5:1

←

Total displacement (cc)

1,998

←

Camshaft arrangement

DOHC

←

Max. power

175 ps / 4,000 rpm

←

Max. torque

360 Nm /

2,000~3,000 rpm

←

Idle speed

A/T

780 ± 20 rpm

←

M/T

750 ± 20 rpm

←

Cooling system

Water-cooled / forced

circulation

←

Coolant capacity (ℓ)

8.5

←

Lubrication type

Gear pump, forced

circulation

←

Max. oil capacity (ℓ)

(when shipping)

6.0

←

Turbocharger and cooling type

Turbocharger, water-

cooled

←

Summary of Contents for Korando 2010

Page 1: ...TION 3 EXTERIOR LAMP SYSTEM LAYOUT 4 INTERIOR LAMP SYSTEM LAYOUT 5 SWITCH SYSTEM LAYOUT 6 CAN COMMUNICATION CONFIGURATION 2 2 3 5 6 7 ELECTRIC DEVICE GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 2 HOW TO CHECK TERMINAL NUMBER OF CONNECTOR 3 PART LOCATION ACCORDING TO CONNECTOR NUMBER 8 10 11 ...

Page 2: ...i 2 The chassis number KPTA0B1SSAP012345 is stamped on the right side in the engine compartment passenger side 1 The engine number 671 950 0 2 5000001 is stamped on the lower area of cylinder block in exhaust manifold side 1 MAJOR DIMENSION GENERAL INFORMATION 2 VEHICLE IDENTIFICATION Top View Side View Front view Rear view ...

Page 3: ...n signal lamp Side repeater lamp Puddle lamp 3 EXTERIOR LAMP SYSTEM LAYOUT Front fog lamp Position lamp Headlamp assembly Backup lamp High mounted stop lamp Tail stop lamp Reflector Rear turn signal lamp Tail lamp License plate lamp Front view Rear view ...

Page 4: ... lamp Puddle approach lamp High beam low beam Turn signal lamp Position lamp 1 2 3 Stop lamp and tail lamp Turn signal lamp Backup lamp Stop lamp For Korea Rear fog lamp 1 2 3 4 Vehicle without spoiler Vehicle with spoiler License plate lamp Headlamp Front fog lamp Side repeater lamp ...

Page 5: ...01 5 GENERAL INFORMATION undefined 0000 00 Front room lamp Sun visor lamp 4 INTERIOR LAMP SYSTEM LAYOUT Glove box lamp Door courtesy lamp Luggage lamp Center room lamp ...

Page 6: ... switch RH Front seat heated wire switch STD Front seat heated wire switch DLX Drive door main switch Outside rear view mirror switch Passenger door switch Steering wheel remote control switch Lower main panel switch Overhead console switch Cruise control switch Hazard warning switch and bezel assembly Multifunction switch FATC switch 5 SWITCH SYSTEM LAYOUT ...

Page 7: ...Meaning Function GCU Glow Control Unit Glow control unit EPS Electronic Power Steering Unit Electrically driven power steering unit BCM Body Control Module Body control module 2 CAN Communication Wiring Diagram Splice pack Wiring Location S101 Floor wiring LH Under fuse and relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind the instrument cluster co...

Page 8: ...01 8 undefined 0000 00 GENERAL INFORMATION ELECTRIC DEVICE GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 1 HOW TO READ ELECTRICAL WIRING DIAGRAM ...

Page 9: ... color so at the head of character Y means background color of wiring and the rear character R means middle color of wiring H G means Ground and 203 means Ground Number I Below horizontal line means Ground Ground position G101 G401 B Body Ground Identification Symbol Meaning C Connector D Diode Ef Fuse in Engine room Fuse Relay Box F Indoor Fuse Box G Ground S Splice pack Junction connector SB1 SB...

Page 10: ...ctor terminal number is given from left to right direction of Locking upper position through the Female Terminal Exceptionally Control unit such as Engine ECU TCU and Instrument Cluster was used a specific number which marked on the draft If a lot of connectors was connected to one parts the connector was marked as A B C in front of terminal number In case of terminal number was carved into connec...

Page 11: ...er startsfrom left bottom and proceeds clockwise In the fuse and relay box or the instrument panel the partnumber is assigned from left top to light bottom 02 Connector Numbering Order Symbol Character Description C Connector Connecting part that connects two wiring harness D Diode G Ground S Splice pack Joint connector that connects various wiring harness Connector Number Location 1 Engine Compar...

Page 12: ...COMPONENTS LOCATION 8210 00 CONNECTOR GROUND SPLICE PACK 2 4 CONNECTOR GROUND 8210 01 W H MAIN 8212 01 W H FLOOR LH 8212 02 W H FLOOR RH 1413 02 W H ENGINE MAIN 8211 01 W H ENGINE EXTN 8213 09 W H ROOF 8810 22 W H AIR BAG 8810 23 W H AIR BAG EXTN 8213 03 W H DRIVER DOOR 8213 04 W H PASSENGER DOOR 8213 06 W H REAR DOOR 8213 10 W H TAIL GATE 11 13 15 16 17 18 19 19 20 20 21 21 ...

Page 13: ...02 2 undefined 8210 00 CONNECTOR GROUND WIRING HARNESS 1 WIRING HARNESS 8210 00 WIRING HARNESS COMPONENTS LOCATION ...

Page 14: ...02 3 CONNECTOR GROUND undefined 8210 00 2 COMPONENTS LOCATION ...

Page 15: ...02 4 undefined 8210 00 CONNECTOR GROUND CONNECTOR GROUND SPLICE PACK 8210 00 CONNECTOR GROUND SPLICE PACK 1 CONNECTOR GROUND SPLICE PACK ...

Page 16: ...02 5 CONNECTOR GROUND undefined 8210 00 1 S101 HS CAN 2 SPLICE PACK CIRCUIT 2 S102 HS CAN 3 S201 LS CAN 4 S202 HS CAN 5 S203 ILL ...

Page 17: ...02 6 undefined 8210 00 CONNECTOR GROUND 6 S204 GND 7 S205 HS CAN 8 S301 ...

Page 18: ...02 7 CONNECTOR GROUND undefined 8210 00 3 WIRING CONNECTOR PARTS SHAPE NUMBERING ...

Page 19: ...02 8 undefined 8210 00 CONNECTOR GROUND 4 THE OTHERS PARTS SHAPE NUMBERING UNIT PART SWITCH PART ...

Page 20: ...02 9 CONNECTOR GROUND undefined 8210 00 MOTOR PART LAMP PART SENSOR PART ...

Page 21: ...02 10 undefined 8210 00 CONNECTOR GROUND THE OTHER PART ...

Page 22: ...02 11 CONNECTOR GROUND undefined 8210 01 CONNECTOR GROUND 8210 01 W H MAIN ...

Page 23: ...02 12 undefined 8210 01 CONNECTOR GROUND ...

Page 24: ...02 13 CONNECTOR GROUND undefined 8212 01 8212 01 W H FLOOR LH ...

Page 25: ...02 14 undefined 8212 01 CONNECTOR GROUND ...

Page 26: ...02 15 CONNECTOR GROUND undefined 8212 02 8212 02 W H FLOOR RH ...

Page 27: ...02 16 undefined 1413 02 CONNECTOR GROUND 1413 02 W H ENGINE MAIN TOP VIEW FRONT VIEW ...

Page 28: ...02 17 CONNECTOR GROUND undefined 8211 01 8211 01 W H ENGINE EXTN ...

Page 29: ...02 18 undefined 8213 09 CONNECTOR GROUND 8213 09 W H ROOF ...

Page 30: ...02 19 CONNECTOR GROUND undefined 8810 22 8810 22 W H AIR BAG 8810 23 W H AIR BAG EXTN ...

Page 31: ...02 20 undefined 8213 03 CONNECTOR GROUND 8213 03 W H DRIVER DOOR 8213 04 W H PASSENGER DOOR ...

Page 32: ...02 21 CONNECTOR GROUND undefined 8213 06 8213 06 W H REAR DOOR 8213 10 W H TAIL GATE ...

Page 33: ...POWERDISTRIBUTION 8210 00 8410 04 8410 05 POWER DISTRIBUTION FUSE 8210 00 ENGINE ROOM FUSE RELAY BOX 8410 04 INDOOR FUSE BOX 8410 05 ICM RELAY BOX 2 9 14 ...

Page 34: ... 1 ENGINE ROOM FUSE RELAY BOX TOP VIEW 2 ENG ROOM FUSE RELAY BOX UNDER VIEW 3 ENGINE ROOM FUSE RELAY BOX LOCATION 4 BATTERY FUSE BOX LOCATION ...

Page 35: ... 5 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 6 ENGINE ROOM FUSE BOX CONNECTOR NUMBER ...

Page 36: ... 7 ENGINE ROOM FUSE RELAY BOX CIRCUIT SB1 SB6 SB10 Ef18 Ef19 START RELAY BLOWER RELAY DEFOGGER RELAY DEICER RELAY ...

Page 37: ...SB7 SB9 Ef1 Ef5 Ef9 Ef11 PTC RELAY FUEL HEATER RELAY HEAD LAMP RELAY HI LO ...

Page 38: ...SB11 SB14 Ef12 Ef13 Ef24 ENG MAIN RELAY C FAN RELAY C FAN RELAY HI LO COMP RELAY ...

Page 39: ...Ef2 Ef4 Ef6 Ef8 Ef10 Ef14 Ef16 TAIL LAMP RELAY FRT FOG LAMP RELAY ...

Page 40: ...Ef17 Ef20 Ef23 Ef25 Ef26 WIPER MOTOR RELAY HI LO HORN RELAY POWER WINDOW RELAY ...

Page 41: ... 1 INDOOR FUSE BOX 2 POWER SUPPLY ...

Page 42: ... 3 INDOOR FUSE BOX CIRCUIT F27 F34 ...

Page 43: ...F35 F41 ...

Page 44: ...F42 F50 ...

Page 45: ...F51 F53 ...

Page 46: ...RR FOG LAMP RELAY POWER OUTLET RELAY BURGLAR HORN RELAY RR WIPER RELAY SHIFT LOCK RELAY ...

Page 47: ...T GATE OPEN RELAY FOLDING MIRROR RELAY IGN 1 RELAY ACC RELAY IGN 2 RELAY ...

Page 48: ...7410 02 POWER SEAT FRT SEAT WARMER 8510 48 REAR SEAT WARMER 8620 01 BCM BODY CONTROL MODULE 8510 05 POWER WINDOW 8510 52 OUTSIDE MIRROR 7810 01 FRT RR WIPER WASHER 11 12 13 14 15 16 18 19 20 8610 06 HORN 7632 16 CIGAR LIGHTER POWER OUTLET 7840 01 DEFOGGER DEICER 8710 03 DOOR LOCK CIRCUIT 7340 03 SUN ROOF 8310 01 HEAD LAMP 8310 01 HEAD LAMP LEVEL G DEVICE EXP 8320 01 TAIL LAMP 8310 01 TURN SIGNAL L...

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Page 51: ... 1 ENG MAIN RELAY PEDAL MODULE VALVE THROTTLE INLET METERING EGR SENSOR HFM O2 COOLANT TEMP FUEL TEMP ...

Page 52: ... 2 STOP LAMP W SPEED SENSOR T PRESSURE SW INJECTOR SENSOR FUEL FILTER R PRESSURE CAM POSITION MAP KNOCK E GAS TEMP ...

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Page 63: ... 1 POWER GROUND B HORN BUZZER CLUSTER HAZARD ROOM LAMP M FUNCTION SW IMMO A LIGHT ...

Page 64: ... 2 DR LOCK FOLDING DEFOG DEICER P WINDOW WIPER WASHER DR SWITCH ...

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Page 90: ...VEHICLE GENERAL V 0000 00 VEHICLE GENERAL 1 VEHICLE IDENTIFICATION 2 SPECIFICATION 3 OIL SPECIFICATIONS AND CAPACITY 3 5 7 SPECIFICATIONS AND CHECK ITEMS ...

Page 91: ......

Page 92: ...mber 671 950 0 2 5000001 is stamped on the lower area of cylinder block in exhaust manifold side 2 The chassis number KPTA0B1SSAP012345 is stamped on the right side in the engine compartment passenger side 3 The certification label is affixed on the bottom of driver side B pillar 30 psi ...

Page 93: ...01 4 korando 2010 10 0000 00 VEHICLE GENERAL VIN number Engine number ...

Page 94: ...2 1 611 M T 1 672 1 591 Fuel Diesel Fuel tank capacity ℓ 57 Engine Engine D20DTF Number of cylinders Compression ratio 4 16 5 1 Total displacement cc 1 998 Camshaft arrangement DOHC Max power 175 ps 4 000 rpm Max torque 360 Nm 2 000 3 000 rpm Idle speed A T 780 20 rpm M T 750 20 rpm Cooling system Water cooled forced circulation Coolant capacity ℓ 8 5 Lubrication type Gear pump forced circulation ...

Page 95: ... 0 814 5th 0 734 6th 0 628 Reverse 3 910 Automatic Transaxle Model Electronic 6 speed Operating type Floor change type Gear ratio 1st 4 156 2nd 2 375 3rd 1 522 4th 1 144 5th 0 859 6th 0 676 Reverse 3 178 Transfer Case Model AWD Type On demand type Clutch M T Operating type Hydraulic type Disc type Dry single diaphragm type Power Steering Type Rack and pinion EPS HPS Steering angle Inner 39 0 Outer...

Page 96: ...ld up type Brake Master cylinder type Tandem type Booster type Vacuum assisted booster type Brake type Front wheel Disc Rear wheel Disc Parking brake Mechanical type Suspension Front suspension MacPherson Coil spring Rear suspension Multi link Coil spring Air Conditioner Refrigerant capacity R 134a 430 30g Electrical Battery type Capacity V AH MF 12 90 Starter capacity V KW 12 2 3 Alternator capac...

Page 97: ...20DTF 8 5 ℓ Ssangyong genuine coolant Anti Freeze SYC 1025 Automatic Transaxle Fluid 9 5 ℓ Ssangyong genuine oil FUCHS TITAN ATF 3292 Manual Transaxle Fluid 1 6 ℓ Ssangyong genuine oil SAE 75W 85 API GL 4 Transfer Case PTU Fluid AWD 0 58 ℓ Ssangyong genuine oil IDEMITSU LW 80W 90 Rear Axle Oil AWD 0 7 ℓ Ssangyong genuine oil SAE 80W 90 API GL 5 Brake Clutch Fluid As required Ssangyong genuine oil ...

Page 98: ...RAL INFORMATION 1 ENGINE LAYOUT 2 MAJOR COMPONENTS DURING SERVICE WORK 1 GUIDELINES FOR SERVICE WORK SAFETY 2 JACK UP POINTS 3 STANDARD BOLTS SPECIFICATIONS SPECIAL TOOL 1 NEW SPECIAL TOOLS 2 NORMAL EQUIPMENTS 3 4 6 11 12 13 14 GENERAL INFORMATION ...

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Page 100: ...01 3 D20DTF ENGINE INFORMATION korando 2010 10 0000 00 1 ENGINE LAYOUT Front view Rear view Right view Left view ...

Page 101: ... position sensor Power steering pump pulley Water pump pulley Alternator pulley Idler bearing 1 A C compressor pulley Auto tensioner Idler bearing 2 Isolation damper Rear view E EGR valve Fuel temperature sensor Fuel HP pump assembly E VGT actuator Coolant temperature sensor IMV Magnetic triggering Crankshaft position sensor ...

Page 102: ...erature sensor Rear exhaust gas temperature sensor CDPF assembly E VGT Pressure port after CDPF Oil drain plug Left view Thermostat assembly Knock sensor 1 connector Variable swirl valve assembly Oil cooler assembly E EGR valve Knock sensor 2 connector E EGR solenoid valve EGR cooler Electronic throttle body T MAP sensor Oil level switch ...

Page 103: ...tailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works However above references and cautions cannot be inclusive measures so should have habits of taking concerns and cautions based on common senses 2 Equipment Korando C is FF Front Engine Front Drive type vehicle an...

Page 104: ... nut Replace them with new If reused normal functions cannot be maintained Align the disassembled parts in clean according to disassembling order and group for easy assembling According to installing positions the bolts and nuts have different hardness and design So be careful not to mix removed bolts and nuts each other and align them according installing positions To inspect and assemble clean t...

Page 105: ...tely Inspect the complete system including the catalytic converter if equipped Inspect the body near the exhaust system Look for broken damaged missing or out of position parts as well as open seams holes loose connections or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment 4 Tires Be alert to any vibration of ...

Page 106: ...nstallation While removing engine drain engine oil coolant and fuel in fuel system to prevent leakage During service work of removal installation be sure to check each connected portions to engine not to make interference To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection repair and to secure optimum engine performance and safety after...

Page 107: ...n 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 injector should be replaced with new ones when removed 1 2 3 3 Elect...

Page 108: ...POINTS Stand jack up points and installation status front side Jack up points for 2 post lift Mounting status Stand jack up points and installation status rear side Mounting status Stand jack up points and installation status front side Jack up points for 2 post lift ...

Page 109: ...ndard tightening torque during 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 P...

Page 110: ...nts and conventional tools are used Name and Part Number Special tool Use Vehicle Part number T99410010A Name Belt tension adjuster Use Used to release tension without removing belt when replacing pulley or pump Use Engine Part number T99110010A Name Flywheel fixing device Use Used to fix flywheel or drive shaft to prevent engine from rotating when removing crankshaft pulley ...

Page 111: ... C to support module when lowering engine and transmission mounted to sub frame at the same time replacing manual transmission Name Engine stand 1 tone or more Use Used to fix the removed engine or engine and transmission transaxle and can support at least 1 tone Name Engine crane 1 tone or more Use Used to move engine module including transaxle to working space or engine stand and can support at ...

Page 112: ... to hold engine to prevent it from dropping when removing engine mounting RH insulator or sub frame Name Oil pan gasket remover Use Used to separate oil pan and minimize damage when removing oil pan Name Torque angle gauge Use Used to angle tighten correctly after torque tightening Name Fuel sender cover remover installer ...

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Page 114: ...ting rod End play 0 5 to 1 5 mm Camshaft Axial end 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 g...

Page 115: ...heel M10 22 8 45 5 Nm 90 10 60 to 100 Nm Crankshaft center bolt M18 50 1 200 20 Nm 180 20 660 to 720 Nm 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 M12 177 12 85 8 5 Nm 270 10 Camshaft cap M6 16 10 1 Nm M8 4 25 2 5 Nm Exhaust stud bolt 10 40 4 Nm Exhaust sprocket bolt...

Page 116: ...turn pipe M6 16 turbo side 2 10 1 Nm M6 16 block side 2 10 1 Nm EGR valve M8 22 2 25 2 5 Nm EGR pipe bolt Intake side M8 16 2 25 2 5 Nm EGR pipe bolt EGR cooler side M8 16 2 25 2 5 Nm EGR combination bolt M6 16 4 10 1 Nm M8 16 16 25 2 5 Nm Tensioner pulley 1 45 4 5 Nm Glow plug M5 4 20 2 Nm Vacuum pump M8 25 3 25 2 5 Nm Component Size Bolt Quantity Specified torque Nm Remark Total torque Hot water...

Page 117: ... 10 High pressure pipe between HP pump and fuel rail M17 1 30 3 Nm High pressure pipe between fuel rail and injector M17 4 30 3 Nm Crank position sensor M5 14 1 8 0 4 Nm Main wiring M6 16 5 10 1 Nm Intake duct bracket M8 16 3 25 2 5 Nm Power steering pump M8 100 3 25 2 5 Nm Component Size Bolt Quantity Specified torque Nm Remark Total torque Cooling fan bracket M6 25 5 10 1 Nm M6 60 1 10 1 Nm M6 8...

Page 118: ...ts piston piston ring intake and exhaust vale cylinder head 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 Warm the engine...

Page 119: ...ylinder pressure leakage test 5 6 7 2 Cylinder pressure leakage test 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 If the measured value of the compression pressure test is not within the specifications perform the cylinder pressure leakage test Specified value Perform this test in th...

Page 120: ...MBLY korando 2010 10 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 121: ...n of cylinder head below 0 1 mm Peak to valley of surface 0 004 mm valve recess a Intake valve 0 1 to 0 7 mm Exhaust valve 0 1 to 0 7 mm Measure the cylinder head height A 1 Insert the valves into the valve guides and measure the recesses 2 Valve recess a 0 1 to 0 7 mm If the height is less than the limit the cylinder head must be replaced If the measured value is out of the specified range machin...

Page 122: ...ld Removal of valves Place the pressure plate on a flat bed work bench 1 Examine the cylinder head for air bubbling If the air bubbles are seen replace the cylinder head Install the cylinder head on the pressure plate 2 Immerse the cylinder head with the pressure plate into warm water approx 60 C and pressurize with compressed air to 2 bar 3 ...

Page 123: ... mistake There should be no leak from fuel injection system HP pump fuel hose high pressure pipe of the D20DTF engine So they should be protected from foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine When removing the engine use only the safety hook on engine and engine hanger Do not ...

Page 124: ...ehicle fire or personal injury Fuel and lubrication system Painted surface of the body can be damaged or rubber products hose can be corroded if engine oil and fuel are spilled over If spilled over engine foreign materials in air can be accumulated on the engine damaging fuel system If work on the fluid system such as fuel and oil working area should be well ventilated and mechanic should not smok...

Page 125: ...t and has components on the oil filter housing as FEAD Front End Accessories Drive type Components HPS EPS 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pulley 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 NO 1 idler pulley 9 NO 2 idler pulley 10 Power steering pump NO 3 idler pulley with HPS hydraulic power steering ...

Page 126: ...ACUUM PUMP Vacuum 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 Vacuum pump Pump capacity 210 cc rev Speed 700 to 6 000 rpm Lubrication temperature 40 to 155 C Oil 5W30 Drive type Driven by exhaust Camshaft sprocket Brake booste...

Page 127: ...r axle housing and body side member Location Left mounting Rear mounting assembly Location Rear side of transfer axle housing and front side of sub frame Location Rear mounting 3 ENGINE MOUNTINGS D20DTF engine mounting is 4 point mounting type and supports the engine and transaxle Front and rear mountings are rubber type and support the torque reaction Left and right mountings support the power tr...

Page 128: ...th 8 bolts The variable swirl valve is introduced 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 Intake manifold Exhaust manifold Components ...

Page 129: ...ENGINE ASSEMBLY 5 CYLINDER HEAD 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 Oil separator PCV valve ...

Page 130: ...der 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 ...

Page 131: ...orando 2010 10 0000 00 ENGINE ASSEMBLY Camshaft sprocket Intake exhaust Camshafts Finger follower HLA Components Vacuum pump drive Cylinder head Camshaft position sensor HP pump drive gear Cylinder head gasket ...

Page 132: ...0 EA Clamping rail Installed between exhaust Camshaft sprocket and crankshaft sprocket Mechanical type tensioner Operated by internal spring Chain lower bush Chain type single bush Chains 60 EA 7 CHAIN AND GEAR DRIVE SYSTEM D20DTF engine uses single stage chain drive system Timing chain drives the exhaust side and gear drive the intake side Timing chain is single bush type Upper chain drives HP pu...

Page 133: ...02 22 korando 2010 10 0000 00 ENGINE ASSEMBLY Intake exhaust Camshaft assembly Components Intake Camshaft HP pump drive gear Exhaust Camshaft Connected to vacuum pump ...

Page 134: ...02 23 ENGINE ASSEMBLY korando 2010 10 0000 00 Timing gear cover case TGCC TGCC Oil seal Screw plug ...

Page 135: ...02 24 korando 2010 10 0000 00 ENGINE ASSEMBLY Mass Balance Unit MBU Fuel HP pump HP pump gear HP pump drive gear Crankshaft MBU drive gear MBU ...

Page 136: ...he oil level sensor in oil pan monitors the oil level and turns on the oil level warning lamp on the meter cluster when the oil level goes down below the specified value And A C compressor bracket and the oil dipstick tube are mounted on the oil pan Components Oil drain plug Dust cover Oil dipstick tube hole A C compressor bracket Oil level sensor For details refer to Chapter Engine Control ...

Page 137: ...NE ASSEMBLY 9 MASS BALANCE SHAFT UNIT MBU The balance shaft in MBU Mass Balance shaft Unit improves the NVH performance by decreasing the unbalanced force Components Crankshaft drive gear Mass balance shaft unit Mass balance shaft unit ...

Page 138: ...xceed the vehicle rating of the transmission The friction ring is the weak spot in the system and can wear out if excessive engine torque loads are applied through it The system also has a center support bearing that carries the load between the inner and outer flywheel and is fitted with damper springs to absorb shocks 2 Drive Plate Drive plate receives the power from the start motor when startin...

Page 139: ...RANKSHAFT CYLINDER BLOCK This vehicle is FF driving type and the engine is installed in lateral direction The crankshaft and the cylinder block convert the compression pressure to the rotating energy Components Cylinder block Piston Connecting rod Crankshaft ...

Page 140: ...aration interval every 20 000 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 Operating pressure 1800 bar Operating temperature 30 120 Low pressure fuel pump Type Vane type Gear ratio pump engine 0 5 1 Pressure 6 bar Fuel tan...

Page 141: ...om getting into fuel system 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 ...

Page 142: ...ks at connections Once installed the pipes have been deformed according to the force during installation therefore they are not reusable The 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 co...

Page 143: ...00 ENGINE FUEL SYSTEM Check the installed components again and connect the negative battery cable Start the engine and check the operating status With Scan Tool check if there are current faults and erase the history faults 8 9 ...

Page 144: ...diagnostic device check 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 145: ...xcessive backleak 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 146: ...ow Loss of HP pump pressure 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 147: ...ce for high pressure 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 148: ...Fuel System Check Procedure 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 149: ...03 12 korando 2010 10 0000 00 ENGINE FUEL SYSTEM 4 Fuel System Check Procedure ...

Page 150: ...rail pressure sensor 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 151: ...r Press the TEST button 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 152: ...re a special tool for 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 ar...

Page 153: ...nipple of the injector 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...

Page 154: ...al tool 1 2 Connect the 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 co...

Page 155: ...d of the close 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 p...

Page 156: ...afety mode is activated 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 ...

Page 157: ...rials injector remains 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 fue...

Page 158: ...r see fuel system System supplement and remedy against water in 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 ...

Page 159: ...ow pressure line which supplies low pressure fuel to the low pressure pump includes high pressure 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 signals from various sensors HP fuel pump Common rail and Injector Fuel filter Priming pump Fuel su...

Page 160: ...ensor Determines the injection order Injector C3I Pre injection main injection after injection by signals from ECU Fuel tank Fuel metering by dual sender Supply the fuel in main fuel tank and sub fuel tank through fuel inlet tube 2 SYSTEM LAYOUT AND OPERATION 1 Layout Fuel supply line Fuel return line For sensor and actuator control logic refer to Chapter ENGINE CONTROL ...

Page 161: ...ke air mass and temperature Engine ECU D20DTF Engine control by various signals Fuel filter assembly Supply clean fuel fuel heating water separation by priming pump Accelerator pedal position sensor Detects driver s intention for speed up down High pressure pump Generates the high pressurized fuel and supply it Plunger type HP pump 1 800 bar Vane type transfer pump 6bar ...

Page 162: ...e rail and injected by 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 pum...

Page 163: ...03 26 korando 2010 10 0000 00 ENGINE FUEL SYSTEM 3 Input Output devices ...

Page 164: ...ts the amount of the 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 ma...

Page 165: ...03 28 korando 2010 10 0000 00 ENGINE FUEL SYSTEM 4 Flow Diagram of Fuel Supply System ...

Page 166: ...03 29 ENGINE FUEL SYSTEM korando 2010 10 0000 00 5 Circuit Diagram of Duel Supply System ...

Page 167: ...ement Filter area 0 64 m Replace interval EU change every 20000 km or 12months But shorten the service interval under severe conditions GEN change every 15000 km or 12months But shorten the service interval under severe conditions Air cleaner assembly Weight 1 13 kg Operating temperature 30 100 Capacity 6 5 L Intercooler Core material Aluminum Size 510 x 110 x 70 W x H x T Core size 510 x 110 x 63...

Page 168: ...rten the service interval under severe conditions GEN change every 15000 km or 12months But shorten the service interval under severe conditions Change at every 30 000 km of driving Air cleaner assembly Weight 1 13 kg Operating temperature 30 100 Capacity 6 5 L Intercooler Core material Aluminum Size 510 x 110 x 70 W x H x T Core size 510 x 110 x 63 W x H x T Tank material Plastic Molding Efficien...

Page 169: ...ctly when reconnecting 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 ...

Page 170: ...ircuit the intake 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...

Page 171: ...cut off the intake air 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 1719 16 Electric throttle body For more information refer to Engine Control section 1719 02 Swirl control valve Works variably in accordance with th...

Page 172: ...8 korando 2010 10 1719 00 INTAKE SYSTEM 2313 15 HFM sensor HFM sensor version 6 For more information refer to Engine Control section 2313 01 Air cleaner assembly and resonator 2330 01 Intercooler assembly ...

Page 173: ...04 9 INTAKE SYSTEM korando 2010 10 1719 00 3 INPUT OUTPUT DEVICES ECU DCM 3 7 ...

Page 174: ...04 10 korando 2010 10 1719 00 INTAKE SYSTEM 4 OPERATING PROCESS Work Flow ...

Page 175: ...04 11 INTAKE SYSTEM korando 2010 10 1719 00 5 WIRING DIAGRAM ...

Page 176: ...05 3 EXHAUST SYSTEM korando 2010 10 1729 00 1 TROUBLESHOOTING 1 Work Flow ...

Page 177: ... makes sure that the 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 ...

Page 178: ...aust pipe No 2 exhaust pipe No 3 muffler pipe 1 OVERVIEW This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion 2 COMPONENT Fore details about the CDPF assembly refer to Chapter CDPF System ...

Page 179: ...05 6 korando 2010 10 1729 00 EXHAUST SYSTEM 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 180: ... 2010 10 1914 00 1 SPECIFICATION Component Item Specification Turbocharger Max expansion coefficient 5 0 Max turbine speed 213 000 rpm Max temperature of turbine housing 830 Weight 7 2 kg E Actuator Operation duty cycle 300 Hz ...

Page 181: ...gine for about 1 minute 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 ...

Page 182: ...r wall section of the exhaust gas opening Problems in turbocharger In case where the oil is smeared on only at the exhaust gas outlet section 2 Inspection of Turbocharger When problem occurs with the turbocharger it could cause engine power decline excessive discharge of exhaust gas outbreak of abnormal noise and excessive consumption of oil On board Inspection 1 Check the bolts and nuts foe loose...

Page 183: ...re 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 not high which makes neg...

Page 184: ...g tries to understand 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 185: ...06 8 korando 2010 10 1914 00 TURBOCHARGER Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 186: ...06 9 TURBOCHARGER korando 2010 10 1914 00 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 187: ...06 10 korando 2010 10 1914 00 TURBOCHARGER Defects caused by reasons other than that of the turbocharger 4 ...

Page 188: ...er 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 discharge of carbon in connecting area of the duct When the engine rotates or in case where there is change in noise l...

Page 189: ...06 12 korando 2010 10 1914 00 TURBOCHARGER 2 Work Flow for Troubleshooting ...

Page 190: ...06 13 TURBOCHARGER korando 2010 10 1914 00 ...

Page 191: ...06 14 korando 2010 10 1914 00 TURBOCHARGER ...

Page 192: ...06 15 TURBOCHARGER korando 2010 10 1914 00 ...

Page 193: ...06 16 korando 2010 10 1914 00 TURBOCHARGER ...

Page 194: ...y improves as the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger 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 D20DTF engine variably controls the passages of the turbine housing to regu...

Page 195: ... control with CDPF 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 c...

Page 196: ......

Page 197: ...0 TURBOCHARGER T MAP sensor Booster pressure and temperature E VGT Improves engine power 2 COMPONENT For more information about control logic refer to Engine Control For more information about control logic refer to Engine Control ...

Page 198: ...l Accelerator pedal sensor Transfers driver s will to accelerate to ECU For more information about control logic refer to Engine Control For more information about control logic refer to Engine Control Atmospheric pressure RPM signal For more information about control logic refer to Engine Control For more information about control logic refer to Engine Control ...

Page 199: ...06 22 korando 2010 10 1914 00 TURBOCHARGER 3 INPUT OUTPUT DEVICES ...

Page 200: ...ed of exhaust gas 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...

Page 201: ...asing force of abundant 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...

Page 202: ...dy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Item Specifications Oil pump Lubrication system Gear pump forced circulation Type Inscribed gear Oil pump capacity 74 L at 4 000 rpm 3 bar Relief pressure 6 3 bar 0 3 bar Oil filter Type Full flow Paper element Engine oil Specified oil SAE 5W30 appr...

Page 203: ...ing vehicle with insufficient 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 ge...

Page 204: ...e burned and stuck 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...

Page 205: ...brication system cooling system and some mechanical devices as below System Components Supplementary devices Power steering pump HPS Alternator A C compressor Belt drive Belt tensioner Idle pulley Cooling Water pump Thermostat Cooler housing and Pipes Lubrication Oil filter Oil cooler except coolant pipes ...

Page 206: ...07 7 LUBRICATION SYSTEM korando 2010 10 1543 00 1 Operation Flow 2 OPERATING PROCESS ...

Page 207: ...n cooling capacity over 68 000kcal h Antifreeze Type Long life coolant Mixing ratio water antifreeze 50 50 Cooling fan module Type Electric Capacity 220W Ø360 150W Ø360 Control type Series low speed Parallel high speed Coolant reservoir Capacity over 2 2L Circulation Closed roof type Pressure cap Screw type 1 4bar Vacuum valve Screw type 1 4bar Thermostat Type Wax pallet type Opening temperature 9...

Page 208: ...ge Coolant level is low 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 blo...

Page 209: ...ould be between the 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 MA...

Page 210: ...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 temperature Valve opening temperature 90 2 Never open the cap ...

Page 211: ...ning or hot can cause 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...

Page 212: ...servoir Long life coolant is used Water pump The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine Thermostat When the engine coolant reaches 90 the thermostat starts to open fully open at 100 and lets the coolant flow to the radiator to maintain the engine temperature Oil filter module ...

Page 213: ...res the coolant temperature and sends the result to the engine ECU Electric fan Circulates the fresh air forcibly to exchange 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 ...

Page 214: ...08 10 korando 2010 10 1520 00 ENGINE COOLING SYSTEM 2 Schematic Diagram ...

Page 215: ......

Page 216: ...08 12 korando 2010 10 1520 00 ENGINE COOLING SYSTEM 3 System Layout ...

Page 217: ...08 13 ENGINE COOLING SYSTEM korando 2010 10 1520 00 ...

Page 218: ...3 00 1 SPECIFICATION Alternator Typ HPS EPS Capacity 120 A 140 A Normal output 70 120 A at 1 800 6 500 rpm 76 140 A at 1 800 6 500 rpm Regulator voltage 14 6 V Brush Length 12 5 mm Wear limit 7 mm Battery Typ Maintenance Free Capacity 90 AH ...

Page 219: ... terminal Move the 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...

Page 220: ...e 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 Repair Charge warning...

Page 221: ...09 6 korando 2010 10 1453 00 CHARGE SYSTEM 3 Checking Battery ...

Page 222: ...y capacity by fixing 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 alterna...

Page 223: ...e block or a front towing hook 1 2 3 4 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 v...

Page 224: ...y connected If 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 batte...

Page 225: ...r 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 Alternator The alternator charges the battery and supplies power to each electric unit by converting the mechanical energy to the electrical energy Battery It converts the chemical energy to the ...

Page 226: ...09 11 CHARGE SYSTEM korando 2010 10 1453 00 2 OPERATING PROCESS ...

Page 227: ...09 12 korando 2010 10 1453 00 CHARGE SYSTEM 3 CIRCUIT DIAGRAM ...

Page 228: ...1 SPECIFICATION Description Specification Glow plug Rated voltage 12 V Operating voltage 6 to 16 V Maximum temperature 1 300 C Operating temperature 1 100 C Glow plug control unit EMS operating voltage 6 to 16 V Operating temperature 40 C to 110 C Dark current Max 1 mA ...

Page 229: ...10 4 korando 2010 10 0000 00 PRE HEATING 2 TIGHTENING TORQUE No Name Tightening torque 1 Glow plug 20 2 Nm 2 Glow plug control unit bolt Glow plug GCU Glow plug Control Unit ...

Page 230: ...r 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 plug con...

Page 231: ...10 6 korando 2010 10 0000 00 PRE HEATING 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 232: ...10 7 PRE HEATING korando 2010 10 0000 00 3 Circuit Diagram ...

Page 233: ...IGN terminal from the battery the GCU supplies the battery power to raise the temperature of the glow plug to 1000 by the pre heating request from the engine ECU before starting The time for pre heating is controlled by the ECU If the input power VB is 11 5 V or less the GCU supplies the battery power for arrival time T1 If the input power VB is greater than 11 5 V the GCU supplies the voltage of ...

Page 234: ...ived after the 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 Coolant temperature approx 20 C 10 C 0 C 20 C 80 C Operating time approx 100 s...

Page 235: ...10 10 1461 00 1 SPECIFICATION Capacity 12V 2 3kW 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 236: ...uit Faulty ignition 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 flywhee...

Page 237: ...rt motor starts the engine 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 System Configuration ...

Page 238: ...11 6 korando 2010 10 1461 00 STARTING SYSTEM 2 OPERATING PROCESS 1 System Layout ...

Page 239: ...11 7 STARTING SYSTEM korando 2010 10 1461 00 2 Circuit Diagram ...

Page 240: ...ccelerator 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 241: ...ammed driving on motorways 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 242: ...12 5 CRUISE CONTROL korando 2010 10 8530 00 2 CONFIGURATION 1 Circuit Diagram ...

Page 243: ...12 6 korando 2010 10 8530 00 CRUISE CONTROL 2 Configuration ...

Page 244: ...switch of the cruise control 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 awar...

Page 245: ...er 38 km h Push up the 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 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 t...

Page 246: ...h When the desired speed is reached release the lever 1 2 2 When the cruise control system is not running To decrease the vehicle speed with the cruise control system when the system is not running follow the procedures below Push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached while the vehicle speed is over 40 km h And then release the accelerato...

Page 247: ...ures below Push down the DECEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap down switching When you operate a tap down switching the vehicle is decelerated for 1 km h below the previous set speed If you want to decelerate for 10 km h operate the tap down switching ten times without the brake pedal intervention 1 ...

Page 248: ... when the current vehicle speed is over 38 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 prope...

Page 249: ...us set cruise speed can be recovered by pushing down the cruise control lever when the current vehicle speed is over 38 km h without an acceleration intervention In this operation the smooth acceleration to the set cruise speed can be achieved by optimized fuel consumption When this mode is activated ECO indicator comes on ...

Page 250: ...l is depressed When the cruising speed is downed less than 38 km h When pushing the ON OFF switch of the cruise control lever When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be operated again in driving state 1 2 3 4 5 6 Keep the main cruise control switch in the neutral position when not using th...

Page 251: ...engine brake and foot 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 7 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...

Page 252: ... Item E EGR valve Motor EGR response time 50 ms Driven by DC motor Valve EGR gas flow rate 120 kg h E EGR cooler 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 ...

Page 253: ...exhaust gas to the intake system and it lowers the combustion temperature by increasing the CO2 content in the intake air to reduce the emission of NOx Benefits of E EGR valve Improved accuracy and response through electric control Feedback function Potentiometer Preventing chattering of EGR valve and improved durability Self cleaning function ...

Page 254: ......

Page 255: ...d as a main map value to control the EGR The coolant temperature engine rpm engine load intake air temperature HFM decreased at 60 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 intake duct ...

Page 256: ...perature of the exhaust gas and the bypass valve directly supplies the exhaust gas to the intake duct without passing through the EGR cooler to reduce the emission of exhaust gas before warming up the engine EGR cooler EGR bypass E EGR valve Receives the electric signal from the ECU to control the valve ...

Page 257: ...13 8 korando 2010 10 1793 00 E EGR SYSTEM 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 258: ...de compensation Compensation by the boost pressure deviation the difference between the requested value and the measured value of boost pressure Compensation by the engine load During sudden acceleration Compensation by the 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...

Page 259: ...spheric pressure 0 92 bar or more Engine coolant temperature between 0 and 100 C When there is no fault code related to EGR 2 Shut off conditions Abrupt acceleration with engine speed of 2600 rpm or more When the engine is idling for more than 1 minute Vehicle speed 100 km h or more Engine torque 380 Nm or more ...

Page 260: ......

Page 261: ...CIFICATION Emission Regulation Euro V Front Area 182 41 Size DOC 124 X 158 X 78L DPF 124 X 158 X 194 mm CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 4 2 L Material of Filter AT Aluminum Titanium Alloy ...

Page 262: ...ecessarily Do not 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 ...

Page 263: ...ss is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increase the temperature of the exhaust gas The driver may not feel any particular difference from the vehicle 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 Wh...

Page 264: ...ture Then an excessive 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...

Page 265: ...armless through 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 266: ...ger Rear temperature sensor Measures the temperature of fuel combustion CDPF DOC DPF Throttle valve Regulates the rate of air intake Engine ECU DCM 3 7 Post injection Differential pressure sensor Calculates the amount of PM collected by reading the pressure difference between before and after the CDPF ...

Page 267: ...0 1 2 If the temperature 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 Electr...

Page 268: ...e of exhaust gas is 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...

Page 269: ...he pressure difference between before and after the CDPF exceeds the specified value Front EGT sensor Measures the temperature of DOC The DOC performs the redox reaction at between 300 and 500 and the front EGT sensor monitors the temperature of DOC HFM sensor T MAP sensor Intake air volume Post injection Intake air volume Control Detecting excess of PM amount limit Boost pressure temperature Rear...

Page 270: ... 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 Collecting PM Regeneration The engine ECU detects the amount of PM collected by the information from the temperature sensors and differential pressure sensor When the soot is accumulated the engine ECU performs post injection ...

Page 271: ...14 13 CDPF SYSTEM korando 2010 10 2412 00 6 OPERATING TEMPERATURE ...

Page 272: ...14 14 korando 2010 10 2412 00 CDPF SYSTEM 7 ELECTRIC CIRCUIT DIAGRAM ...

Page 273: ...rottle position angle TA 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 04 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 sel...

Page 274: ...TEM Electronic throttle body T MAP sensor Temp Pres Injector C3I 1 MAJOR COMPONENT Rear exhaust gas temp sensor Oxygen sensor Front exhaust gas temp sensor Camshaft position sensor Glow plug Variable swirl valve Knock sensor 2 Oil level sensor ...

Page 275: ...CONTROL SYSTEM undefined 0000 00 HFM air mass temperature Fuel temp sensor GCU Glow plug control unit Differential pres sensor D20DTF ECU Coolant temp sensor IMV E EGR bypass valve E EGR valve Fuel rail pres sensor ...

Page 276: ...15 6 undefined 0000 00 ENGINE CONTROL SYSTEM 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 277: ... sensor Exhaust gas temp sensor HFM sensor 2 Components for ECU Input Crankshaft posi sensor Accel pedal posi sensor Throttle posi sensor Knock sensor T MAP sensor Camshaft posi sensor CAN ABS ESP GCU Meter cluster TCU BCM Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal Oil level sensor Differential pressure sensor ...

Page 278: ...EGR cooler bypass valve Engine room relay box E VGT actuator IMV Throttle posi sensor Injector A C compressor Start motor Variable swirl valve 3 Components for ECU Input PTC heater CAN Glow plug unit ABS ESP unit BCM E coupling unit EPS GCU Meter cluster TCU Self diagnosis ...

Page 279: ...e status and defectives 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 Curre...

Page 280: ... smoke and damages engine durability Fuel 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 coolan...

Page 281: ...to adapt the timing advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities ...

Page 282: ...han the flow limit determined by the 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 inject...

Page 283: ...s the maximum fuel which 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 choos...

Page 284: ...issions to be reduced 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 faul...

Page 285: ...d on the basis of the engine speed and the coolant temperature 6 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 c...

Page 286: ...ated from the cylinder is detected The knock sensor detects the vibration from the engine after a small volume of fuel is injected And the time interval between the points of injection and vibration is measured so that MDP can be learned MDP learning is helpful to prevent engine vibration high emission and power reduction through performing calibration for the old injectors During MDP learning a l...

Page 287: ...ow is used to establish the background noise level of the accelerometer 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 ma...

Page 288: ...which a fault is signaled 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...

Page 289: ...could not be generated because the air flow is slow To generate strong 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...

Page 290: ...15 20 undefined 0000 00 ENGINE CONTROL SYSTEM b Input Output for variable swirl valve ...

Page 291: ... flow Fast flow decreases the PM during combustion and increases the EGR ratio by better combustion efficiency Load Engine speed Swirl valve Amount of swirl Remarks Low speed Low load below 3 000 rpm Closed Heavy Increased EGR ratio better air fuel mixture reduce exhaust gas High speed High load over 3 000 rpm Open Light Increase charge efficiency higher engine power The variable swirl valve actua...

Page 292: ...yond a certain limit If the swirl valve operates in this moment the limit of EGR ratio will be higher Relationship between swirl and fuel injection pressure The injector for DI engine uses the multi hole design For this vehicle there are 8 holes in injector If the swirl is too strong the injection angles might be overlapped and may cause the increased PM and insufficient engine power Also if the i...

Page 293: ... regulation The solenoid type actuator is used in the conventional model but in this new model the DC motor type actuator with improved response rate is adopted Also the hall sensor which provides a more stabilized signal than the potentiometer and the EGR bypass flap which improves engine warming up efficiency are also used The HFM sensor and the position sensor are used to feedback the amount of...

Page 294: ...15 24 undefined 0000 00 ENGINE CONTROL SYSTEM c Input Output of E EGR system ...

Page 295: ...ting EGR ratio Engine 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 ...

Page 296: ...erature and accordingly 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 297: ...ust gas by adjusting the passage in turbine housing 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 E VGT actuator Coolant temperature Front EGT sensor T MAP sensor Crankshaft pos sensor HFM sens...

Page 298: ...15 28 undefined 0000 00 ENGINE CONTROL SYSTEM c Input Output for E VGT system ...

Page 299: ...acks the turbocharger 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 ra...

Page 300: ... 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 oxygen sensor measures the oxygen density in exhaust gas and sends it to ECU to control the EGR more pr...

Page 301: ...15 31 ENGINE CONTROL SYSTEM undefined 0000 00 c Input Output for oxygen sensor ...

Page 302: ...movement of oxygen ions 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 303: ... of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools The heat from automatic transaxle is also cooled down through the radiator by circulating the oil through the oil pump There are two cooling fans 200W 150W in D20DTF engine ECU controls the electric cooling fans with three cooling fan relays to improve the engine torque and air conditioning performanc...

Page 304: ...15 34 undefined 0000 00 ENGINE CONTROL SYSTEM c Input Output for cooling fan and A C compressor ...

Page 305: ...5 Coolant temp ON LO Coolant temp 105 Refrigerant pressure 18 bar 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 ...

Page 306: ...or and HFM sensor This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required PTC does not operate during engine cranking while the battery voltage is lower than 11 V or during preheating process of glow plugs b Components PTC heater Coolant temp sensor ECU Eng...

Page 307: ...igh at a certain 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 308: ...intake air temperature 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 309: ...nauthorized persons The transponder integrated 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 BCM b Components Basic components ignition key system Immobilizer k...

Page 310: ...ied to BCM and ECU ECU 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 311: ...d with an extra filter to collect the soot 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 Rear temp sensor CDPF DOC DPF Throttle valve D...

Page 312: ...15 42 undefined 0000 00 ENGINE CONTROL SYSTEM c Input Output for CDPF control ...

Page 313: ...uel 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 the amount of fuel while decreasing the amount of intake air Front temp sensor Measure DOC tem...

Page 314: ...hes and keeps accumulating Eventually this ashes will block the filter 3 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 4 Problems when using unspecified engine oil The service li...

Page 315: ...N of communication according to the communication speed Instrument cluster BCM and diagnostic connector use both types of communication And ECU ABS ESP TCU GCU E coupling and EPS unit use P CAN communication because it is faster than B CAN The terminal resistances are installed in ECU and BCM Abbreviation Function GCU Glow Control Unit EPS Electronic Power Steering Unit BCM Body Control Module ...

Page 316: ...Wiring harness Location S101 Floor wiring LH Under fuse relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind meter cluster cowl cross member S202 Main wiring Behind meter cluster cowl cross member S205 Floor wiring LH Under driver s door scarf ...

Page 317: ...15 47 ENGINE CONTROL SYSTEM undefined 0000 00 3 Input Output for CAN communication ...

Page 318: ... 01 GENERAL INFORMATION ELECTRIC GENERAL INFORMATION 1 EXTERIOR LAMP SYSTEM LAYOUT 2 INTERIOR LAMP SYSTEM LAYOUT 3 SWITCH SYSTEM LAYOUT 4 SCHEMATIC DIAGRAM FOR WIRING AND ELECTRICAL DEVICES 5 CAN COMMUNICATION CONFIGURATION 3 6 8 10 14 ...

Page 319: ......

Page 320: ...ront turn signal lamp Side repeater lamp Puddle lamp 1 EXTERIOR LAMP SYSTEM LAYOUT Front fog lamp Position lamp Headlamp assembly Backup lamp High mounted stop lamp Tail stop lamp Reflector Rear turn signal lamp Tail lamp License plate lamp Front view Rear view ...

Page 321: ...01 4 korando 2010 10 0000 00 ELECTRIC GENERAL INFORMATION Side repeater lamp Puddle approach lamp Front fog lamp Headlamp High beam low beam Turn signal lamp Position lamp 1 2 3 ...

Page 322: ...ION korando 2010 10 0000 00 Stop lamp and tail lamp Turn signal lamp Backup lamp Stop lamp For Korea Rear fog lamp 1 2 3 4 Vehicle without spoiler Vehicle with spoiler License plate lamp High mounted stop lamp Rear combination lamp ...

Page 323: ...01 6 korando 2010 10 0000 00 ELECTRIC GENERAL INFORMATION Front room lamp Sun visor lamp Glove box lamp 2 INTERIOR LAMP SYSTEM LAYOUT ...

Page 324: ...01 7 ELECTRIC GENERAL INFORMATION korando 2010 10 0000 00 Center room lamp Luggage lamp Door courtesy lamp ...

Page 325: ...heel remote control switch Passenger door switch Lower main panel switch Overhead console switch Cruise control switch Hazard warning switch and bezel assembly Multifunction switch FATC switch Drive door main switch Outside rear view mirror switch 3 SWITCH SYSTEM LAYOUT ...

Page 326: ...ECTRIC GENERAL INFORMATION korando 2010 10 0000 00 Center room lamp switch Front seat heated wire switch STD Rear door switch RH Rear door switch LH Tailgate switch Luggage lamp switch Driver power seat switch ...

Page 327: ...01 10 korando 2010 10 0000 00 ELECTRIC GENERAL INFORMATION 4 SCHEMATIC DIAGRAM FOR WIRING AND ELECTRICAL DEVICES 1 Wiring Harness Arrangement ...

Page 328: ...01 11 ELECTRIC GENERAL INFORMATION korando 2010 10 0000 00 2 Electrical devices mounting locations ...

Page 329: ...01 12 korando 2010 10 0000 00 ELECTRIC GENERAL INFORMATION 3 Connector Ground And Splice Pack Connector ...

Page 330: ...01 13 ELECTRIC GENERAL INFORMATION korando 2010 10 0000 00 Ground Splice pack ...

Page 331: ...to the communication speed The instrument cluster and BCM Body Control Module communicate through both P CAN and B CAN at the same time 1 CAN Configurations P CAN B CAN Abbreviations Meaning Function GCU Glow Control Unit Glow control unit EPS Electronic Power Steering Unit Electrically driven power steering unit BCM Body Control Module Body control module ...

Page 332: ...ck Wiring Location S101 Floor wiring LH Under fuse and relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind the instrument cluster cowl cross member S202 Main wiring Behind the instrument cluster cowl cross member S205 Floor wiring LH Under driver door scuff ...

Page 333: ......

Page 334: ...e to turn OFF the ignition switch and other lamp switches before disconnecting or connecting the negative battery cable Otherwise semiconductor parts can be damaged If a fuse is blown replace it with a rated capacity fuse If you use a fuse with capacity higher than the specification corresponding parts can be damaged or a fire can break out Do not drop or apply excessive impact to sensors and rela...

Page 335: ...e or continuity of the connector terminal with a circuit tester insert the tester s probe from the harness side For a seal type connector the probe should be inserted through the hole in the rubber cap of the wiring At this time take care not to damage insulation of the wires and insert the probe until it contacts with the end of the connector terminal When inspecting the airbag system make sure t...

Page 336: ...hicle body or other parts Check that the grounding part has continuity with mounting bolts and vehicle body Check that wires are properly routed Make sure that wires are securely fixed to avoid contact with sharp body parts and high temperature parts such as the exhaust manifold and exhaust pipes The rotating parts such as fan pulley and fan belt perturbative parts and wiring should be secured tig...

Page 337: ...engine compartment There are 3 fuse relay boxes in this vehicle 2 SYSTEM LAYOUT 1 OVERVIEW Fuse and relay box in engine compartment Interior fuse box ICM Integrated Control Module Rear wiper rear fog lamp mirror folding ACC IGN1 2 horn tailgate power outlet shift lock relay A T 1 2 3 ...

Page 338: ...2010 10 8410 06 3 OPERATING PROCESS 1 Fuse Relay Box in Engine Compartment The fuse relay box is located beside the battery It contains wiper horn heated wire fog lamp tail lamp and PTC relays the B is supplied from ALT Fuse relay ...

Page 339: ...01 8 korando 2010 10 8410 06 FUSE AND RELAY Circuit diagram I ...

Page 340: ...01 9 FUSE AND RELAY korando 2010 10 8410 06 Circuit diagram II ...

Page 341: ...01 10 korando 2010 10 8410 06 FUSE AND RELAY Fuse relay box III ...

Page 342: ...01 11 FUSE AND RELAY korando 2010 10 8410 06 2 Interior Fuse Box This fuse box is located in the left side of instrument panel Fuse relay ...

Page 343: ...01 12 korando 2010 10 8410 06 FUSE AND RELAY Circuit diagram I ...

Page 344: ...01 13 FUSE AND RELAY korando 2010 10 8410 06 Circuit diagram II ...

Page 345: ...01 14 korando 2010 10 8410 06 FUSE AND RELAY 3 ICM Box Function descriptions ...

Page 346: ... Fuse box 8 B CE box 9 10 Ground Connector B Pin No Function 1 Multifunction switch RH 2 ACC F47 3 BCM Mirror folding control 4 BCM 5 ICM C10 6 IGN2 F39 7 Rear wiper motor Pin No Function 8 Rear wiper motor 9 Front rear power outlet 10 B F46 11 Fuse box 12 Ground 13 BCM Mirror unfolding control 14 Mirror unfolding motor ...

Page 347: ...AY Connector C Pin No Function 1 Stop lamp switch 2 BCM 3 IGN F31 4 BCM 5 B F45 6 Rear fog lamp 7 TGS lever 8 TGS lever Pin No Function 9 Warning horn 10 B F42 11 Tailgate actuator 12 B F45 13 Mirror folding motor 14 Ground 15 ICM C16 16 B F52 ...

Page 348: ...01 17 FUSE AND RELAY korando 2010 10 8410 06 ICM box is located behind the instrument cluster Circuit board ...

Page 349: ... ON headlamp ON condition the rear fog lamps are turned ON When pressing the rear fog lamp switch again during the operation the rear fog lamps are turned OFF The rear fog lamps do not come ON when the engine is not running or the light switch is OFF The rear fog lamps should not automatically come on again if they have been turned OFF by any other way other than the switch 1 2 3 4 Power supply Me...

Page 350: ...o 45 Operating signal BCM D16 D17 Folding Unfolding Manual operation When pressing the mirror folding unfolding switch with IGN ON the mirrors are folded or un floded according to the mirror condition in 16 6 seconds 4 Horn relay Power supply SB1 Interior fuse box No 45 ICM C5 Operating signal BCM A24 ON OFF ...

Page 351: ... signal BCM D6 ON OFF Non operating conditions The tailgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h 6 Shift lock relay for A T Power supply SB2 Interior fuse box No 31 ICM C1 with stop lamp switch ON Operating signal No 10 in gear selector lever connector ON OFF ...

Page 352: ...01 21 FUSE AND RELAY korando 2010 10 8410 06 7 Power outlet relay Power supply SB1 Interior fuse box No 46 ICM B10 Operating signal Interior fuse box No 47 with key ACC ICM B12 grounded ...

Page 353: ...01 22 korando 2010 10 8410 02 FUSE AND RELAY Connectors Connector A Connector B Connector C Connector D Fuse Relay Box ...

Page 354: ...01 23 FUSE AND RELAY korando 2010 10 8410 02 Function descriptions of connectors Connector A Pin No Function 1 Glow control ...

Page 355: ...e box No 42 46 8 BCM A15 9 10 TGS Auto light 11 12 Light switch High beam 1 13 Position lamp LH 2 14 15 16 BCM D3 Low beam relay Connector B Pin No Function 17 18 BCM D3 High beam relay 19 Position lamp RH 2 20 DI ECU B56 21 Driver seat switch 10 22 Light switch Low beam 8 23 24 DI ECU B57 25 Tail lamp LH 2 S203 19 ILL 26 PTC heater2 3 27 DI ECU B3 28 DI ECU B1 29 PTC heater 1 1 30 C104 21 31 32 3...

Page 356: ... lamp LH 2 17 18 DI ECU B37 19 BCM D8 Power window 20 21 HFM 1 Glow control unit A5 VGT 1 Connector C Pin No Function 22 Sunroof motor 1 23 Sunroof motor 1 24 25 26 27 28 29 IMV 1 30 31 32 33 PTC heater 3 5 34 Interior fuse box No 51 52 35 Power window switch 2 Power window motor 5 passenger 36 Power window switch 8 Power window motor 6 driver 37 Outside mirror motor passenger 6 heated wire 38 Win...

Page 357: ...5 wiper Lo 9 G101 10 11 G101 12 BCM D15 wiper Hi 13 14 Wiper motor Hi 6 15 BCM A25 Hazard glass heated wire switch 8 16 Connector D Pin No Function 17 18 19 20 21 C104 31 22 Inhibitor switch 2 A T Clutch switch 1 M T 23 DI ECU B51 24 A C compressor 2 25 Wiper motor 3 26 Rear glass heated wire 1 27 ABS ESP unit 1 28 Fuel heater 2 29 Start motor ST 30 G101 31 Low beam LH 2 32 32 ...

Page 358: ... V CAN Operating temperature 30 to 80 C Storage temperature 40 to 85 C Transponder Frequency 134 2 kHz 4 kHz Operating temperature 40 to 85 C Max humidity 95 High resistant voltage 24 V Dark current Below 7 0 mA All switches OFF key out all doors LOCK and Sleep mode Voltage drop Below 1 0 V at pin B6 and all pins for IN OUT 8710 01 BCM BODY CONTROL MODULE ...

Page 359: ...i lock function when opening door O 3 Tail lamp control Tail lamp ON warning O External lamp warning display X Tail lamp auto OFF O 4 Door ajar warning Door status management X Door ajar warning O 5 Seat belt control Seat belt warning O Seat belt reminder O 6 Sunroof warning Sunroof warning control O Sunroof warning display X 7 Room lamp control Door coupled room lamp and dimming control O Room la...

Page 360: ...ntrol by door lock switch O Lock unlock control by central door lock switch O Lock unlock control by REKES signal O Auto door lock control O Auto door unlock crash signal control O 12 Panic alarm Panic alarm control by REKES signal O 13 Tailgate open control Tailgate open control O 14 Theft deterrent mode control Theft deterrent mode control O 15 Time lag power window control Time lag power window...

Page 361: ...sher control w ABS O 18 DRL Daytime Running Light control DRL Daytime Running Light control O 19 Fog lamp control Fog lamp control O 20 Auto light control LIN Auto light control O 21 Immobilizer function Key coding and synchronization O Challenge O CAN information O 22 Mirror folding unfolding control Folding unfolding control O Auto folding unfolding control O 23 Approach puddle lamp control Appr...

Page 362: ...tric equipment on car body and outputs the control and warning signals as below 1 Wiper Control 1 Wiper mist washer coupled wiper Wiper mist When turning ON the front washer switch with IGN1 ON the front wipers operate after T1 When releasing the switch the wipers will stop at parking positions 1 ...

Page 363: ...10 10 8710 01 BCM Front washer coupled wiper When holding the front washer switch at ON position for more than T2 with IGN1 ON the washer fluid is sprayed onto the windshield glass and the wipers operate three times 1 ...

Page 364: ...e washer fluid is sprayed onto the tailgate glass 1 When holding the front washer switch at ON position for more than 0 6 seconds with the wiper switch AUTO the washer fluid is sprayed onto the windshield glass and the wipers operate three times When holding it between 0 1 and 0 59 seconds the wiper will operate only once 2 ...

Page 365: ...onds and the wipers operate 3 times again The auto washer function is not available during the operation of auto washer coupled wiper The auto washer function is not available while the wiper system is in intermittent wiping mode When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent wiping mode will be started Th...

Page 366: ...02 11 BCM korando 2010 10 8710 01 Rain sensor coupled wiper LIN System layout 1 ...

Page 367: ...rned OFF S_AUTOH high relay ON min one cycle ON However low relay is turned ON The washer function is not available when the wiper switch is in LO or HI POSITION The washer coupled wiper function is available only when the wiper switch is in AUTO position Power up reminder wiper If the wiper switch is in AUTO position the wiper motor does not operate even when turning the ignition switch to ON pos...

Page 368: ...sor Even though the wiping system is in washer coupled wiper mode the operating data are sent to rain sensor 1 2 Sensitivity adjustment When increasing the wiping speed ex sensitivity 0 1 with volume dial with IGN2 ON wiper switch AUTO and wiper motor stop parking the wipers operate one cycle through the low relay only when the signal from rain sensor is raining 1 If the volume sensitivity is chan...

Page 369: ...th IGN2 ON and wiper switch AUTO 1 When the parking terminal is fixed at IGN HIGH with IGN2 ON and wiper switch AUTO the wiper system sends the wiper operating signal for 2 seconds then continuously sends the wiper parking signal 2 The wiper motor runs only when the rain sensor requires the wiper operation The wiper motor runs only when the rain sensor requires the wiper operation ...

Page 370: ...tch AUTO while receiving S_RSFAULT defective rain sensor signal from rain sensor the wipers operate one cycle through the low relay 1 When changing the volume sensitivity to 3 from 4 with IGN2 ON and wiper switch AUTO while receiving S_COMMFAULT communication error signal from rain sensor the wipers operate one cycle through the low relay 2 ...

Page 371: ...operate When moving the wiper switch to AUTO from OFF position after turning the ignition switch to ON position the wipers operate one cycle Vehicle speed and volume sensitivity controls the intermittent wiping operation 1 2 3 The system calculates and changes the intermittent interval by using vehicle speed and volume sensitivity with IGN2 ON and wiper switch AUTO Intermittent interval at 0 km h ...

Page 372: ...per operation The wiper relay should stay ON during wiper operation in low high mode even though the system does not receive P POS signal In AUTO mode the wiper relay should be turned OFF after 5 seconds if there is no P POS signal for 3 seconds inform to car owner In high low mode the front washer motor should operate when turning ON the front washer switch In high low mode the rear washer motor ...

Page 373: ...on warning When opening the driver door while the ignition key is in ignition switch the buzzer sound for 10 seconds with the interval of 0 02s ON 1 38s OFF When removing the ignition key or closing the driver door during the period the buzzer stops its operation This function is not available when the ignition switch is in ON position 1 2 3 ...

Page 374: ...ce but immediately unlocked The doors should be stayed in UNLOCK condition for T2 even when locking them by door lock switch in T1 after closing the opened door However the doors should not be unlocked when removing the ignition key during the locking process by door lock switch 1 2 3 1 Driver door lock switch or passenger door lock switch 2 Driver door switch or passenger door switch ...

Page 375: ...ey OUT and IGN ON The doors should be stayed in UNLOCK condition for T1 when closing the door during unlock process with key OUT and IGN ON The system performs the ignition key reminder function while the ignition key is in ignition switch This function is not available when the vehicle speed is over 10 km h 1 2 3 4 1 Driver door lock switch or passenger door lock switch 2 Driver door switch or pa...

Page 376: ...he interval of 0 02s ON 1 38 OFF when opening the driver door with key removed and tail lamp ON The buzzer stops its operation when turning off the tail lamp or closing the driver door during buzzer operation The buzzer stays ON when turning the tail lamp on again after turning it off during buzzer operation This function is not available when the ignition switch is in ON position 1 2 3 4 ...

Page 377: ...the ignition switch with the tail lamp ON the tail lamps go off automatically In above conditions the tail lamps come ON again The tail lamp should not go off when turning ON the tail lamps with key IN The tail lamps should not go off when turning OFF and then ON the tail lamp with the power Off or ACC ON The system will be reset when inserting the ignition key into key switch 1 2 3 4 5 6 ...

Page 378: ...able only when any of doors or tailgate except engine hood is open The instrument cluster module controls the door ajar warning lamp through the signals from BCM Also the instrument cluster module controls the blinking function according to the vehicle speed 1 2 1 Ajar any of doors or tailgate is open Closed all doors and tailgate are closed ...

Page 379: ...M The instrument cluster module controls the seat belt warning lamps by seat belt warning signals from BCM When turning the ignition switch to OFF position during the warning operation the buzzer stops and the warning lamp goes off If the seat belt switch is ON seat belt fastened during the warning operation the buzzer stops but the warning lamp blinks for the remaining time of the period If the s...

Page 380: ...nder is initially operated due to unfastened driver seat belt the buzzer sounds for 5 minutes with the interval of 0 02s ON 1 18s OFF the instrument cluster module sends the driver seat belt warning signal SBR and the seat belt warning lamp stays on If the seat belt reminder is operated due to unfastened passenger seat belt the instrument cluster module sends the passenger seat belt warning signal...

Page 381: ...02 26 korando 2010 10 8710 01 BCM ...

Page 382: ... key with the sunroof open the buzzer sounds for 10 seconds with the interval of 0 02s ON 1 58s OFF When opening and then closing the driver door or closing the sunroof during buzzer operation the buzzer stops its operation immediately The sunroof warning has a priority over the tail lamp left On warning 1 2 3 ...

Page 383: ... ON the room lamps go off immediately When closing the door with IGN OFF the room lamps stays on for T1 and are dimmed out for T2 When turning the ignition switch to ON position during dimming out operation the room lamps go off immediately When receiving the door unlock signal with IGN OFF key OUT and door closed the room lamps come on for T3 When receiving the door unlock signal again in Step 4 ...

Page 384: ...o theft deterrent mode the lamp goes off The key hole illumination function has a priority over the immobilizer function If the immobilizer fails to get authorization the lamp comes on for 11 seconds with the interval of 0 5s ON 0 5s OFF regardless of the operating conditions of key hole lamp When turning the ignition switch to ON position in Vergin condition the lamp comes on for 8 seconds with t...

Page 385: ...ger switch during the operation the defogger stops working The defogger operates for T1 If turning ON the defogger again in T2 after completion of the first operation the defogger additionally operates for T3 But if the defogger has been turned off by engine stop or defogger switch this additional operation is not available The defogger stops working when turning the ignition switch to OFF positio...

Page 386: ...g the operation the defogger stops working The defogger operates for T1 If turning ON the defogger again in T2 after completion of the first operation the defogger additionally operates for T3 But if the defogger has been turned off by engine stop or defogger switch this additional operation is not available The defogger stops working when turning the ignition switch to OFF position 1 2 3 4 ...

Page 387: ...02 32 korando 2010 10 8710 01 BCM 10 Keyless Entry Transmitter REKES key The switches on the remote control key sends some vehicle control messages Function 1 Data format 2 ...

Page 388: ... 1 2 When ID code is registered successfully the horn sounds once and the turn signal lamps flash once Code output condition 4 The available function codes are LOCK UNLOCK PANIC Remote door lock When briefly pressing below 0 5s the LOCK switch on the transmitter the doors are locked BCM sends the door lock signal immediately after receiving the door lock message from the transmitter The REKES oper...

Page 389: ...lly unlocked The REKES operation is not available when the ignition key is in the key switch Also it is not possible to use the switches on the remote control key for 1 second after removing the ignition key from the ignition switch to avoid unintended operation 1 2 3 4 Remote Panic When pressing over 2 0s the PANIC switch on the transmitter the panic alarm is activated When receiving the panic me...

Page 390: ...e If a door or tailgate is not opened within 30 seconds after unlocking the doors with remote control key in theft deterrent mode all doors will be automatically locked again change to theft deterrent mode When entering into the theft deterrent mode the turn signal lamps blink twice and the horn sounds once 1 ...

Page 391: ...ger door lock knob switch to UNLOCK from LOCK position BCM sends the UNLOCK signal for T2 The LOCK UNLOCK operation by the door lock knob switch is not available when sending the LOCK UNLOCK signal by any other method such as remote control key When reconnecting the battery the door lock knob switch is not operational before turning the ignition switch to ON position All doors stay unlocked when r...

Page 392: ...le when the system is in theft deterrent mode When stopping the engine all doors are automatically unlocked When pressing the central door lock switch with any door open the system unlocks the doors immediately after locking them 1 2 3 4 Door lock unlock control by remote control switch When pressing the LOCK switch on the remote control key the door lock relay is turned ON for T2 When pressing th...

Page 393: ...s any failed door the auto door lock function is not available Even though the vehicle speed is increased over 30 km h again after decreased below 30 km h BCM does not send the auto door lock signal When receiving the unlock signal for another door during Step 2 BCM sends the lock signal for the door up to 5 times When stopping the engine all doors are unlocked When stopping the engine the fail re...

Page 394: ...crash from OFF BCM sends the door unlock signal for 5 seconds after T2 The unlock signal is sent for the remaining of the period even when turning OFF the ignition switch while receiving the unlock signal due to the crash The room lamps come ON when receiving the crash signal except when the front room lamp switch is in OFF position The turn signal lamps blink when receiving the crash signal This ...

Page 395: ...lock or panic signal during the panic operation the panic alarm stops The theft deterrent functions are as below 1 2 3 The theft deterrent alarm stops when receiving the panic alarm during its operation The panic alarm stops and then the theft deterrent alarm starts its operation when occurring the theft deterrent alarm conditions during panic alarm This function should not be activated when the i...

Page 396: ... driver door unlocked and vehicle speed below 3 0 1 km h the tailgate open relay is turned ON for T2 The tailgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h 1 2 Tailgate open REKES unlock disarmed deterrent mode Tailgate open signal Tailgate open ...

Page 397: ...ing them first When receiving the door lock signal with the tailgate or engine hood open the doors are closed if they are open but the theft deterrent mode is not activated However when closing the opened tailgate or engine hood the theft deterrent mode is activated with two blinks of turn signal lamps If a door or tailgate is not opened within 30 seconds after unlocking the doors with remote cont...

Page 398: ...completion of theft deterrent alarm for 30 seconds the horn and the turn signal lamps operate for 30 seconds with the interval of 0 5s ON 0 5s OFF Disarming conditions of theft deterrent mode 5 When pressing any switch lock unlock panic on the remote control key during the theft deterrent alarm the alarm stops its operation When turning the ignition switch to ON position during the theft deterrent...

Page 399: ...02 44 korando 2010 10 8710 01 BCM ...

Page 400: ...not changed for 6 seconds with all doors and tailgate closed key OUT IGN1 and IGN2 OFF the System Sleep Mode is activated If any of conditions in Step 1 is not satisfied the System Wake up mode is activated If there is not any change with all output conditions and ready conditions released the System Sleep Mode is activated When turning on the front room lamp switch the front room lamps come on fo...

Page 401: ...tep 1 the turn signal lamp blinks with the interval of 100 min and the internal horn sounds with same interval Defective conditions for Step 4 Open below 3 0 A Short over 7 0 A When turning ON the turn signal switch the lamp blinks 3 times When turning OFF the switch during the operation the turn signal lamp blinks 3 times and goes off When turning OFF and then immediately ON the turn signal switc...

Page 402: ...he operation This function is available if the battery is connected B If the turn signal lamp is defective during Step 1 the left turn signal lamp blinks with the interval of 100 min and the internal horn sounds with same interval The tolerance between left turn signal lamp and right turn signal lamp should be below 100 ms The hazard flasher has a priority over the turn signal lamp Priority of haz...

Page 403: ...sing the hazard flasher switch the hazard flasher indicator on the instrument cluster blinks with the interval of 75 min When pressing the hazard flasher again switch during Step 1 the indicator stops its operation This function is available if the battery is connected B 1 2 3 ...

Page 404: ...h the interval of 4 Hz When receiving the emergency hazard flasher OFF blink with the interval of 1 25 Hz normal operating speed However the manual operation of the switch has a priority over this function OFF conditions 2 3 The hazard flasher blinks with the interval of 4 Hz and then lower the interval to normal operating speed The hazard flasher is turned OFF when pressing the hazard flasher swi...

Page 405: ... not available in the vehicle with DRL system If there is no DRL activation signal the light system operates in normal conditions 1 2 3 4 5 19 Fog Lamp Control When pressing the rear fog lamp switch with IGN2 ON headlamp ON condition the rear fog lamps are turned ON When pressing the rear fog lamp switch again during the operation the rear fog lamps are turned OFF The rear fog lamps do not come ON...

Page 406: ... switch to ON position and controls the tail lamps and the headlamps with the light switch AUTO But the communication with the rain sensor is possible even when the tail lamp switch is in ON position 1 21 Immobilizer Function Due to the security reasons detailed information will be supplied by seperate technical information ...

Page 407: ...tery the mirror folding operation is performed This control must be available for 30 seconds time lag period after turning the ignition switch to OFF from ON position When receiving the folding unfolding signal during the mirror folding unfolding operation BCM stops current operation and operates the newly commended operation after 10 ms The folding unfolding operation is performed regardless of t...

Page 408: ...itch to ON position after unlocking the doors with the mirror folded the mirrors are unfolded automatically When the auto folding function is set the automatic unfolding is not available if the mirrors have been folded manually The factory setting is the enabling the auto folding function 3 4 5 23 Approach Puddle Lamp Control Lamp ON 1 When receiving the UNLOCK signal from the remote control key i...

Page 409: ...02 54 korando 2010 10 8710 01 BCM 24 Buzzer Control Priority are as below SBR Seat Belt Reminder ...

Page 410: ...sponder integrated 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 The immobilizer indicator on the instrument cluster comes on during the communication If there is something wrong in the sys...

Page 411: ... the ECU Engine Control Unit checks the crypto code of the key and if correct allows your vehicle to start the engine BCM REKES key Immobilizer antenna ECU CAN line In the following cases you may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When the key is close to any device sending or receiving electromagnetic fields or...

Page 412: ...e cannot be started When an old code should be replaced or another key is added car owner should observe the whole process In any case the immobilizer system cannot be removed from the vehicle If you attempt to remove and damage the system it is impossible to start the engine So never attempt to remove damage or modify it Any remote engine starter cannot be installed to the vehicle equipped with t...

Page 413: ...02 58 korando 2010 10 8710 01 BCM 5 Coding Procedure for REKES Key Connect the SCAN TOOL to the vehicle and select the vehicle model and the system Select BCM ...

Page 414: ...02 59 BCM korando 2010 10 8710 01 ...

Page 415: ...02 60 korando 2010 10 8710 01 BCM ...

Page 416: ...10 01 When one of remote control key is lost and a new remote control key is purchased bring the other old key to the Ssangyong Dealer or Ssangyong Authorized Service Center and have it recoded Otherwise the old key will not work ...

Page 417: ...02 78 korando 2010 10 0000 00 BCM 진단 가이드 데이터 삽입 ...

Page 418: ...scription Specification Rated voltage DC 13 5 V Operating voltage DC 9 V to 16 V CAN operating voltage DC 7 V to 18 V Inspection voltage DC 13 5 V Operating temperature 30 to 80 Storage temperature 40 to 90 Dark current below 1 mA 12 V 25 CAN wake up HIGH CAN Turn the ignition ON Smart key only ...

Page 419: ...03 4 korando 2010 10 8010 01 INSTRUMENT CLUSTER LCD Tachometer Speed meter 1 SYSTEM LAYOUT ...

Page 420: ...03 5 INSTRUMENT CLUSTER korando 2010 10 8010 01 2 WARNING LAMPS AND INDICATORS ...

Page 421: ...itch is turned to ON this indicator comes on and stays for a short time or may go off right away When the glow plugs are sufficiently heated the light will go out When the water level inside the water separator in the fuel filter exceeds a certain level this warning lamp comes on and a buzzer sounds This indicator comes on when the high beam headlamp is switched on This indicator comes on when the...

Page 422: ...bnormally hot the engine overheat warning lamp blinks and a warning buzzer sounds This lamp comes on when a door or the tailgate is either opened or not closed completely When the ignition switch is turned to the ON position and the driver s seat belt is not fastened the reminder lamp will come on and the seat belt warning chime will sound for 6 seconds When the ignition is switched on this warnin...

Page 423: ...g lamp comes on when the ignition switch is turned on and it goes off when the engine is started If this lamp doesn t go off after engine starting or comes on while driving it means there is a malfunction in the system This warning lamp comes on when the ignition switch is turned on and it goes off when the engine is started If this lamp comes on during driving check the engine oil level and leaks...

Page 424: ...enger air bag disable switch to ON position to disable the passenger air bag This indicator blinks when the immobilizer system is defective This warning lamp comes on when the EPS system is defective This warning lamp comes on when the parking brake is applied and or the brake fluid level is lower than a specified level This warning lamp comes on when the ignition switch is turned to ON and should...

Page 425: ... the cruise control system is switched on This indicator comes on when pressing the 4WD LOCK switch to use 4WD LOCK mode This indicator goes out when pressing the switch again to release 4WD LOCK mode This warning lamp comes on when the 4WD system is defective This indicator blinks when the hazard warning flashers are switched on This indicator comes on when the ECO cruise system is switched on ...

Page 426: ...er mode W switch near the gear selector lever is pressed Use this mode to drive off smoothly on an icy and slippery road When the ignition switch is turned to the ON position and the passenger s seat belt is not fastened the reminder lamp will come on and the seat belt warning chime will sound for 6 seconds This reminding operation stops when the passenger fastens the seat belt even during its ope...

Page 427: ...03 12 korando 2010 10 8010 01 INSTRUMENT CLUSTER 3 OPERATING PROCESS ...

Page 428: ......

Page 429: ...03 14 korando 2010 10 8010 01 INSTRUMENT CLUSTER 1 Block Diagram ...

Page 430: ...03 15 INSTRUMENT CLUSTER korando 2010 10 8010 01 ...

Page 431: ...t air temperature mode the LCD changes the mode to odometer mode Operating time of Trip switch Function below 1 second 60 to 980 ms Mode change ODO Trip A TRIP B DTE AFC IFC ILLUMINATION OUT TEMP over 1 second Reset function Trip A B AFC Change function Illumination 6 to 1 level Unit of ambient temperature over 3 seconds Ready Mode change Illumination Ambient temperature ODO ...

Page 432: ... the LCD backlight is illuminated right after the ignition is turned OFF or ON is ignored The LCD backlight and other lamps are illuminated 0 4 0 1 second after the ignition ON is detected The LCD display LCD backlight dial lamp and indicator lamp are turned on or off by the IGN switch ON OFF operation ...

Page 433: ...2 Brightness Power Supply Illumination Level Main LCD Pointer Day Night Day Night B B CAN Wake UP OFF OFF OFF OFF IGN1 Level 1 100 20 100 20 Level 2 100 30 100 30 Level 3 100 40 100 40 Level 4 100 50 100 50 Level 5 100 60 100 60 Level 6 100 70 100 70 ...

Page 434: ...03 19 INSTRUMENT CLUSTER korando 2010 10 8010 01 Symbol 4 System Analysis ...

Page 435: ...USTER The pre warning is performed for 4 seconds after turning the ignition switch to ON position BCM checks that the warning lamps ABS ESP ESP OFF 4WD CHECK 4WD LOCK are matched with CAN signals The pre warning is performed by the variant code ...

Page 436: ...999 9 miles is calculated and displayed by programmed pulse km in EEPROM Applicable maximum driving speed is 300 km h If the vehicle speed goes over the limit ODO and Trip meter stops the operation and the pointer indicates the maximum km h MPH The pulse count information is supplied from the speed module according to CAN data corresponding vehicle frequency ...

Page 437: ...ious trip distance is stored Data clear Reconnecting the battery initial B ON When pressing the Mode switch over 1 second Maximum Odo value Trip meter stops the operation and the pointer indicates the maximum km h MPH Function Signal Display Input data Speed signal Display type 6 digits Display range 0 to 999999 km mile Hold Resolution 1 km mile Maximum Odo value Odo meter stops the operation and ...

Page 438: ...Empty Mode The LCD display indicates how long drive the vehicle with current amount of fuel in fuel tank 6 Display Mode Function Signal Display Display type 3 digits Display range 50 km to 999 km 30 miles 999 miles Resolution 1 km miles Display interval every 1 second ...

Page 439: ... type 3 digits Display range 0 0 km to 99 9 km 0 miles to 99 9 miles Resolution 0 1 km miles Display interval every 10 seconds 3 Instant Fuel Consumption Mode The LCD display indicates the instant fuel consumption at every two seconds Function Signal Display Display type 3 digits Display range 0 0 to 99 9 MPG ℓ 100 km km ℓ Resolution 0 1 km miles Display interval every 2 seconds ...

Page 440: ... below 1 second change to next mode Pressing the switch over 1 second Enter into illumination level mode Level change by 1 step up and down ex Level 4 5 6 5 4 3 2 1 If the Trip Reset switch is not pressed in 3 seconds after getting into the illumination mode the LCD changes the mode to odometer mode Function Signal Display Display type 3 digits Display range Resolution 1 1 30 to 90 22 to 194 31 to...

Page 441: ... Except Middle East Buzzer Priority ON_Time OFF_Time PAS O O 0 Over speed warning O X 500 ms 200 ms 1 ESP O O 100 ms 100 ms 2 Temperature warning O O 500 ms 500 ms 3 Water separator O O 500 ms 500 ms 4 Parking brake O O 2 8 s 1 5 s 5 Modulating frequency 1 96 kHz If the signal with higher priority is activated during the operation of signal with lower priority the current operation should be compl...

Page 442: ...he gear shift lever to R position If the system is defective Fail due to open sensor or communication problem the information for the failed sensor is sent to the instrument cluster Fail condition However in case that there is not any obstacle in 30 cm 1 When the signal line is open 2 When the power supply line is open Buzzer interval during self diagnosis ...

Page 443: ...03 28 korando 2010 10 8010 01 INSTRUMENT CLUSTER Buzzer interval during reverse driving ...

Page 444: ... fog lamp 3 ETC When entering into the self diagnosis node the dimmer Micom output will be 100 Remaining segments are ON If CAN messages are OK the symbols are ON If not blinking The mode and illumination switch inputs are overridden 5 VARIANT CODING The instrument cluster enables all functions by receiving the vehicle s variant codes through CAN when turning the ignition switch to ON position The...

Page 445: ...korando 2010 10 8510 01 1 OVERVIEW Switch cluster Door panel switch Instrument panel switch Steering wheel switch Front console switch Headlining switch Trunk switch 1 2 3 4 5 6 1 Mounting Locations 8510 01 SWITCH ...

Page 446: ...rando 2010 10 8510 01 SWITCH Switch layout Steering wheel remote control switch Horn switch Lower panel switch Front console switch FATC switch Driver s power seat switch Trip Reset switch Multifunction switch ...

Page 447: ...10 8510 01 Rear seat warmer switch RH Luggage room lamp switch Cruise control switch Rear seat warmer switch LH Power window main switch Front seat warmer switch Power window sub switch Center room lamp switch Trunk open switch ...

Page 448: ...Power window main switch 1 Driver Door 2 SWITCH CLUSTER ON DOOR TRIM 1 Power window main switch Driver door window switch Rear LH window switch Window lock switch Passenger door window switch Rear RH window switch Door lock unlock switch ...

Page 449: ...itch is operated Rear RH window switch The window is up and down while this switch is operated Driver door window switch When opening the window When the front of the switch is lightly pressed the window will be lowered while the switch is pressed When pressed to its end the window will open automatically until it is fully open If you want to stop the window while automatic lowering lightly press ...

Page 450: ...the power window relay is turned ON The power window relay keeps ON for T1 even when stopping the engine However the power window relay is turned OFF when opening a front door When locking the door with the remote control key activation of theft deterrent mode the power window relay is immediately turned OFF 1 2 3 ...

Page 451: ...f them can control the corresponding door lock and unlock separately But the driver door lock switch can control all door locks Door lock unlock relay integrated in BCM Door lock unlock switch When the door lock unlock switch is pressed while all doors including the tailgate are locked all doors will be unlocked When the switch is pressed again all doors will be locked ...

Page 452: ...k knob switch to UNLOCK from LOCK position BCM sends the UNLOCK signal for T2 The LOCK UNLOCK operation by the door lock knob switch is not available when sending the LOCK UNLOCK signal by any other method such as remote control key When reconnecting the battery the door lock knob switch is not operational before turning the ignition switch to ON position All doors stay unlocked when receiving the...

Page 453: ...UNLOCK signal according to the previous condition of driver door lock switch for T1 The central door dock switch is not available when the system is in theft deterrent mode When stopping the engine all doors are automatically unlocked When pressing the central door lock switch with any door open the system unlocks the doors immediately after locking them 1 2 3 4 ...

Page 454: ...lection switch To fold the outside rearview mirrors press the switch To unfold the mirrors press again L Driver side mirror R Passenger side mirror Aiming switch Adjust the selected mirror up down left or right by pressing the corresponding edges of the switch to get a desired view Outside mirror switch ...

Page 455: ...uto folding function is released and the internal buzzer sounds twice ON 100 ms OFF 200 ms Auto folding sequence 2 When receiving the LOCK signal from the remote control key the system operates in the sequence of Door lock Theft deterrent mode activation Mirror folding When turning the ignition switch to ON position after unlocking the doors with the mirror folded the mirrors are unfolded automati...

Page 456: ...ing operation is performed This control must be available for 30 seconds time lag period after turning the ignition switch to OFF from ON position When receiving the folding unfolding signal during the mirror folding unfolding operation BCM stops current operation and operates the newly commended operation after 10 ms The folding unfolding operation is performed regardless of the vehicle speed Man...

Page 457: ...s set and the BCM inner buzzer is output twice ON 100 ms OFF 200 ms Auto folding unfolding operating sequence 2 For the vehicle without SKM REKES lock signal received Door lock Theft deterrent mode Mirror folding For the vehicle with SKM Smart key remote controller door lock signal or outside handle switch signal received Door lock Theft deterrent mode Mirror folding The auto unfolding after auto ...

Page 458: ...04 16 korando 2010 10 8510 01 SWITCH 2 Passenger Door Switch Passenger door switch The window is up and down while this switch is operated Power window main switch ...

Page 459: ... RH door switch 3 Rear Door Switch Seat warmer switch Power window switch The window is up and down while this switch is operated Press the switch to heat the seat and press again to stop the seat heating During heating the indicator light on the switch comes on ...

Page 460: ...korando 2010 10 8510 01 SWITCH FATC switch 1 FATC Switch Air circulation switch Temperature dial Mode dial Fan speed dial Air conditioner switch In car temperature sensor 3 SWITCH CLUSTER ON INSTRUMENT PANEL ...

Page 461: ...l Air circulation switch When pressing this switch recirculation indicator comes on and the system is changed into the recirculation mode When pressing the switch again recirculation indicator goes out and the system is changed into the fresh air mode Air conditioner switch When you press this switch the indicator comes on and the air conditioner starts to operate When you press the switch again t...

Page 462: ...witch Hazard flasher switch Trip Reset switch Digital clock Rear glass outside mirror heated wire switch Windshield heated wire The center fascia switch contains the hazard flasher switch windshield heated wire switch digital clock rear glass heated wire switch and trip switch ...

Page 463: ... completion of its first operation cycle The indicator in the switch comes on when in use Trip Reset switch Various vehicle information of the vehicle are displayed on LCD display when pressing this switch The LCD display shows each information according to the specified sequence when pressing the switch Rear glass outside mirror heated wire switch Press this switch to turn on the tailgate and out...

Page 464: ...erates for about 12 minutes Press the switch again to stop the operation This switch is designed to defrost or defog the tailgate glass and outside rearview mirrors The heated wire operates for about 6 minutes when the switch is pressed again within 10 minutes after completion of its first operation cycle This function is available only when the engine is running ...

Page 465: ... wire operates for about 12 minutes Press the switch again to stop the operation Use this to prevent the windshield wiper blades from being frozen The heated wire operates for about 6 minutes when the switch is pressed again within 10 minutes after completion of its first operation cycle This function is available only when the engine is running ...

Page 466: ... switch Description Default is DTE mode LCD display TRIP A TRIP B Mode switch Time Function Briefly press below 1 second 60 to 980 ms Mode change Odo Trip A Trip B DTE Average fuel consumption Instant fuel consumption Illumination level Ambient air temperature Press and hold over 1 second Reset Trip A B DTE Change Illumination level 6 to 1 Temperature unit Not press over 3 seconds Mode change Illu...

Page 467: ...04 25 SWITCH korando 2010 10 8510 01 Lower switch panel 3 Lower Switch Panel 4WD LOCK switch Rear fog lamp switch ESP OFF switch Headlamp leveling switch ...

Page 468: ...is turned on To turn it off push the switch again ESP OFF switch If you press the ESP OFF switch ESP function is deactivated and the ESP OFF indicator in the instrument cluster comes on To resume the ESP function press this switch again At this time ESP OFF indicator goes out Headlamp leveling switch The headlamp aiming can be adjusted by 4 steps 0 to 3 by using this switch Turning up the switch H...

Page 469: ...04 27 SWITCH korando 2010 10 8510 01 Power seat switch 1 Power seat switch Driver side 4 Power Seat Switch Assembly Sliding Seatback reclining Seat height adjustment ...

Page 470: ...04 28 korando 2010 10 8510 01 SWITCH Sliding Seatback reclining Seat height adjustment ...

Page 471: ...04 29 SWITCH korando 2010 10 8510 01 RH LH 1 Audio Remote Control Switch 4 STEERING WHEEL SWITCH MUTE MODE switch Volume switch SEEK switch Bluetooth switch Tip switch D Tip switch D ...

Page 472: ...ss and hold the switch again To eliminate the sound MUTE briefly press this switch To resume the sound press the switch again To change the audio mode AM FM1 FM2 press and hold this switch Volume switch Increases decreases volume Tip switch D To select the lower gear in M mode press this switch In CD player mode briefly press Next Previous track press and hold Moving in same track In radio mode br...

Page 473: ... switch Front fog lamp switch Front wiper switch Wiper speed dial Rear wiper switch Front auto washer switch The multifunction switch contains the auto washer and wiper switch and front fog lamp switch And in the vehicle with air bag the air bag spring clock is installed on the multifunction switch ...

Page 474: ...tensity of the sunlight analyzed by the automatic light sensor Lights OFF Headlamp high beam To turn on the headlamp high beam push the lever towards the instrument cluster with the headlamp low beam on Right turn signal switch Passing Regardless of the position of the light switch when holding the lever toward the steering wheel the headlights are on high beam during the hold Front fog lamp switc...

Page 475: ...old the lever for more than 0 6 seconds Three wiping cycles with washer spray Stop the operation Operates automatically according to the vehicle speed or amount of rain Continuous wipe fast operation Continuous wipe slow operation MIST OFF AUTO LO HI Auto washer switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operat...

Page 476: ...rate When the switch is released it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Page 477: ...rol system that maintains a desired driving speed without using the accelerator pedal The vehicle speed must be greater than 36 km h to engage the cruise control This feature is especially useful for motorway driving Cruise control ON Cruise control OFF Cruise control Acceleration Cruise control Deceleration Cruise control Reset ...

Page 478: ...04 36 korando 2010 10 8510 01 SWITCH 4 Horn Switch Horn switch Two horns are installed in the engine compartment When pressing the horn switch in steering wheel the horns dual horn sound ...

Page 479: ...ger seat warmer switch Rear LH seat warmer switch Rear RH seat warmer switch Press the HI High temperature or LO Low temperature on the seat heating switch to heat the seat and seatback When the temperature reaches 40 5 the thermistor integrated in seat connects and cuts the power to keep the temperature stable There is no seat warmer unit ...

Page 480: ...enter room lamp come on go out when opening closing a door in the switch pressed in door coupled operation mode When closing the door the lamps are dimmed out in 3 seconds The front room lamp turns on when pressing in this switch Front room lamp switch Door coupled operation switch Sunroof switch Front room lamp connector Sunroof connector ...

Page 481: ...pen When pushing up the sunroof switch briefly the sunroof is automatically opened by two third of its travel first step When pushing up and holding the sunroof switch again the sunroof is completely opened second step The sunroof is opened as long as pushing up the switch Pull down the switch briefly auto sliding close Pull down and hold the switch manual sliding close When pulling down the sunro...

Page 482: ...room lamps go off immediately When closing the door with IGN OFF the room lamps stays on for T1 and are dimmed out for T2 When turning the ignition switch to ON position during dimming out operation the room lamps go off immediately When receiving the door unlock signal with IGN OFF key OUT and door closed the room lamps come on for T3 When receiving the door unlock signal again in Step 4 the fron...

Page 483: ...he sunroof open the buzzer sounds for 10 seconds with the interval of 0 02s ON 1 58s OFF When opening and then closing the driver door or closing the sunroof during buzzer operation the buzzer stops its operation immediately The sunroof warning has a priority over the tail lamp left On warning 1 2 3 ...

Page 484: ...04 42 korando 2010 10 8510 01 SWITCH Tailgate open switch 7 TAILGATE OPEN SWITCH Tailgate open switch ...

Page 485: ... driver door unlocked and vehicle speed below 3 0 1 km h the tailgate open relay is turned ON for T2 The tailgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h 1 2 Tailgate open REKES unlock disarmed deterrent mode Tailgate open signal Tailgate open ...

Page 486: ...antages of LED It is not glaring and doesn t have short circuit unlike the conventional lamps It is semi permanent and doesn t generate heat Its power consumption is much lower than those of conventional bulbs LED 1 Exterior Lamps Description Type Amount Front lamp Headlamp high low beam BULB H4 2 Turn signal lamp BULB PY21W 2 Position lamp BULB W5W 2 Fog lamp BULB H27W 2 2 Rear lamp Stop tail lam...

Page 487: ...tivity of the human eye The unit of luminous intensity is the candela cd Luminous intensity Brightness is an attribute of visual perception in which a source appears to be radiating or reflecting light In other words brightness is the perception elicited by the luminance of a visual target This is a subjective attribute property of an object being observed The unit of brightness is the stilb sb or...

Page 488: ... lamp Back up lamp Turn signal lamp Rear fog lamp High mounted stop lamp Reflector Side lamp LH RH side repeater lamp Puddle lamp High mounted stop lamp Tail stop lamp Turn signal lamp Back up lamp Turn signal lamp Headlamp High low beam Front lamp Rear lamp 1 Overview License plate lamp Fog lamp Side repeater lamp Puddle lamp Position lamp Reflector Rear fog lamp ...

Page 489: ...bination lamp License plate lamp High mounted stop lamp Low beam high beam Turn signal lamp Position lamp 1 2 3 Tail stop lamp Turn signal lamp Back up lamp Rear fog lamp 1 2 3 4 Front fog lamp Puddle lamp Side repeater lamp without spoiler with spoiler ...

Page 490: ...rned ON When pressing the rear fog lamp switch again during the operation the rear fog lamps are turned OFF The rear fog lamps do not come ON when the engine is not running or the light switch is OFF The rear fog lamps should not automatically come on again if they have been turned OFF by any other way other than the switch 1 2 3 4 3 Operating Process ...

Page 491: ...The buzzer stops its operation when turning off the tail lamp or closing the driver s door during buzzer operation The buzzer stays ON when turning the tail lamp on again after turning it off during buzzer operation This function is not available when the ignition switch is in ON position 1 2 3 4 Tail lamp left ON warning however sunroof and ignition key reminder functions have the priority ...

Page 492: ...h with the tail lamp ON the tail lamps go off automatically In above conditions the tail lamps come ON again The tail lamp should not go off when turning ON the tail lamps with key IN The tail lamps should not go off when turning OFF and then ON the tail lamp with the power Off or ACC ON The system will be reset when inserting the ignition key into key switch 1 2 3 4 5 6 Tail lamp auto cut ...

Page 493: ... signal lamp blinks with the interval of 100 min and the internal horn sounds with same interval Defective conditions for Step 4 Open below 3 0 A Short over 7 0 A When turning ON the turn signal switch the lamp blinks 3 times When turning OFF the switch during the operation the turn signal lamp blinks 3 times and goes off When turning OFF and then immediately ON the turn signal switch during auto ...

Page 494: ...CM communicates with the rain sensor when turning the ignition switch to ON position and controls the tail lamps and the headlamps with the light switch AUTO But the communication with the rain sensor is possible even when the tail lamp switch is in ON position 1 ...

Page 495: ... for 30 seconds When turning the ignition switch to OFF from ON position and opening the driver s door the approach lamps come ON Lamp OFF 2 When receiving the door lock signal with the approach lamps ON the lamps go OFF reactivation of theft deterrent mode When turning the ignition switch to ON position with the approach lamps ON the lamps go OFF The approach lamps go OFF after 30 seconds ...

Page 496: ...01 Front lamp center room lamp luggage room lamp door courtesy lamp sun visor lamp glove box lamp Sun visor lamp Luggage room lamp Front room lamp Door courtesy lamp 2 Layout 2 INTERIOR LAMP Glove box lamp Center room lamp 1 Overview ...

Page 497: ...05 14 korando 2010 10 8310 01 LAMP Front room lamp Center room lamp Luggage room lamp Sun visor lamp Glove box lamp Door courtesy lamp ...

Page 498: ... closing the door with IGN OFF the room lamps stays on for T1 and are dimmed out for T2 When turning the ignition switch to ON position during dimming out operation the room lamps go off immediately When receiving the door unlock signal with IGN OFF key OUT and door closed the room lamps come on for T3 When receiving the door unlock signal again in Step 4 the front and center room lamps stays on f...

Page 499: ... lamp will be OFF To prevent the battery from being discharged when the front or center room lamp switch is not in Door position The room lamps will go OFF after 10 minutes from removing the ignition key When inserting the ignition key into the key switch the ground for room lamp will be ON 1 2 Room lamp auto cut control ...

Page 500: ...F position before any car wash to avoid unwanted operation of the wipers MIST Washer coupled wiper Auto washer coupled wiper Rain sensing wiper LIN Speed sensitive intermittent wiper Wiper LO HI control Check if the sensor is off the position Check if the rain sensor cover is securely installed Check if the customer is familiar to how to control the wiper sensitivity That is check if the customer ...

Page 501: ...fluid is sprayed onto the windshield glass for 2 seconds and the wipers operate 4 times After then additionally the washer fluid is sprayed for 1 5 seconds and the wipers operate 3 times again 2 Rear Washer Fluid Supply System The rear washer system uses the washer fluid from front washer fluid reservoir Rear wiper washer operating position Auto washer switch press ...

Page 502: ...ncoming into engine compartment thoroughly clean the glass surface before installing the washer nozzle The spraying shape of washer fluid is continuously changed as shown in the picture below according to the operating time The spraying direction is changed by swirl and counterflow in washer nozzle Washer inlet port Spraying passage Counterflow Passage Washer outlet port Swirl Washer nozzle ...

Page 503: ...ng unit Wiper AUTO switch and speed control switch The emitting section of the rain sensing unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode AUTO automatic wiping by rain sensor FAST SLOW The rain sensor controls the wiping speed by detecting the amount of rain drops Emitter lens Light receiving area of auto light...

Page 504: ...TEM undefined 7810 01 BCM The rain sensing unit sends only the rain drop data to BCM BCM controls the wiper operation BCM also sends the data for wiper and washer operation to the rain sensor BCM Fuse box for engine compartment ...

Page 505: ...01 WIPER AND WASHER SYSTEM 3 SYSTEM LAYOUT INCLUDING RAIN SENSOR Wiper washer switch Rain sensor unit Wiper Front wiper Rear wiper Rear washer hose and nozzle For vehicle with rear spoiler For vehicle without rear spoiler ...

Page 506: ...06 9 WIPER AND WASHER SYSTEM undefined 7810 01 BCM Washer reservoir assembly Front nozzle ...

Page 507: ...e OFF position when released Wiper and Washer coupled operation Pull the lever briefly for less than 0 6 seconds One wiping cycle with washer spray Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray Stop the operation Operates automatically according to the vehicle speed or amount of rain Continuous wipe fast operation Continuous wipe slow operation MIST OFF AU...

Page 508: ...PER AND WASHER SYSTEM undefined 7810 01 1 Wiper MIST When turning ON the front washer switch with IGN1 ON the front wipers operate after T1 When releasing the switch the wipers will stop at parking positions 1 ...

Page 509: ...uring wiper operation The wiper relay should stay ON during wiper operation in low high mode even though the system does not receive P POS signal In AUTO mode the wiper relay should be turned OFF after 5 seconds if there is no P POS signal for 3 seconds inform to car owner In high low mode the front washer motor should operate when turning ON the front washer switch In high low mode the rear washe...

Page 510: ...washer fluid is sprayed onto the windshield glass and the wipers operate three times 1 2 Front Washer Control 1 Washer coupled wiper Washer coupled wiper operation Pull the lever briefly for less than 0 6 seconds One wiping cycle with washer spray Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray ...

Page 511: ... the front washer switch at ON position for more than 0 6 seconds with the wiper switch AUTO the washer fluid is sprayed onto the windshield glass and the wipers operate three times When holding it between 0 1 and 0 59 seconds the wiper will operate only once 2 ...

Page 512: ... washer function is not available while the wiper system is in intermittent wiping mode When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent wiping mode will be started The front rear washer function are not available during the operation of auto washer 1 2 3 4 5 2 Auto washer coupled wiper Auto washer switch Wh...

Page 513: ...When the switch is released it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer 3 Rear Wiper Control ...

Page 514: ...h key IN IGN1 ON the washer fluid is sprayed onto the tailgate glass 1 Rear washer motor control When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Page 515: ...0 01 WIPER AND WASHER SYSTEM AUTO switch and speed control switch 5 Rain Sensor Coupled Wiper Control AUTO Automatic wiping by rain sensor FAST SLOW Operates automatically according to the vehicle speed or amount of rain ...

Page 516: ...06 19 WIPER AND WASHER SYSTEM undefined 7810 01 Block diagram 1 Rain sensor coupled wiper LIN ...

Page 517: ...ning the ignition switch to ON position When moving the wiper switch to AUTO from OFF position with IGN2 ON the wipers operate one cycle through wiper low relay regardless of the communication with the rain sensor Afterward the wipers operate only when receiving S_RAIN raining signal from the rain sensor 1 2 2 Power up reminder wiper ...

Page 518: ...N2 ON and wiper switch AUTO in rain sensing mode the wiper operate in washer coupled mode regardless of the communication with rain sensor Even though the wiping system is in washer coupled wiper mode the operating data are sent to rain sensor 1 2 3 Washer coupled wiper in rain sensing mode ...

Page 519: ...th volume dial with IGN2 ON wiper switch AUTO and wiper motor stop parking the wipers operate one cycle through the low relay only when the signal from rain sensor is raining If the volume sensitivity is changed within 2 seconds the wipers operate only one cycle 1 4 Sensitivity adjustment Instant wiping ...

Page 520: ...onds then continuously sends the wiper parking signal The wiper motor runs only when the rain sensor requires the wiper operation 2 The wiper system continuously sends the wiper parking signal when the wiper parking terminal is grounded with IGN2 ON and wiper switch AUTO The wiper motor runs only when the rain sensor requires the wiper operation 1 5 Fault strategy for wiper parking signal ...

Page 521: ...S_COMMFAULT communication error signal from rain sensor the wipers operate one cycle through the low relay 2 When changing the volume sensitivity to 2 from 3 with IGN2 ON and wiper switch AUTO while receiving S_RSFAULT defective rain sensor signal from rain sensor the wipers operate one cycle through the low relay 1 6 Fault strategy for rain sensor ...

Page 522: ... switch to AUTO from OFF position after turning the ignition switch to ON position the wipers operate one cycle Vehicle speed and volume sensitivity controls the intermittent wiping operation 1 2 3 7 Speed sensitive intermittent wiper The system calculates and changes the intermittent interval by using vehicle speed and volume sensitivity with IGN2 ON and wiper switch AUTO Intermittent interval at...

Page 523: ...06 26 undefined 7810 00 WIPER AND WASHER SYSTEM Motor assy FRT wiper Linkage assy windshield wiper Bolt Arm assy windshield WPR Nut Cap wiper arm Blade assy windshield wiper 1 2 3 4 5 6 7 ...

Page 524: ...ssy washer reservoir Screw Nut Guide assy washer reservoir Cap washer reservoir 1 2 3 4 5 6 10 11 Hose assy washer Hose assy windshield washer Nozzle assy windshield washer Hose assy T gate washer FRT Hose assy T gate washer Hose assy T gate washer Nozzle assy washer T gate Nozzle washer T gate 20 21 22 30 31 32 33 35 ...

Page 525: ...06 28 undefined 7830 00 WIPER AND WASHER SYSTEM Blade assy RR wiper Arm assy T gate wiper Motor assy RR wiper Spacer assy T gate wiper Splash ring T gate wiper Nut Cap wiper arm 1 2 3 5 6 7 9 ...

Page 526: ...er will return to the OFF position when released Stop the operation Operates automatically according to the vehicle speed or amount of rain Continuous wipe slow operation Continuous wipe fast operation Front automatic wiping speed control switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position Fast...

Page 527: ...y Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray While being held down the wiper and washer will keep working Front auto washer switch When the front wiper switch is off and this switch is pressed washer fl uid will be sprayed and the wiper will automatically operate 4 times Then the fl uid will be sprayed again and the wiper will automatically operate 3 ti...

Page 528: ...per switch function When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops OFF ...

Page 529: ...SYSTEM 4 Rear Wiper Switch When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Page 530: ...ER SYSTEM undefined 7810 03 Rear wiper motor Front wiper motor 1 Specification 2 Mounting Locations Description Specification Rated voltage 12 V Operating voltage 10 V to 15 V Minimum operating voltage Max 8 V Wiper motor ...

Page 531: ...undefined 7810 03 WIPER AND WASHER SYSTEM 3 Connector Front wiper Rear wiper Pin No Function 1 2 Wiper parking 3 B 4 Ground 5 Wiper LOW 6 Wiper HIGH Pin No Function 1 B 2 Wiper switch 3 Wiper parking 4 Ground ...

Page 532: ...06 35 WIPER AND WASHER SYSTEM undefined 7815 05 Front wiper 1 Mounting Locations Rear wiper ...

Page 533: ...ER AND WASHER SYSTEM 2 Wiper Blade Size 1 Front wiper blade Driver side 600 mm 24 in Passenger side 400 mm 16 in 2 Rear wiper blade Rear wiper blade 350 mm 14 in Driver side wiper blade Passenger side wiper blade Rear wiper blade ...

Page 534: ...06 37 WIPER AND WASHER SYSTEM undefined 7820 01 1 Mounting Locations Reservoir Washer motor ...

Page 535: ...ting section of the rain sensing unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode Then the unit operates the wipers at high or low speed according to this data for the driver s convenience Auto light and rain sensor Wiper switch AUTO operation ...

Page 536: ...Unit latch Housing and receiver lens Housing and PCB PCB assembly and emitter lens The receiver lens guides the reflected infrared rays from the windshield to the photodiode The LED which emits the infrared rays is located at bottom and the lens guides the infrared rays to target point Receiver lens Emitter lens ...

Page 537: ...or communications between BCM and the rain sensor the No 1 terminal sends the detected value from the rain sensor to BCM then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing w...

Page 538: ...FF the wiper operates one cycle It always operates one cycle for the initial operation however the wiper does not operate afterwards to prevent 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 2 terminal on the rain sensor If any defective cannot be found check the...

Page 539: ...peration by pressing the washer switch 5 Irregular operations abrupt operations Check the sensor for coming off Check the rain sensor cover s installation status Check that the customer is familiar to how to control the wiper sensitivity Check that the customer can select the sensitivity by selecting the variable resistance value stage 1 to stage 5 that is the wiper sensitivity control value And a...

Page 540: ...ng the engine while the wiper switch is in the AUTO position When starting the engine with the multifunction wiper switch in the AUTO position the wiper operates one cycle to remind a driver that the wiper switch is in the AUTO position When the wiper switch is turned to AUTO from OFF the wiper operates one cycle It always operates one cycle for the initial operation however the wiper does not ope...

Page 541: ...uously even on the dry glass Check the wiper blade for wear If the wiper blade cannot wipe the glass uniformly and clearly this problem could be occurred In this case replace the wiper blade with a new one Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Ther...

Page 542: ...06 45 WIPER AND WASHER SYSTEM undefined 7810 01 ...

Page 543: ...n water drops snow or mud Not defective but improperly working When driving on rough roads gravel roads hills or grass When the bumper height is changed due to a heavy load When receiving other ultrasonic signals metal sounds or air braking noises from heavy commercial vehicles When a high power radio is turned on When there is heavy rainfall or water drops When the sensor is hindered by improperl...

Page 544: ...ctivated and three sensors in the rear bumper detect the distance to any obstacle Driver can figure out the distance from the obstacle to the vehicle by the alarming sound The alarm interval becomes faster as the vehicle approaches the obstacle 1 OVERVIEW Buzzer for PAS Buzzer sounds according to the distance Gear select lever ...

Page 545: ...07 5 PAS PARKING AID SYSTEM korando 2010 10 8790 01 2 CONFIGURATION Location of sensors Parking aid unit PAS sensor ...

Page 546: ...S PARKING AID SYSTEM 3 OPERATING PROCESS 1 Block Diagram When PAS receives R signal it starts to detect the obstacles behind vehicle after self diagnosis If the system detects the obstacle the buzzer sounds according to the distance ...

Page 547: ...ndo 2010 10 8790 01 1st area two beeps with long interval 2nd area three beeps with short interval 3rd area one long beep Sensing distance Area in 20 cm from bumper Objects may not be detected in this range Alarm interval 2 PAS Sensor ...

Page 548: ...07 8 korando 2010 10 8790 01 PAS PARKING AID SYSTEM Circuit diagram of ECU Internal circuit diagram of sensors ...

Page 549: ...01 Sensor operating sequence The ultrasonic sensors on the rear bumper transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it The left sensor transmits the signal first then the center sensor and then the right sensor ...

Page 550: ...it in signal line 2 Open circuit in power line Fail conditions Alarm interval for self diagnosis When placing the gear select lever to R position the self diagnosis is performed once If it detects the Fail condition due to sensor defect or communication error the buzzer sounds as shown in the picture If the system is OK the buzzer sounds for 65 ms ...

Page 551: ...rom sensors Description Specification Rated voltage DC 12 0 V Operating voltage DC 9 0 V to 16 0 V Operating temperature 30 80 Storage temperature 40 to 85 Maximum permissible current below 100 mA 2 Connector Pin No Function Pin No Function 1 8 2 9 LH signal 3 10 Center signal 4 11 Temp signal 5 RH signal 12 6 Ground sensor 13 Ground 7 14 Power ...

Page 552: ...tion Specification Rated voltage DC 12 0 V Operating voltage DC 8 0 V Operating temperature 30 to 80 Storage temperature 40 to 85 Maximum permissible current below 20 mA Maximum humidity 95 Operating frequency 40 KHz 2 KHz Pin No Function center sensor 1 Power 8 V 2 Ground 3 Communication signal 4 Temperature signal Pin No Function LH RH sensor 1 Power 8 V 2 Ground 3 Communication signal 4 ...

Page 553: ...07 13 PAS PARKING AID SYSTEM korando 2010 10 8790 01 ...

Page 554: ...STEM GENERAL INFORMATION 8910 05 RDS RADIO DATA SYSTEM AUDIO OVERVIEW AND OPERATING PROCESS 1 LOCATION OF CONTROLS 2 DISPLAY WINDOW 3 CONNECTORS AUDIO REAR VIEW 8530 10 STEERING WHEEL AUDIO SWITCH 8910 10 USB PORT AND AUX JACK 8930 11 POLE ANTENNA 3 6 7 8 9 12 14 ...

Page 555: ...08 2 korando 2010 10 8910 05 AUDIO SYSTEM ...

Page 556: ...en tuned to an FM station which provides the RDS service the RDS indicator lights up the station frequency and then the station name if sent is displayed Not all FM stations provide RDS service nor do all RDS stations provide same services If in doubt check with local radio stations for details on RDS services in your area This machine can use the following RDS service PS Programme Service name PT...

Page 557: ...08 4 korando 2010 10 8910 05 AUDIO SYSTEM Audio unit AUX jack USB port Steering wheel audio switch ...

Page 558: ...08 5 AUDIO SYSTEM korando 2010 10 8910 05 FRT RH Speaker FRT RH Tweeter speaker RR RH Speaker FRT RH Tweeter speaker RR RH Speaker RR RH Speaker Pole ANT ...

Page 559: ...ume or sound setup items rotate turn on the power or mute press and turn off the power press and hold 1 2 3 4 5 6 7 8 Number 1 to 6 buttons 9 During radio reception To receive stored stations press to store station press and hold During CD playback 2 RPT Repeat playback 3 INT Intro playback 4 RDM Random playback 5 D Folder down 6 D Folder up BAND AST button To select the radio function or band pre...

Page 560: ... on Stereo indicator Band indicator Multi function display area 3 4 5 CD MP3 WMA function Disc indicator Media indicator CDP lights up when an audio CD is loaded MP3 lights up when a MP3 file is loaded WMA lights up when a WMA file is loaded Current folder directory number Current file track number USB indicator 6 7 8 9 10 Folder select mode indicator Playback mode indicators RPT Repeat INT Intro ...

Page 561: ...onnector 18 pin 1 2 3 4 Input Output connector 18 Pin Front right channel speaker Rear right channel speaker Illumination ACC Back up B BT MIC Rear left channel speaker Front left channel speaker Front right channel speaker 1 2 3 4 5 6 7 8 9 Rear right channel speaker Illumination Antenna power Remote control ground Ground BT MIC Remote control front signal Rear left channel speaker Front left cha...

Page 562: ...n listening to a station Press to go to the next previous preset station Press and hold to search the next previous radio station The radio seeks stations only with a strong signal that are in the selected band When playing a CD or USB Press to go to the next previous track Press and hold to fast forward backward through the tracks PHONE During the standby Press to make a call via voice activated ...

Page 563: ...Function OHM Output voltage 1 VOL 0 Ω 5 0 to 0 3 V 2 VOL 3 3 kΩ 5 0 4 to 1 0 V 3 MODE 6 kΩ 5 1 1 to 1 4 V 4 MUTE 9 9 kΩ 5 1 5 to 1 8 V 5 SEEK UP 16 7 kΩ 5 1 9 to 2 25 V 6 SEEK DOWN 31 3 kΩ 5 2 26 to 2 65 V 7 TIP 670 kΩ 5 8 TIP 1 08 kΩ 5 9 B T 64 7 kΩ 5 2 66 to 3 0 V ...

Page 564: ...Pin No Function 1 Illumination 2 Illumination 3 ECU signal 4 ECU ground 5 Audio H U Signal IN 6 Audio H U Ground 7 Audio Signal OUT 8 NC Pin No Function 1 Illumination 2 Illumination 3 ECU signal 4 ECU ground 5 Audio Signal OUT 6 Audio H U Ground 7 NC 8 NC ...

Page 565: ...B memory stick or an external audio device through with the speakers in your vehicle For detailed information refer to the audio operation manual provided with this manual Some USB memory sticks and external audio devices may not work in this audio system Circuit diagram Steering wheel audio switch Audio system AUX jack USB port ...

Page 566: ...08 13 AUDIO SYSTEM korando 2010 10 8910 10 Connector ...

Page 567: ...14 korando 2010 10 8930 11 AUDIO SYSTEM Antenna Specification Circuit diagram Band Local Frequency Gain dB AM GEN 531 KHz 1 0 2 1000 KHz 1 0 2 1602 KHz 1 0 2 FM GEN 88 MHz 7 0 2 98 MHz 7 0 2 108 MHz 7 0 2 ...

Page 568: ...RING GEAR BOX LAYOUT 4 FRONT SUSPENSION COMPONENT LAYOUT 5 REAR SUSPENSION COMPONENT LAYOUT 6 BRAKE SYSTEM AND ESP SYSTEM LAYOUT 7 STEERING SYSTEM LAYOUT DURING SERVICE WORK 1 GUIDELINES FOR SERVICE WORK SAFETY 2 JACK UP POINTS 3 STANDARD BOLTS SPECIFICATIONS SPECIAL TOOLS AND EQUIPMENT 1 NEW SPECIAL TOOLS 2 NORMAL EQUIPMENTS 2 4 6 8 10 12 14 16 20 21 22 23 ...

Page 569: ...the ESP Electronic Stability Program system And it receives signals of the steering wheel angle sensor from the ESP HECU Hydraulic Electronic Control Unit Motor HU Hydraulic Unit ECU Electronic Control Unit Motor HU Hydraulic Unit ECU Electronic Control Unit Motor angle 8P Motor power 3P Torque angle sensor 8P Battery 2P Connector to vehicle 8P HECU Hydraulic Electronic Control Unit HECU for ABS H...

Page 570: ...ol unit which determines the magnetic force by considering CAN signals wheel speed engine torque pedal opening ABS ESP CAN signals etc from other ECUs TCU unit The transmission control unit TCU is installed under the driver seat and controls the transmission The TCU is operated by the ignition power supply and receives and processes the following information from the inner sensors through CAN buse...

Page 571: ...direction by 90 in the front wheel drive type 4WD vehicle Rear axle assembly The rear axle installed in this car is a removable axle called IRDA Independent Rear Differential Axle The rear differential carrier is installed directly on the sub frame and there is an independent suspension that allows each wheel on the same axle to move vertically independently of each other with the universal joint ...

Page 572: ...fied from the one that used in other vehicle so that it can be applied to FF Front engine Front wheel driving type vehicle and has an axle in one piece The engine torque and gear ratio of this transmission have been optimized to maximize driving performance It provides 6 speeds for forward travel and 1 reverse travel The 2WD vehicle with manual transmission is a front wheel drive type vehicle that...

Page 573: ...hydraulic pressure pipe of the HPS type steering gear box 3 SUB FRAME AND STEERING GEAR BOX LAYOUT Front sub frame with EPS type steering gear box assembly This kind of front sub frame system has the same mounting structure with the frame with HPS But the EPS type steering gear box has no hydraulic pressure pipe since it is driven by the electric motor Rear side Front side HPS type steering gear b...

Page 574: ...powertrain and road and also control the torque Rear side Front side Body mounting Rear sub frame assembly for 2WD The rear sub frame for 2WD vehicle functions in the same way as the one for 4WD vehicle but the structure is different from the one for 4WD It consists of 4 body bush mountings Body mounting Body mounting Body mounting Axle mounting Front side Body mounting Body mounting Rear side Bod...

Page 575: ...The lower arm is installed on sub frame and large strut damper is installed on the knuckle to support the tire Stabilizer bar assembly The stabilizer bar assembly is not activated if the left right wheels move up down simultaneously but if both wheels move up down differently it is activated with frame to minimize the tilting of the body Lower arm assembly The lower arm assembly connects the frame...

Page 576: ... to form the coil shape Its energy absorption rate per weight is higher than that of the leaf spring and it allows to absorb small vibration properly resulted in keeping the ride comforts Therefore it s difficult to make an effect on vibration damping because there is not any friction between coils Coil spring Shock absorber assembly ...

Page 577: ...rack rod Shock absorber assembly This vehicle uses the gas shock absorber This relieves the vertical vibrations of vehicle to provide ride comforts prevents the spring break enhances drivability and extends the life span of steering components Upper arm assembly Upper arm is installed between knuckle and sub frame and controls the lateral load and vehicle height Trailing arm assembly Trailing arm ...

Page 578: ...y it is activated with frame to minimize the tilting of the body Coil spring Coil spring is installed between the coil spring link and body frame It relieves the vibrations and impacts from wheels to vehicle body Lower arm assembly The lower arm is installed between knuckle and rear sub frame and relieves the load to coil spring from wheel In other word it controls the longitudinal load Stabilizer...

Page 579: ...luster B Master cylinder assembly Description for master cylinder in this chapter is based on ABS ESP equipped vehicle For CBS there is an extra pressure valve mounted to the master cylinder C HECU assembly The HECU assemblies for ABS and ESP have similar appearance but they have different inner structure and connector connections from each other ESP indicator ABS warning lamp Parking brake warnin...

Page 580: ...e When pulling up the lever the parking brake cable between the lever and the rear drum brake trailing shoe pulls the parking brake lining to contact to drum Caliper G Brake pedal H Parking brake 4WD and 2WD Front side 2WD Rear side The wheel speed sensor for 4WD has the same structure and mounting location with the one for 2WD vehicle But the rear side wheel speed sensor for 2WD vehicle has diffe...

Page 581: ...d a ignition switch assembly on the column shaft The lower shaft minimizes the torque change using a CV joint which has constant angular speed The steering gear box assembly consists of power cylinder and control valve The power cylinder has a cylinder piston and piston rod The control valve directs the oil to one end face of the piston to enhance the steering force There is a safety check valve w...

Page 582: ...ng force It functions independently regardless of whether the engine is running or not unlike the existing hydraulic power steering The lower shafts functions in the same way as the hydraulic type When the driver turns the steering wheel a torque is generated and the torque sensor and the steering angle sensor in the EPS system detect the rotation of the steering column to run the electric motor A...

Page 583: ...detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works However above references and cautions cannot be inclusive measures so should have habits of taking concerns and cautions based on common senses 2 Equipment Korando C is FF Front Engine Front Drive type vehicle ...

Page 584: ...g nut Replace them with new If reused normal functions cannot be maintained Align the disassembled parts in clean according to disassembling order and group for easy assembling According to installing positions the bolts and nuts have different hardness and design So be careful not to mix removed bolts and nuts each other and align them according installing positions To inspect and assemble clean ...

Page 585: ...iately Inspect the complete system including the catalytic converter if equipped Inspect the body near the exhaust system Look for broken damaged missing or out of position parts as well as open seams holes loose connections or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment 4 Tires Be alert to any vibration o...

Page 586: ...el in the coolant reservoir and coolant condition contamination foreign material coolant hose damage or leakage Replace or add Ssangyong genuine coolant if needed 8 Engine drive belt Check all drive belts of the engine for wear crack looseness tension Retighten or replace the belt if needed ...

Page 587: ... POINTS Stand jack up points and installation status front side Jack up points for 2 post lift Mounting status Stand jack up points and installation status rear side Mounting status Stand jack up points and installation status front side Jack up points for 2 post lift ...

Page 588: ...andard tightening torque during 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 ...

Page 589: ...Part number T99300010A Name Centering pin for installing clutch Use Used when installing clutch disc and pressure plate to engine Part number T99410010A Name Rear knuckle bushing adapter Use Used when removing and installing rear knuckle bushing Part number T99420010A Name Differential gear oil seal installer Use Used when installing differential side gear side inner oil seal with a dedicated tool...

Page 590: ...n lowering engine and transmission mounted to sub frame at the same time replacing manual transmission Name Engine stand 1 tone or more Use Used to fix the removed engine or engine and transmission transaxle and can support at least 1 tone Name Engine crane 1 tone or more Use Used to move engine module including transaxle to working space or engine stand and can support at least 1 tonne 1 Engine A...

Page 591: ...ansmission after disassembling It consists of 14 components Name 1 Differential carrier taper roller bearing installer Use Used when installing taper roller bearing of differential carrier Name 2 Differential carrier taper roller bearing installer Use Used when installing taper roller bearing of differential carrier 2 Tool Only For Manual Transmission ...

Page 592: ...ting rod 13 when installing clutch housing oil seal Name 5 Differential carrier front bearing outer race installer Use Used as a connecting rod 13 when installing differential carrier front bearing outer race of clutch housing outer diameter 89 mm Name 6 Primary output shaft bearing race installer Use Used as a connecting rod 13 when installing bearing outer race of primary output shaft outer diam...

Page 593: ... and hubs to output shafts Name 8 Output shaft bearing installer Use Used as a bearing support installer 7 when installing taper roller bearing to output shafts Name 9 Bearing outer race installer Use Used as a connecting rod 13 when installing differential carrier bearing outer race of transmission housing outer diameter 75 5 mm Name 10 Control shaft oil seal installer Use Used when installing co...

Page 594: ...g input shaft and secondary output shaft bearing Outer diameter 70 5 mm Name 12 Bearing outer race installer Use Used as a connecting rod 13 when installing clutch housing input shaft bearing outer race Outer diameter 64 5 mm Name 14 Synchro hub installer Use Used as a bearing support installer 7 when installing gear and hub to output shafts Secondary output shaft Input shaft Connecting rod ...

Page 595: ......

Page 596: ...ly controlled brake bands Three multi plate clutches One multi plate brake All hydraulic functions are directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications 1 2 3 4 Inhibitor switch Oil pan Torque converter TCU located under driver s seat TCU is located under the driver s seat and controls the transaxle operations TCU...

Page 597: ...ift up Shift down Tip switches on steering wheel Meter cluster This indicator shows the current position of the gear Gear selector lever Lever positions P Park R reverse N Neutral D Drive Mode switch W Winter mode pressed OUT S Standard mode pressed IN Toggle the mode between winter mode and standard mode by pressing this switch Tip switch manual shift switch The shiftable gear can be adjusted by ...

Page 598: ...1 144 5th gear 0 859 6th gear 0 676 Reverse gear 3 178 Oil Type Fuchs TITAN ATF 3292 Capacity approx 7 5 L Change interval EU Change every 20000 km or 12 months But shorten the service interval under severe condition General Change every 15000 km or 12 months But shorten the service interval under severe condition Resistance of oil temperature sensor 20 430 7 to 533 9 kΩ 0 146 8 to 175 7 kΩ 20 56 ...

Page 599: ...ned 3680 01 DSI 6 SPEED AUTO TRANSAXLE 2 Sectional Diagram Double planetary gear set Clutch pack Valve body Single planetary gear set Oil pump Torque converter Input shaft Intermediate shaft Differential assembly ...

Page 600: ...4 0 Valve body screw T30 mm X 25 16 0 Torque converter Mounting bolt 13 mm X 6 40 0 to 42 0 Cable Link nut switch side 13 mm X 1 13 7 to 19 6 Link nut cable side 12 mm X 1 14 7 to 22 5 Mounting nut floor side 12 mm X 1 17 6 to 21 6 Mounting nut dash panel side 12 mm X 2 17 6 to 21 6 TGS lever Mounting nut 12 mm X 4 17 6 to 21 6 TCU Mounting nut 8 mm X 2 5 0 to 6 0 Inhibitor switch Mounting nut 12 ...

Page 601: ...netary set This type of gear set arrangement is commonly known as Lepelletier type gear set The Model M11 6 speed automatic transaxle is electronically controlled The control system is comprised of the following components External transaxle control unit TCU Internal embedded memory module EMM Input and output speed sensors Valve body unit comprised of four ON OFF solenoid valves and six variable ...

Page 602: ...gagements from either Park or Neutral are performed in less than 2 2 seconds There is no drive engagement prevention strategy implemented on the transaxle system as there is sufficient engine strategy to protect the system However reverse engagement is prevented until engine speed is less than 1 400 rpm and the accelerator pedal position is less than 12 and vehicle speed is less than 10 km h Conve...

Page 603: ...cooler 3 Shift Strategy Gear Change Transaxle gear change is controlled 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 Coast down Coast down down shifts occur at 0 pedal when the vehicle is coasting down to a stop Torque Demand Torque demand down shifts ...

Page 604: ...by pressing this switch 2 Selection of Manual Automatic Shift Function D Automatic shift according to the driving condition M Manual shift 3 Mode switch 4 Lever positions P Park R reverse N Neutral D Drive 5 Tip switch manual shift switch The shiftable gear can be adjusted by moving this switch to forward and rearward when the gear selector lever is in M position 2 M Mode Manual Mode This allows t...

Page 605: ...lay on the instrument cluster 3 2 and 3 1 automatic kick down shifts are available 3rd gear has engine braking available 4th Gear State The 4th gear state will display on the instrument cluster 4 3 and 4 2 automatic kick down shifts are available 4th gear has engine braking available 5th Gear State The 5th gear state will display on the instrument cluster 5 4 and 5 3 automatic kick down shift is a...

Page 606: ...ments of OBD II legislation monitoring all components which may effect vehicle emissions 1 2 3 4 When the transaxle overheats Limp home mode may also be engaged if the battery charge falls below 8V If the transaxle overheats the shift patterns will automatically change to enable improved transaxle cooling During transaxle overheat the instrument cluster transaxle selector position display and the ...

Page 607: ...complish this the TCU operates six variable bleed control solenoids and four on off solenoids to control transaxle operation 2 TCU Transmission Control Unit The transaxle control unit TCU is mounted under the driver s seat and controls the operation of the transaxle The TCU is activated and deactivated by the ignition power supply and is connected to the transaxle link harness by a 26 pin connecto...

Page 608: ...ect transaxle fluid flow to control the fluid pressure within the three clutches and two bands Separate pressure regulators are used exclusively for torque converter clutch control and main transaxle line pressure The TCU monitors all TCU inputs and outputs to confirm correct system operation If a fault occurs the TCU is able to perform default action and inform the driver of the problem through t...

Page 609: ...e When winter mode is selected starting in second gear is facilitated and the WINTER mode indicator light is switched ON To prevent wheel spin on slippery surfaces the transmission will not allow first gear unless manually overridden Warm up Schedule Used typically when transaxle fluid temperature is below 20 C The torque converter will not lock up below 20 C to assist in transaxle warm up Hot Mod...

Page 610: ...The TCU sends signals to be used by other vehicle systems via the CAN bus such as Selector lever position Selected gear state Manual mode activation Output torque Transaxle fluid temperature Engine torque reduction requests Schematic Diagram of Network Communication ...

Page 611: ...gagement Element Gear Gear ratio Engagement element clutch band C1 C2 C3 B1 B2 1 2 OWC M1 4 156 ON ON 1st 4 156 ON ON 2nd 2 375 ON ON 3rd 1 522 ON ON 4th 1 144 ON ON 5th 0 859 ON ON 6th 0 676 ON ON Reverse 3 178 ON ON Gear ON OFF solenoid valve Variable bleed solenoid valve VBS 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...

Page 612: ...gear Front sun gear FSG Planetary hear pinion PP Ring gear Internal 1 2 3 Rear planetary gear Forward sun gear FSG Reverse sun gear RSG Short pinion SPP Long oinion LPP Ring gear RG 4 5 6 7 8 Intermediate gear Drive gear Driven gear 9 10 Differential gear Pinion Differential 11 12 ...

Page 613: ...02 20 undefined 3680 01 DSI 6 SPEED AUTO TRANSAXLE 3 Hydraulic Circuit Diagram ...

Page 614: ...02 21 DSI 6 SPEED AUTO TRANSAXLE undefined 3680 01 ...

Page 615: ...02 22 undefined 3680 01 DSI 6 SPEED AUTO TRANSAXLE 4 Power Transfer in Each Gear 1 Manual position M 4 156 1 Power flow 2 Drive 1st Gear 1st Auto 4 156 1 Power flow ...

Page 616: ...02 23 DSI 6 SPEED AUTO TRANSAXLE undefined 3680 01 3 Drive 2nd 2nd Auto 2 375 1 Power flow 4 Drive 3rd 3rd Auto 1 522 1 Power flow ...

Page 617: ...02 24 undefined 3680 01 DSI 6 SPEED AUTO TRANSAXLE 5 Drive 4th 4th Auto 1 144 1 Power flow 6 Drive 5th 5th Auto 0 859 1 Power flow ...

Page 618: ...02 25 DSI 6 SPEED AUTO TRANSAXLE undefined 3680 01 7 Drive 6th 6th Auto 0 676 1 Power flow 8 Reverse 3 178 1 Power flow ...

Page 619: ...02 26 undefined 3680 01 DSI 6 SPEED AUTO TRANSAXLE 9 Neutral Park Power flow ...

Page 620: ... transmission fluid 62 kgf 2WD 63 kgf 4WD Gear ratio 1st 3 538 2nd 1 909 3rd 1 179 4th 0 814 5th 0 734 6th 0 628 Reverse 3 910 Synchronizer ring type 1st T Triple cone 2nd T Triple cone 3rd T Triple cone 4th D Double cone 5th D Double cone 6th S Single cone Reverse T Triple cone Shifting Type Remote Cable type Gear selector lever position Reversing Reverse ring pull type ...

Page 621: ...I GL 4 Capacity 1 6 L Replacement interval EU Inspect and replenish every 60000 km or 3 years Normal driving condition Fill for Life Severe driving condition Change every 120000 km GEN Inspect and replenish every 60000 km or 4 years Normal driving condition Fill for Life Severe driving condition Change every 120000 km ...

Page 622: ...unting bolt 19 6 to 26 5 Nm 22 EA 4 Concentric slave cylinder mounting bolt 11 8 to 14 7 Nm 3 EA 5 Backup lamp switch 29 4 to 34 3 Nm 6 Neutral switch 29 4 to 34 3 Nm 7 Oil filler plug 58 8 to 78 4 Nm 8 Oil drain plug 58 8 to 78 4 Nm 9 Oil plug 58 8 to 78 4 Nm 10 Shift lever mounting nut 42 2 to 53 9 Nm 11 Selector lever mounting nut 42 2 to 53 9 Nm 12 Control shaft assembly mounting bolt 9 8 to 1...

Page 623: ...Rear view 1 OVERVIEW This vehicle is equipped with WM6F1 M T Manual Transmission This transmission is integrated with an axle and designed to maximize the driving performance by optimizing the gear ratio according to the engine torque WM6F1 M T assembly ...

Page 624: ...pull type clutch is used for Reverse gear shifting Features triple double single synchronization Clutch housing Transmission case Input shaft Concentric slave cylinder Shift lever Selector lever Wiring bracket Neutral switch Backup lamp switch Reverse idle shaft mounting bolt 1 2 3 4 5 6 7 8 9 10 Control guide bolt Oil filler plug for servicing Oil drain plug Oil filler plug for manufacturing Air ...

Page 625: ...03 8 korando 2010 10 3190 01 6 SPEED M T 2 Internal Configuration ...

Page 626: ...nal gear Total gear ratio Number of teeth Gear ratio Number of teeth Gear ratio Input Output Input Output 1st 13 46 3 538 13 59 4 538 16 059 2nd 22 42 1 909 8 664 3rd 28 33 1 179 5 349 4th 43 35 0 814 3 694 5th 38 28 0 737 15 59 3 933 2 898 6th 43 27 0 628 2 47 Reverse 13 17 3 91 15 377 24 36 ...

Page 627: ...03 10 korando 2010 10 3190 01 6 SPEED M T 2 POWER FLOWS 1st speed gear 2nd speed gear 3rd speed gear Sectional view of WM6F1 M T ...

Page 628: ...03 11 6 SPEED M T korando 2010 10 3190 01 Reverse gear 4th speed gear 5th speed gear 6th speed gear ...

Page 629: ...t Shift lever Selector lever 5th 6th speed gear shift lug Reverse gear shift fork 5th 6th speed gear shift fork 5th 6th speed gear Reverse shift rail 1st 2nd speed gear shift fork 3rd 4th speed gear shift fork 1st 2nd 3rd 4th speed gear shift rail 3rd 4th speed gear shift lug ...

Page 630: ... 3 mm Pedal free play Transverse 3 mm Clutch disc Type Dry type single diaphragm Rigid type Diameter of facing Outer 250 1 mm Inner 160 0 8 mm Thickness of disc Free 8 7 0 3 mm When loaded 8 0 0 2 at 7 800 N Numbers of disc 2 Weight 1 18 kg Flywheel type DMF Dual Mass Flywheel Setting load of clutch cover assembly At least 7 800 N Clutch master cylinder Operating travel 30 mm Inner diameter 17 46 ...

Page 631: ... bolt Hexagon 6 mm 21 0 to 27 0 Nm 6 Concentric slave cylinder bolt Hexagon 5 mm 10 to 16 Nm 3 Concentric slave cylinder oil pipe nut 24 5 to 28 4 Nm Master cylinder nut 12 mm 7 8 to 17 6 Nm Master cylinder oil pipe nut 10 mm 14 7 to 17 6 Nm Master cylinder push rod lock nut 8 8 to 13 7 Nm Clutch oil chamber screw and bolt 10 mm 3 9 to 7 8 Nm Oil pipe nut 10 mm 14 7 to 17 6 Nm Clutch pedal mountin...

Page 632: ...tch damper Clutch 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 flywhe...

Page 633: ...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 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 Diaphragm spring...

Page 634: ...entric slave cylinder pipe mounted inside of transmission Driving elements The driving elements consist of two flat surfaces machined to a smooth finish One of these is the rear face of the engine flywheel and the other is the clutch pressure plate The clutch pressure plate is fitted into a clutch steel cover which is bolted to the flywheel Driven elements The driven element is the clutch disc wit...

Page 635: ...04 8 korando 2010 10 0000 00 CLUTCH 3 Layout Clutch disc Clutch cover assembly Concentric slave cylinder Dual mass flywheel DMF ...

Page 636: ...of the transmission 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 Prima...

Page 637: ...verall size Ø62 5 mm Dimension Length x Dia No 1 shaft TM to spider 1 069 x Ø60 mm No 2 shaft spider to axle 847 5 x Ø60 mm Runout of tube after installation 0 3 mm Unbalance 80g mm 3 000rpm second measurement 120 g mm U joint Starting torque 0 3 to 0 7 Nm Minimum starting angle 18 Amount of grease in CV joint 210 10g 2 TIGHTENING TORQUE Fastener Tightening torque Bolt nut for rubber coupling rear...

Page 638: ... the slip joint on the E coupling side to accommodate the height and length changes which occur as the shaft rotates at high speed And the rubber bushing for center bearing in the center of the propeller shaft keeps the balance of the shaft and absorbs its vibration Function of propeller shaft Transmits driving torque Accommodates the angle change universal joint CV joint Accommodates the axial le...

Page 639: ...l bearing 5 Circlip 22 Dust shield 6 Clamp big 23 Intermediate shaft 7 Boot 24 Fork yoke 8 Clamp small 25 Rubber coupling 9 Stub shaft 26 Alignment support 10 Bending absorber 27 Bolt 11 Paper damper 28 Washer 12 Tube yoke 29 Lock nut 13 Oil seal 30 Balance weight 14 Spider 31 Protecter 15 Bearing cap 32 Tube 16 Intermediate yoke 33 Tube 17 Bolt 34 Bending absorber ...

Page 640: ...e Inside Cross groove joint Outside Ball joint Max allowed angle Inside 23 Outside 23 Rear differential carrier Type Independent Rear Drive Axle IRDA Reduction gear type Hypoid gear Gear reduction ratio 2 93 Diameter of gear Ø152 mm Oil type Hypoid gear oil SAE 75W 90 Final drive gear backlash 0 10 to 0 15 mm Differential gear backlash 0 to 0 076 mm Propeller shaft Joint type PTU side CV joint Rea...

Page 641: ... COMPONENT For AWD vehicle For 2WD vehicle Front drive shaft LH Front drive shaft RH Intermediate shaft Power transfer unit Propeller shaft 4WD 1 2 3 4 5 E coupling Rear differential carrier Rear drive shaft LH 4WD Rear drive shaft RH 4WD 6 7 8 9 ...

Page 642: ... Especially for a FWD vehicle this mechanical condition can cause the steering effect because of the output torque rotational force produced by the gyroscope This rotational force is due to the difference in distance between the left right front wheels and the transaxle which leads to the change of the shaft bending angle To prevent this the intermediate shaft called Intermediate shaft is employed...

Page 643: ...ovable axle called IRDA Independent Rear Differential Axle The rear differential carrier is installed directly on the sub frame and there is an independent suspension that allows each wheel on the same axle to move vertically and independently of each other with the universal joint and the slip joint ...

Page 644: ...poid gear 23 38 Weight 21 5 kg with oil Oil LW 80W 90 Oil capacity 0 6 L 600 ml Operating temperature 40 to 150 C E coupling Maximum torque 1 000 Nm Operating temperature 40 to 120 C Numbers of main clutch Outer 11 Inner 11 Numbers of pilot clutch Outer 4 Inner 3 Coil windings 240 turns Weight 8 kg Oil ECF107 ATF based EMCD special oil Oil capacity 0 145 L 145 ml ...

Page 645: ...K mode when pressing 4WD LOCK switch This mode provides the highest traction Use this mode when driving on unpaved rugged steep sandy wet or slippery roads In 4WD LOCK mode if the rear wheel speed exceeds 40 km h 4WD LOCK mode is canceled and 4WD AUTO mode is activated Indicator OFF If the speed is decreased below 35 km h 4WD LOCK mode is resumed Indicator ON again Mode table 4WD LOCK switch Vehic...

Page 646: ...ing Electronic Coupling E Coupling transfer the engine torque from PTU to rear axle and controls to distribute it between front wheels and rear wheels 3 E Coupling Control Unit ECU E Coupling controls the current clutch engagement force of EMCD in E Coupling according to CAN signals wheel speed engine torque pedal position ABS ESP signals EMCD Electro Magnetic Control Device PTU assembly E couplin...

Page 647: ...hanges the angle of engine torque to 90 by combination between helical gear and hypoid gear and transfer it to E coupling to distribute the torque to rear wheels 1 Component Input shaft Helical gear Dust seal Helical gear 1 2 3 4 Hypoid gear Hypoid gear Output shaft Companion flange 5 6 7 8 ...

Page 648: ... Flow and Gear Combination PTU Gear ratio 2 929 22 39 helical gear x 23 38 hypoid gear 0 341 PTU gear ratio 1 0 341 2 929 3 Engagement of Input Shaft PTU is engaged with the ring gear on transaxle and always runs to rotate the propeller shaft ...

Page 649: ...07 8 korando 2010 10 3280 01 AWD 1 Component Coupling assy Electric Coupling Electric BRG assy Race Cover 1 2 3 4 Seal Dust Flange assy Companion Nut Drive pinion Wiring assy Harness 5 6 7 8 ...

Page 650: ...peller shaft 9 10 11 12 13 14 15 16 The housing is engaged with propeller shaft through companion flange and rubber coupling and turns with propeller shaft The outer main clutch and the outer pilot clutch are connected to housing and the inner main clutch is connected to hub The inner pilot clutch is connected to hub through cap ball and pressure plate E Coupling is filled with oil The hub is conn...

Page 651: ...ue from PTU is transferred to housing through propeller shaft rubber coupling and companion flange But if the current is not supplied to the magnet the pilot clutch is not engaged and the cam thrust cannot be generates Thus the main clutch is not engaged and the torque cannot be transferred to the companion flange ...

Page 652: ...f current The magnetic induction moves the armature and engage the pilot clutch If there is a speed difference between front axle and rear axle This also makes the speed difference between cam and pressure plate This difference rotates and slides the ball on the ramp According to this the cam is separated from the pressure plate Therefore the pressure plate with cam thrust pushes the main clutch t...

Page 653: ...to CAN signals wheel speed engine torque pedal position ABS ESP signals 1 Operating mode 4WD AUTO LOCK mode Smart controlling according to steering angle and wheel speed In 4WD LOCK mode if the rear wheel speed exceeds 40 km h 4WD LOCK mode is canceled and 4WD AUTO mode is activated Indicator OFF If the speed is decreased below 35 km h 4WD LOCK mode is resumed Indicator ON again ...

Page 654: ...07 13 AWD korando 2010 10 3280 17 2 Circuit Diagram ...

Page 655: ...07 14 korando 2010 10 3280 17 AWD 3 Block Diagram of Input Output ...

Page 656: ...pling overheat protection function When E Coupling is overheated E Coupling control unit reduces the torque to rear wheels In this mode E Coupling operates as if it is in 2WD mode The oil temperature sensor for E Coupling is not applicable E Coupling control unit recognizes the overheat condition by temperature characteristics of clutch and coil current E Coupling control unit monitors the system ...

Page 657: ...100 0 mm Outer diameter B 163 1 mm Free length C 356 1 mm Installed length D 276 0 mm Coil windings 5 32 turns Winding direction Right direction Rear suspension Driving type AWD 2WD Suspension type trailing upper lower track rod Multi link type Spring type Coil spring Stabilizer type Torsion bar type Shock absorber Type Cylindrical reciprocation type Max length extended 551 mm Min length compresse...

Page 658: ...eel center Wheel house 433 mm Camber maintenance free 0 15 0 5 Caster maintenance free 4 8 0 5 Total toe in 0 0 0 1 adjust by tie rod King pin angle 12 85 Rear Ground clearance A 63 3 5 mm Trim height wheel center Wheel house 437 mm Camber maintenance free 0 5 0 5 adjust by cam bolt on upper arm Total toe in 0 0 0 1 adjust by cam bolt on track rod ...

Page 659: ...08 5 SUSPENSION SYSTEM korando 2010 10 0000 00 2 TIGHTENING TORQUE Front suspension assembly ...

Page 660: ...08 6 korando 2010 10 0000 00 SUSPENSION SYSTEM Rear suspension assembly ...

Page 661: ...connect the axle and vehicle It absorbs the vibrations and impacts from road surface which enhances the comforts driving force braking force and drivability Underview of vehicle with 2WD 6M T Underview of vehicle with 4WD 6A T Front suspension Rear suspension Front suspension Rear suspension ...

Page 662: ...me and large strut damper is installed on the knuckle to support the tire This type of suspension is normally applied to the vehicle with monocoque body especially on the front wheel drive type The upper part with spring is mounted at body mount and the strut with shock absorber is linked on the steering knuckle Advantages Compact and simple design Stable wheel alignment Good load distribution and...

Page 663: ...sion is the independent suspension It provides good ride comfort 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 trailing arm upper arm lower arm and track rod Layout ...

Page 664: ...08 10 korando 2010 10 0000 00 SUSPENSION SYSTEM 1 SYSTEM LAYOUT 1 Front Suspension Damper strut assembly Lower arm Stabilizer bar link Stabilizer bar assembly ...

Page 665: ...SYSTEM korando 2010 10 0000 00 2 Rear Suspension Shock absorber Stabilizer bar assembly Coil spring and link Trailing upper arm track rod Stabilizer bar link Coil spring Coil spring link Trailing arm Track rod Upper arm ...

Page 666: ... Its energy absorption rate per weight is higher than that of the leaf spring and it allows to absorb small vibration properly resulted in keeping the ride comforts Therefore it s difficult to make an effect on vibration damping because there is not any friction between coils The lower arm relieves the load to knuckle This enables to absorb the various impacts according to the load shapes and to e...

Page 667: ...vides better drivability even though the structure is complicated This vehicle uses the gas shock absorber This vehicle uses the strut type shock absorber This shock absorber is connected to the piston rod in the strut This relieves the vertical vibrations of vehicle to provide ride comforts prevents the spring break enhances drivability and extends the life span of steering components Coil spring...

Page 668: ...al load Coil spring Coil spring is installed between the coil spring link and body frame It relieves the vibrations and impacts from wheels to vehicle body Symmetry design Lower arm is installed between knuckle and rear sub frame and relieves the load to coil spring from wheel In other word it controls the longitudinal load Frame side Knuckle side Frame side Knuckle side Coil spring Lower arm Trac...

Page 669: ...s a certain type of torsion bar Its both ends are connected to the control arm and the its center area is mounted to the body frame It is not activated when both wheels are moving up or down simultaneously However it minimizes the vehicle s slope when each wheel moves up or down independently Trailing arm Trailing arm is installed between knuckle and vehicle body and controls the front and rear lo...

Page 670: ...tronic Stability Program ABD Automatic Braking Differential ASR Acceleration Slip Regulation AYC Active Yaw Control Understeer and Oversteer Control HBA Hydraulic Brake Assistant ARP Active Rollover Protection HSA Hill Start Assistant 2 Functions Function Vehicle with CBS Vehicle with ABS EBD Vehicle with ESP ABS Not applied Applied Applied EBD Applied ABD Not applied ASR AYC HBA ARP HSA ...

Page 671: ...ESP HECU Not applied Applied Applied Front wheel speed sensor Rear wheel speed sensor ABS warning lamp EBD indicator Longitudinal G sensor 2WD N A 4WD Applied Not applied Sensor cluster Yaw rate sensor lateral longitudinal G sensor Not applied Applied ESP indicator ESP OFF switch and warning lamp Steering wheel angle sensor ...

Page 672: ...nt rear 4WD Rear 2WD H Parking brake A Meter cluster ABS EBD ESP indicator warning lamp B Master cylinder and booster C HECU G Brake pedal 4 Component ABS warning lamp ESP indicator D Front brake assembly E Rear brake assembly Disc Disc Parking brake warning lamp Caliper Caliper ...

Page 673: ...f disc 2WD Ø262 mm 4WD Ø284 mm Thickness of disc 10 mm wear limit 8 4 mm Thickness of brake pad 10 mm wear limit 2 mm Pad wear indicator Mechanical type Brake booster Type Vacuum assist type Size 8 9 Tandem Master cylinder Type Tandem level sensor installed Inner diameter of cylinder Ø25 4 mm Brake pedal Maximum operating stroke 140 3 mm Pedal ratio 3 8 1 Free play 3 to 10 mm Parking brake Type Me...

Page 674: ...chanical type master 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 thr...

Page 675: ...850 00 BRAKE SYSTEM 2 SECTIONAL DIAGRAM Front disc brake Pad guide bolt 25 5 to 30 4 Nm Hose bracket bolt 9 8 to 12 8 Nm Air bleeder screw 8 8 to 10 8 Nm Caliper mounting bolt 83 3 to 102 9 Nm Brake hose bolt 19 6 to 29 4 Nm ...

Page 676: ...09 9 BRAKE SYSTEM korando 2010 10 4850 00 Rear disc brake Caliper Brake hose Brake disc ...

Page 677: ... 2010 10 4850 00 BRAKE SYSTEM 3 SYSTEM LAYOUT Hydraulic line Brake booster Brake 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 678: ...09 11 BRAKE SYSTEM korando 2010 10 4850 00 4 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 679: ...tch Orifice Orifice Wheel speed sensor ABS ESP CBS Operating temperature 40 C to 150 C 40 C to 150 C 40 C to 115 C 40 C to 115 C Operating frequency 1 to 2 500 Hz 1 to 8 000 Hz Operating voltage 4 5 to 20 V 3 3 to 18 V G sensor ABS CBS ESP Operating voltage 4 75 to 5 25 V N A Operating temperature 30 C to 85 C Operating range 1 5 to 1 5 g Output voltage 0 5 to 4 5 V ...

Page 680: ...10 4 korando 2010 10 4890 00 ANTI LOCK BRAKE SYSTEM ABS ESP CBS Circuit diagram of wheel speed sensor ...

Page 681: ...not guarantee perfect safety 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 coupl...

Page 682: ...heel speed sensor for 2WD Located on knuckle The appearance is different from that for 4WD 4 Wheel speed sensor for 4WD Located on knuckle The appearance of front sensor is same with rear sensor 2 ABS warning lamp 1 ABS hydraulic device and control unit Located under the power steering fluid reservoir and contains the pressure sensor 2 COMPONENT ...

Page 683: ...rcuit for ABS operation This unit controls the hydraulic pressure to each wheel If the system needs ABS operation the valves in the unit operate to control HOLD RISE and DUMP according to ECU control logic Motor 3 The motor is operated when ABS is activated The cam shaped output shaft of the motor enables the brake system to receive and supply the brake fluid during the motor operation Wheel speed...

Page 684: ...the vehicle speed reduction and actual wheel speed reduction in the event of braking since the driving wheels are in the front So the ABS HECU can control the vehicle based on a calculation value But on the 4WD vehicle if a speed reduction occurs in the front or rear of the vehicle it affects the other side wheel In other words braking the rear wheels induces also a large speed reduction in the fr...

Page 685: ...n condition while sensing 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 686: ... 3 seconds for self diagnosis and goes off if the system 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 com...

Page 687: ...3 seconds for 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 1 2 3 4 5 When the solenoid va...

Page 688: ...10 12 korando 2010 10 4890 00 ANTI LOCK BRAKE SYSTEM 5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Page 689: ...an only be clearly drawn at the start of braking 2 Brake force on a wheel The maximum possible brake force on a wheel depends on the wheel load and the adhesion coefficient between tire and carriageway With a low adhesion coefficient the brake force which can be obtained is very low You are bound to know the result already from driving on winter roads With a high adhesion coefficient on a dry road...

Page 690: ...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 as the wheel does not ...

Page 691: ...g force remain within the 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 z...

Page 692: ...ed The reference speed 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 d...

Page 693: ...l is performed by comparing the reference speed with 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 ...

Page 694: ...trol of the brake force distribution between the front and 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 ut...

Page 695: ...10 19 ANTI LOCK BRAKE SYSTEM korando 2010 10 4890 00 Matrix of EBD ...

Page 696: ...hydraulic pressure in the 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 ...

Page 697: ...locking the wheels 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 noises Solenoid valve Va...

Page 698: ...cking the hydraulic valve 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 699: ...r to the wheel As the 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 ...

Page 700: ...10 24 korando 2010 10 4890 00 ANTI LOCK BRAKE SYSTEM 7 CIRCUIT DIAGRAM ...

Page 701: ...8 Nm Operating temperature 40 150 Operating frequency 1 2 500 Hz Unit Description ABS ESP HECU Clock frequency 25 MHz Clock frequency 40 MHz Memory 128 KB Memory 512 KB Switch orifice Switch orifice Wheel speed sensor Active type Active type Steering wheel angle sensor None Max detection angle speed 1500 Sec Operating voltage 9 to 12 V Sensor cluster None Yaw rate sensor lateral G sensor longitudi...

Page 702: ...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 3 Specification of Sensor Cluster 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 sen...

Page 703: ...angle sensor under the 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...

Page 704: ...he left side of instrument panel 2 COMPONENTS 2 Steering wheel angle sensor Located on column shaft with contact coil 4 Sensor cluster Located on the floor under front passenger seat 5 Wheel speed sensor 4WD 2WD front Located on knuckle the appearance of front sensor is same with rear sensor 6 Rear wheel speed sensor 2WD Located on knuckle The appearance is different from that for 4WD ...

Page 705: ...ting with the brakes applied 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 Conseq...

Page 706: ...nd goes off if the system 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 lam...

Page 707: ...efective When the voltage 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 swit...

Page 708: ...11 10 korando 2010 10 0000 00 ELECTRONIC STABILITY PROGRAM 5 SYSTEM DESCRIPTION 1 Block Diagram of ESP HECU ...

Page 709: ...e braking force to the 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...

Page 710: ... condition in which the steering 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 direct...

Page 711: ...ions such as when the brake 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 712: ...builds high braking force during 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 ea...

Page 713: ...ts function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns Lateral sensor In sensor cluster Vehicle speed Brake force Radius The vehicle driving condition is controlled by the internally programmed logic ...

Page 714: ...NIC STABILITY PROGRAM 6 HSA Hill Start Assist The HSA Hill Start Assist prevents the vehicle from rolling backward by supplying the hydraulic pressure to the wheels by the HECU after the brake pedal is released when starting off on uphill ...

Page 715: ...11 17 ELECTRONIC STABILITY PROGRAM korando 2010 10 0000 00 6 HYDRAULIC CIRCUIT OF ESP ...

Page 716: ... the vehicle and it cannot 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...

Page 717: ...ndition In this position the 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 718: ...l speed drops and the wheels are locked The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump operates to allow fast oil drainage The shuttle valve and the separation valve do not operate while decompression ...

Page 719: ...alve and outlet valve will 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 720: ...ng Mode The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Page 721: ...braking depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the w...

Page 722: ...11 24 korando 2010 10 0000 00 ELECTRONIC STABILITY PROGRAM 7 CIRCUIT DIAGRAM Wheel speed sensor Stop lamp switch Self diagnostic connector Warning lamp ABS ESP ...

Page 723: ...e 73 mm Steering angle Inner 39 Outer 31 24 Wheel alignment Toe in 2 2 mm Oil pump Type Vane removable pump and reservoir Maximum pressure 100 3 bar Displacement 6 0 to 9 75 ℓ min Pulley diameter Φ 115 mm Steering column Tilting angle Up 2 0 Down 30 Lower shaft Type Ball slip Steering oil Oil type ATF Dexron Ⅱ or Ⅲ Oil reservoir capacity 0 3 ℓ Change interval Check and add at every 24 000 km of dr...

Page 724: ...12 4 korando 2010 10 4610 00 POWER STEERING SYSTEM 2 TIGHTENING TORQUE ...

Page 725: ... 17 mm 4 Oil pipe bracket mounting nut 6 8 to 10 8 Nm 10 mm 5 Tie rod end lock nut 44 1 to 53 9 Nm 17 mm 6 Tie rod nut 63 7 to 78 4 Nm 22 mm 7 Lower shaft Lower mounting bolt gear box side 17 6 to 24 5 Nm 12 mm Upper mounting bolt column side 17 6 to 24 5 Nm 12 mm 8 Column shaft Lower mounting bolt 19 6 to 24 5 Nm 12 mm Upper mounting nut 19 6 to 24 5 Nm 12 mm 9 Steering wheel nut 39 2 to 58 8 Nm ...

Page 726: ...ering system The pressure 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 Ev...

Page 727: ...eservoir and hose Installation of power steering pump and pipe 2 SYSTEM LAYOUT The steering pump is driven by the engine power through a belt This pump circulates the power steering oil from the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Return pipe Supply pipe ...

Page 728: ...fication Remark Tire 16 inch 215 65R 16 Standard 17 inch 225 60R 17 Optional 18 inch 225 55R 18 Optional Tire inflation pressure 32psi Wheel 16 inch 6 5 J X 16 Standard 17 inch 6 5 J X 17 Optional 18 inch 6 5 J X 18 Optional Balance weight Inner Clip on type Outer Adhesive type Tightening torquse of wheel bolt 127 4 156 8 Nm 17mm X 5 Length 56 5 mm ...

Page 729: ... worn unevenly according to the driver s driving habit improper servicing low tire inflation pressure changed tire location etc 1 Structure of Tire Tread This thick layer of rubber provides the interface between the tire and the road Wear resistant rubber is used to protect the carcass and belt against fractures and impacts and to deliver a long driving life Shoulder Located between the tread and ...

Page 730: ...nd tire faces the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly resulting in increased life The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire is excessive so a lot of heat is generated and the t...

Page 731: ...e the tire 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 ...

Page 732: ... not contact with 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 2 Hydro Planing ...

Page 733: ...re 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 2 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 f...

Page 734: ...g voltage Network 8 to 16 V C EPS ECU 8 to 16 V Full Performance 10 to 16 V Motor Type 3 Phase BLAC Brushless AC Rated current voltage 85 A 12 V at idle 0 5 A Position sensor type Hall sensor type Torque angle sensor Type Non contact type Steering column Operating type Manual tilting telescoping Lower shaft Type Sliding Ball slip type Steering gear Gear ratio 46 94 mm rev Rack stroke 146 mm Maximu...

Page 735: ...14 4 korando 2010 10 4610 00 ELECTRIC POWER STEERING 2 TIGHTENING TORQUE ...

Page 736: ...ions by controlling the motor s operation based on the input signals from the sensors such as torque sensor and angle sensor In turn the EPS receives the torque signal by the driver s movements of the steering wheel as well as the vehicle speed and uses the motor to determine the assist torque The EPS controls the motor for this Another features of EPS are fail safe function diagnosis function com...

Page 737: ... sensor in the EPS system detect the rotation of the steering column to run the electric motor At this time the worm gear connected to the motor drives the helical gear mounted to the steering column to generate the assist torque for the steering column This allows the driver to operate the steering wheel easier Output torque 1 Steering force manual torque 2 Assist torque ...

Page 738: ...e 4WD Rear sub frame 2WD Body mounting 4 points bush Transaxle mounting 2 points bush Weight 22 37 kg 1 2 3 Body mounting 4 points bush Axle mounting 4 points bush Weight 16 61 kg 1 2 3 Body mounting 40 points direct mounting Spring link Direct mounting without bracket on rear cross member Weight 12 74 kg 1 2 3 ...

Page 739: ...ont mounting LH RH 1 Transaxle mounting Front 2 TIGHTENING TORQUE Bolt 17 mm Nut 17 mm 68 6 to 88 2 Nm Bolt 17 mm 88 2 to 107 8 Nm Bolt 17 mm 88 2 to 107 8 Nm 2 Bracket mounting bolts 17 mm 88 2 to 107 8 Nm Bolt 14 mm Nut 14 mm 68 6 to 88 2 Nm 3 Bolts 14 mm 29 4 to 49 0 Nm Front sub frame based on 4WD ...

Page 740: ...unting 5 Front mounting LH RH Bolt 17 mm 88 2 to 107 8 Nm 6 Rear mounting LH RH Bolt 17 mm 88 2 to 107 8 Nm Rear mounting bolt 14 mm 68 6 to 88 2 Nm Upper arm bolt 17 mm Nut 19 mm 98 0 to 117 6 Nm Lower arm nut Bolt 19 mm 98 0 to 117 6 Nm Rear sub frame based on 4WD Rear mounting bolt 17 mm 107 8 to 127 4 Nm ...

Page 741: ...gram and Bolts for Front Sub Frame Mounting nut 29 4 to 39 2 Nm Bolt 9 4 to 39 2 Nm Installation Sectional diagram 1 Front 2 Rear Mounting bracket Mounting bolt 3 Transaxle mounting Front For manual transaxle For automatic transaxle diesel 4 Transaxle mounting Rear ...

Page 742: ...5 7 SUB FRAME ASSEMBLY korando 2010 10 4012 00 2 Sectional Diagram and Bolts for Rear Sub Frame Installation Sectional structure 1 Front 4WD 2WD 2 Rear 4WD 2WD 3 Rear axle Front 4WD 4 Rear axle rear 4WD ...

Page 743: ...ion mounting The engine side and transmission side mountings are rubber mountings with brackets and insulators while the body mounting is a rubber bush mounting which is fitted to the frame Installation of front sub frame 4WD The installation of the front sub frame is the same for both automatic transmission and manual transmission For 4WD the PTU and the propeller shaft are installed Installation...

Page 744: ...nstallation of rear sub frame 2WD The installation of the rear sub frame is the same for both automatic transmission and manual transmission The rear sub frame system consists of body bush mountings and direct mountings which reduce the vibration transmitted from the powertrain and road to the vehicle body For 4WD it consists of 4 body mountings bush mountings and 2 axle mountings bush mountings a...

Page 745: ...Evaporator Core size 254 8 x 196 75 x 60 Capacity kcal h 4 700 Blower Supplied power W 240 10 Max at 12V Fan speed rpm 2900 200 Max Rec Mode 420 h PTC Supplied power 1 kW Condenser Core size 588 x 455 x 16 2 625 Capacity kcal h 12 000 Capacity of receiver drier 250 cc Compressor Capacity 170 cc rev Diameter of pulley Ø120 Max speed 8 000 rpm Voltage DC 12 V Current consumption 2 2A ...

Page 746: ...01 4 korando 2010 10 6810 20 AIR CONDITIONING SYSTEM 1 SYSTEM LAYOUT Line port A C compressor Electric fan A C condenser receiver dryer Integrated receiver dryer High pressure hose Low pressure hose ...

Page 747: ...01 5 AIR CONDITIONING SYSTEM korando 2010 10 6810 20 FATC In car sensor Refrigerant pressure sensor Ambient air temperature sensor Sun load sensor Engine ECU ...

Page 748: ...rculation indicator comes on and the system is changed into the recirculation mode When you press the switch again recirculation indicator goes out and the system is changed into the fresh air mode 1 Full Automatic Air Conditioner 2 HEATER AND A C CONTROL To adjust the temperature turn this dial as required LO Low temperature HI High temperature Temperature dial Temperature dial ...

Page 749: ... the windshield and side glasses the air conditioner operates automatically and fresh air comes in Select the desired airflow mode by turning this dial Airflow is changed automatically according to the setting temperature Fan speed dial Manual control Fan speed is manually controlled by this dial The increment is 1 Auto control Fan speed is automatically controlled by temperature setting A C switc...

Page 750: ...trol Fan speed dial To adjust the fan speed turn this dial as required OFF Fan does not operate Fan speed level consists of 7 steps A C switch When you press this switch the indicator comes on and the air conditioner starts to operate When you press the switch again the air conditioner stops operation and the indicator goes out Fan speed dial ...

Page 751: ...ly and fresh air comes in Defrost mode Temperature dial Mode dial Recirculation switch When you press this switch recirculation indicator comes on and the system is changed into the recirculation mode When you press the switch again recirculation indicator goes out and the system is changed into the fresh air mode Foot Defrost Level Foot defrost mode Temperature dial To adjust the temperature turn...

Page 752: ...ir by absorbing the heat from the air around the evaporator Condition Liquid Liquefied gas Function Performs adiabatic expansion and flow control for easier evaporation Condition Gas Liquid Function Cools and condenses the refrigerant by using ambient air to liquefied it in high pressure Condition Gas Function Circulates the refrigerant and increases the pressure and temperature for easier evapora...

Page 753: ... 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 valve detects this and regulate the amount ...

Page 754: ...01 12 korando 2010 10 6810 20 AIR CONDITIONING SYSTEM 4 A C COOLING CIRCUIT ...

Page 755: ...01 13 AIR CONDITIONING SYSTEM korando 2010 10 6810 20 5 A C CIRCUIT DIAGRAM ...

Page 756: ... Blower motor assy Resistor Expansion valve assy Wiring assy Heater evaporator Heater evaporator assy Actuator assy Temp 1 2 3 4 5 6 7 9 10 11 Actuator assy Mode Core assy Heater Core Evaporator Heater assy PTC Control assy Heater A CON Screw Insert assy ventilation Sensor Incar Sensor Intake 12 13 14 15 20 21 22 23 24 ...

Page 757: ... Discharge suction Nut Oil ring Suction Oil ring Discharge Oil ring Hose assy Heater inlet Hose assy Heater outlet Clamp 1 2 3 4 5 6 7 9 10 11 Pipe assy Liquid suction Nut Oil ring Suction Oil ring Liquid Oil ring Suction Oil ring Hose Drain Brkt assy A con comp Bolt Bolt 12 13 14 15 16 17 18 22 23 24 ...

Page 758: ...01 16 korando 2010 10 6830 01 AIR CONDITIONING SYSTEM Duct Foot Duct Foot Duct assy RR heating No1 Duct assy RR heating No1 Duct assy Rr heating No2 Nut 1 2 3 4 5 6 ...

Page 759: ...actuator through micom in the FATC Therefore the temperature of the vehicle interior is kept to the temperature which is set by a driver The driver can check the status of A C through the dial indicator of FATC The fan speed and the temperature are adjusted automatically by the input values from different sensors to keep indoor air fresh If the FATC system has any defect the micom performs self di...

Page 760: ...trol by engine ECU 1 Coolant temperature 20 or less 2 Coolant temperature 115 or more 3 For approx 4 seconds after starting the engine 4 When the engine speed is below 650 rpm 5 When the engine speed is over 4 500 rpm 6 During abrupt acceleration for the vehicle equipped with manual transmission ...

Page 761: ...eed can also be controlled manually Manual control The motor is manually controlled by turning the blower dial Turning the dial clockwise or counterclockwise changes the fan speed by 1 step AUTO control The fan speed is controlled automatically according to the set temperature and the ambient conditions Control in relation to sun load The system increases the fan speed by adding up 2 5 V of voltag...

Page 762: ...temperature sensor is approximately 62 When the defrost mode is selected with the blower dial in AUTO position the blower motor voltage is increased by 1 5 V compared to the AUTO control voltage for a certain amount of time When the intake temperature sensor indicates over 35 C the driver might feel uncomfortable by the air flow from the vent Therefore at the initial operation stage the hot air is...

Page 763: ...ontrolled in accordance with the vehicle speed Operating conditions The air source selection switch recirculation switch should be in AUTO position When the vehicle speed is 30 km h or lower in fresh air mode the air source door is open 20 of its maximum opening If the vehicle speed is 50 km h or more then the air source door is completely open 1 2 4 Mode Control Manual control You can choose a de...

Page 764: ...o into the maximum cooling or maximum heating mode regardless of the sensor signals Manual control Pressing the A C switch or selecting defrost mode turns on the A C AUTO control The A C is controlled in accordance with the inner heat of the air conditioning system and ambient temperature In cold weather the compressor is turned off when the ambient temperature is low 2 or less for protection agai...

Page 765: ...light A5 P1 Mode A23 FATC illumination light A6 Vehicle speed signal B1 A7 REF B2 A8 PTC heater assembly B3 A9 IGN ON power B4 Water temperature sensor signal A10 Battery power B5 Incar sensor signal A11 P1 Intake B6 A12 Compressor operating signal B7 A13 Intake sensor signal B8 A14 Blower feedback signal B9 A15 Blower motor control signal B10 Sun load sensor signal A16 Sensor ground B11 Ambient t...

Page 766: ...01 24 korando 2010 10 6810 00 AIR CONDITIONING SYSTEM 1 Sensors Actuators Mode actuator Temperature actuator Water temperature sensor Intake sensor ...

Page 767: ...01 25 AIR CONDITIONING SYSTEM korando 2010 10 6810 00 PTC heater Blower motor Air filter Intake actuator ...

Page 768: ...flow mode Vent Vent Foot Foot Defrost Foot Defrost 1 Mode Actuator Assembly Maintenance Turn the ignition ON Then check the operation position of the actuator each time the mode is changed If the operating position is not correct check the wiring for open circuit If the wiring is intact replace the mode actuator assembly a b c Mode actuator assembly Mode actuator ...

Page 769: ...IR CONDITIONING SYSTEM korando 2010 10 6810 00 Defrost Foot Mode door actuator operation position Mode door actuator connector Pin No Function 1 2 REF 3 PBR 4 Sensor ground 5 P2 6 P1 Foot Bi level Vent Defrost ...

Page 770: ...e air flow mode is changed If the operating position is not correct check the wiring for open circuit If the wiring is intact replace the intake actuator assembly a b c Intake actuator assembly Intake actuator assembly Controls the air source door intake by the FATC command 2 Intake Actuator Assembly Maintenance Function Intake actuator ...

Page 771: ...01 29 AIR CONDITIONING SYSTEM korando 2010 10 6810 00 Fresh air Recirculation Intake actuator operation position Intake actuator connector Pin No Function 1 2 REF 3 PBR 4 Sensor ground 5 P2 6 P1 ...

Page 772: ...ion is not correct check the wiring for open circuit If the wiring is intact replace the temperature actuator assembly a b c Temperature actuator assembly Temperature actuator assembly Adjusts the temperature of the indoor air by controlling the temperature actuator assembly position according to the FATC command Function Maintenance 3 Temperature Actuator Assembly Temperature actuator ...

Page 773: ...01 31 AIR CONDITIONING SYSTEM korando 2010 10 6810 00 Cooling Heating Temperature actuator operation position Temperature actuator connector Pin No Function 1 2 REF 3 PBR 4 Sensor ground 5 P2 6 P1 ...

Page 774: ... position and measure the voltage between the pin no 25 and 18 of the FATC connector Specified value approx 1 7 V at 25 If the voltage value cannot be measured check the wiring for open circuit If the measured value is within the specified range replace the FATC Mounting location Located to the air intake on the front side of the FATC Function This sensor is a negative temperature coefficient NTC ...

Page 775: ...scribed below a b Turn the ignition switch to ON position and measure the voltage between the pin no 15 and 11 of the FATC connector Specified value approx 1 1 V at 25 If the voltage value cannot be measured check the wiring for open circuit If the measured value is within the specified range replace the FATC Mounting location Located to the heater inlet pipe Function This sensor is a negative tem...

Page 776: ...e ignition switch to ON position and measure the voltage between the pin no 21 and 18 of the FATC connector Specified value approx 5 1 V at 1 If the voltage value cannot be measured check the wiring for open circuit If the measured value is within the specified range replace the FATC Mounting location Located to the side of the evaporator inside the A C Function This sensor is a negative temperatu...

Page 777: ... Fault code 6 check as described below Turn the ignition switch to ON position Measure the voltage between the two 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 If the measured value is out of the specified range check the wiring for open circuit If the wiring is intact replace the resistor MOS module...

Page 778: ...ed below a b Turn the ignition switch to ON position and measure the voltage between the pin no 31 and 18 of the FATC connector Specified value approx 1 7 V at 25 If the voltage value cannot be measured check the wiring for open circuit If the measured value is within the specified range replace the FATC Mounting location Located to the upper center side of the front bumper Function This sensor is...

Page 779: ...in direct sunlight approx 3 1 V under shade If the voltage value cannot be measured check the wiring for open circuit If the measured value is within the specified range replace the FATC Mounting location Located on the left side of the instrument panel Function Detects the sun load enters to the interior through the windshield with a photo diode Then it converts the sun load to current value and ...

Page 780: ...ause the PTC system is heated by electrical power the electric load and alternator capacity is greater than the conventional one For example the alternator capacity of the vehicle with PTC is 140 A while the vehicle with FFH is only 115 A The PTC does not operate when a the engine is cranking b the battery voltage is below 11 V c the glow plug is preheated PTC heater ...

Page 781: ...and 0 When the coolant temperature is 60 or less and the intake air temperature is between 0 and 5 PTC OFF Condition A C blower switch OFF Ambient temperature sensor malfunction short or open circuit in the wiring When the engine is cranking When the battery voltage is 11 V or less the glow plug is preheated Glow indicator ON PTC Operating ON Condition Component PTC heater Heating type Air heating...

Page 782: ...ge temperature 40 to 90 Ignition temperature 30 to 85 Over voltage protection 24 V 2 MAJOR REPLACEMENT PARTS AFTER AIR BAG DEPLOYMENT 1 In Case of Front Air Bag Deployment Air bag unit and its wiring including connector seat belt pretensioner and its wiring including connector whole front air bags instrument panel front impact sensor and other damaged components 2 In Case of Curtain Air Bag Deploy...

Page 783: ...ed or dropping impact onto the road surface with a large angle occurs The air bag seldom deploys when A collision to diagonal direction not a front collision occurs or the vehicle tips over A weak collision which the sensor cannot detect occurs under the activation requirements A collision against narrow objects such as a telegraph pole or a tree occurs The vehicle falls into a drainage or a puddl...

Page 784: ... are installed in both roof side rails Curtain air bag The side air bags are installed in the outer sides of the driver s and passenger s seats to minimize occupants side injuries in case of a side impact Side air bag Driver seat Passenger seat Side airbags and curtain air bags operate independently from the front airbag system ...

Page 785: ...ts including the steering wheel air bag mounting area and harness Incorrect inspection could cause a problem with an air bag and seat belt pretensioner and they cannot protect occupants properly Inspection and repair service should be done only by a qualified technician An infant or a child should not be seated on the front seat alone or on an adult s lap An infant or a child could be severely inj...

Page 786: ...n the dash board You can severely injured when the air bag inflates It is normal that a loud noise dust and smoke occur when the air bag and seat belt pretensioner operate The gas come out of air bag seat belt pretensioner activation is non toxic nitrogen gas However if this gas occurs irritation to your skin eyes nose and so on wash it out with clean water Seek medical help if symptoms develop Th...

Page 787: ... unit should be packaged in an air tight container to prevent any damage Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Disconnect the negative battery cable before installing or removing the part related to the air bag 1 2 3 4 When turning on the ignitio...

Page 788: ......

Page 789: ...02 10 korando 2010 10 8810 00 AIR BAG SYSTEM Driver side air bag Seat belt pretensioner SDM unit BCM Driver air bag module Passenger air bag module 1 SYSTEM CONFIGURATION ...

Page 790: ...02 11 AIR BAG SYSTEM korando 2010 10 8810 00 Inflatable curtain air bag module Side air bag sensor assembly Front impact sensor assembly Air bag warning lamp instrument cluster Height adjuster ...

Page 791: ...loy Side air bag module passenger side Not deploy Deploy Inflatable curtain air bag module driver side Deploy Not deploy Inflatable curtain air bag module passenger side Not deploy Deploy Impact area Front side Driver s air bag Deploy Passenger s air bag Deploy Seat belt pretensioner driver side Deploy Seat belt pretensioner passenger side Deploy When the ignition switch is turned to ON SDM starts...

Page 792: ...eration rate that each collision G sensor reads the air bag unit sends out about 2 to 4 or higher Amp current This current generates some heat which fires the detonator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for a firing 1 Deployment Firing Loop Items Driver side or LH Passenger side or RH Front air bag 0 03...

Page 793: ...her crash out is delayed until the current 200 ms crash out is completed The tolerance at the time of signaling is 5 The signal repeats increasing for 390 ms and decreasing for 10 ms before crash At the time of crash the switch is closed and the signal is kept low condition for 200 ms At the time of crash the crash out signal is changed to the low condition for 200 ms immediately to indicate the c...

Page 794: ...ngs are the specifications of the electrical interface The load resistance of the SDM should be 590 ohms or higher It may not be possible to operate the collision occurrence circuit normally if the resistance value does not reach this specified value Items Minimum Average Maximum Remark Driving current current value when the transistor is turned on 12 31 mA 19 6 mA 30 mA Depending on the battery v...

Page 795: ...al operation Checks the FIS condition and sends the result as OK or NOK and also sends the severe level of the crash Same as FIS Voltage The FIS hardware reset performed under 5 V communication voltage low Same as FIS Fault The fault is found in the current ignition cycle but the fault is deactivated in the next ignition cycle Multiple faults can be found and deactivated in the same ignition cycle...

Page 796: ... cycle and the SDM is running without any active fault right after starting in the ignition cycle When there is no active fault and past faults occurred within 10 times The warning lamp is operated as shown below every time the vehicle is started if the SDM is running without any active fault in the entire time and past faults in the previous ignition cycle occurred within 10 times Battery voltage...

Page 797: ... times or more except battery voltage too low Internal fault Impact record Pretensioner fired only If the connector is not connected properly or SDM battery voltage is out of the specified range internally battery voltage for warning lamp the warning lamp is kept ON Warning lamp condition change during operation The warning lamp comes on or off according to the actual fault condition during SDM op...

Page 798: ...02 19 AIR BAG SYSTEM korando 2010 10 8810 00 4 CIRCUIT DIAGRAM ...

Page 799: ...odule Driver Air bag module Passenger Screw Nut Air bag module INF curtain Brkt Icab FRT 1 2 3 6 7 8 11 12 Bolt T screw Truss_M4x0x12 Grommet screw_M4 Sensor assy Side air bag Screw Sensor assy FRT impact Wiring assy Air bag Wiring assy Air bag EXTN 13 14 15 16 17 18 22 23 ...

Page 800: ... by the deceleration from vehicle collision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver Front side of DAB module Rear side of DAB module 1 Location ...

Page 801: ...ponents Air bag cover Air bag cushion approx 50 liters Retainer ring Air bag housing Inflator approx 195 kP Nut The inflator consists of the detonator explosives and the gas generator It inflates the air bag when the vehicle collides 3 Inflator Circuit ...

Page 802: ...on both seats are made to operate together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and inflates the air bag cushions curtain air bags independently operate in case of the side collisio...

Page 803: ...02 24 korando 2010 10 8620 23 AIR BAG SYSTEM 2 Components 3 Inflator Circuit Air bag cover Air bag cushion approx 50 liters Air bag housing Retainer Inflator approx 330 kP Cowl bracket Nut ...

Page 804: ...d The curtain air bags are installed on both sides of the roof side rails and inside the headlinings Each curtain air bag is also composed of the air bag cushion and the inflator that has the detonator explosives and the gas generator Deployed 1 Location ...

Page 805: ...02 26 korando 2010 10 8621 03 AIR BAG SYSTEM 2 Components Curtain air bag mountings 6 points Inflator mountings Inflator Gas guide Air bag cushion Cover curtain air bag Bolt ...

Page 806: ...02 27 AIR BAG SYSTEM korando 2010 10 8621 03 3 Inflator Circuit ...

Page 807: ... Driver side The side air bags are installed in the outer sides of the driver passenger and rear seats to minimize the side impact applied to the occupant The Side air bags and curtain air bags are operated independently from the front air bag system 1 Mounting Location ...

Page 808: ...02 29 AIR BAG SYSTEM korando 2010 10 7400 13 3 Inflator Circuit 2 Components Air bag cover Air bag cushion Deflector Inflator Wiring harness ...

Page 809: ...re applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat It is to improve comfort and optimize restrictive performance in case of a collision by adjusting the belt position to the occupant s shoulder Height adjuster Pretensioner Height adjuster 1 Location ...

Page 810: ...ioner reel assembly 2 Reel bracket 3 Upper stay for ring 4 D ring 5 Bending tongue 6 Tongue stopper 7 Mini anchor 8 D bolt 9 Washer 10 Fiber washer 11 Rivet 12 D label 13 Plastic washer 14 Steel washer 15 D bolt 16 Label 17 D bolt 18 Spacer 19 Bush 20 Mini anchor cover ...

Page 811: ...02 32 korando 2010 10 7460 13 AIR BAG SYSTEM 3 Inflator Circuit ...

Page 812: ...s activated mainly by the signal from the front impact sensor assembly The SDM unit assembly compares this signal with its longitudinal lateral G sensor values to inflate the front air bag Front impact sensor assembly LH Front impact sensor assembly RH 1 Mounting Location ...

Page 813: ...02 34 korando 2010 10 8627 03 AIR BAG SYSTEM 2 Front Impact Sensor Connector 3 Front Impact Sensor Circuit Pin No Function 1 Signal 2 Ground ...

Page 814: ...signal from the SDM unit assembly independently from the front air bag system The ignition signals of the side air bag system are supplied from the 2 side air bag sensors installed to the side center of the vehicle body 1 Location Side air bag sensor assembly Side air bag sensor connector Left Right ...

Page 815: ...02 36 korando 2010 10 8627 03 AIR BAG SYSTEM 2 Side Air Bag Sensor Connector 3 Side Air Bag Sensor Circuit Pin No Function 1 Signal 2 Ground ...

Page 816: ...02 37 AIR BAG SYSTEM korando 2010 10 8625 03 SDM unit assembly Connector The SDM unit assembly is mounted under the front of the front console 1 Location Location ...

Page 817: ...rters and supplies the firing voltage for the two firing circuits and the internal operating voltage of the SDM If the internal operating voltage falls below a defined threshold a reset is executed Watchdog The watchdog checks the micro controller μC periodically If there is any fault in the micro controller it will be reset and firing loop will be locked Then the warning lamp will come on Detects...

Page 818: ...measuring the energy reserve capacitor If there is any problem in the energy reserve capacitor it sets a diagnostic trouble code associated with an energy reserve function Orthogonal acceleration sensor The integrated electrical acceleration sensor provides an electrical signal of the vehicle s acceleration along the orthogonal axis and longitudinal axis The electrical signals are proportional to ...

Page 819: ...50 mm Reclining 66 20 46 66 20 46 17 5 7 10 5 Lumbar support 2 steps standard Seat warmer cushion seatback ON high low OFF ON high low OFF ON OFF Headrest Conven tional Up Down 90 mm 15 mm x 6 90 mm 15 mm x 6 45 mm 15 mm x 3 Sliding 24 mm 8 mm x 3 24 mm 8 mm x 3 Electronic active type Optional tilting 15 Optional tilting 15 Seat belt 3 point ELR PT L L 3 point ELR PT L L LH RH 3 point ELR Center 2...

Page 820: ...nket cushion or seat cover If the temperature continues to rise turn the switch off and have the system checked by a Ssangyong Dealer or Ssangyong Authorized Service Center In the case of the driver s seat an excessive usage of the heated seat might make you sleepy and could negatively affect your safety Do not place anything sharp on the seat This may cause damage to the seat heater Power seats w...

Page 821: ...03 5 SEAT korando 2010 10 7400 13 ...

Page 822: ...oard assy FRT seat Cover Seat MTG FRT Cover Seat MTG RR Cover Shield OTR 1 2 3 5 6 7 8 9 10 11 12 13 Cover Shield INR Lever Height adjuster Lever Recliner Cap Lever Frame assy FRT seat cushion Frame assy FRT seat cushion Warmer assy Seat cush Warmer assy Seat back Sensor Seat belt reminder Switch assy Power seat Sensor Head rest Nut 14 15 16 17 20 21 22 23 25 26 30 31 ...

Page 823: ...03 7 SEAT korando 2010 10 7400 13 Power seat Manual seat Sliding switch power seat 1 Driver Seat 1 Operation A Sliding Sliding lever manual seat ...

Page 824: ...03 8 korando 2010 10 7400 13 SEAT Height adjust switch power seat B Height adjusting Height adjust lever manual seat C Reclining seatback Reclining switch power seat Reclining lever manual seat ...

Page 825: ...ndo 2010 10 7400 13 Lumbar support switch power seat D Lumbar support Power seat Turn the lever forward to increase the amount of lumbar support To decrease it turn the lever backward Lumbar support lever manual seat ...

Page 826: ...03 10 korando 2010 10 7400 13 SEAT Seat warmer switch 2 Seat warmer accessories Seatback pocket grocery hook Seat heated wire ...

Page 827: ...2 Passenger seat Reclining To change the seatback angle lean forward slightly and raise the lever Sliding To move the seat forward or backward pull and hold the seat slide lever up and move the seat as desired 1 Operation Passenger seat 2 Seat warmer accessories Seat warmer switch ...

Page 828: ...eve H rest Sleeve H rest Cover RR seat mtg Tether anchor Cover Housing Folding lever Arm rest assy RR 1st back 1 2 3 4 5 6 7 8 9 10 Cover Arm rest FRT Cover Arm rest RR Cover assy Recliner otr Cover Recliner inr Cover Linkage Warmer assy RR 1st back Warmer assy RR 1st cushion Bolt Cap Bolt 11 12 13 14 15 16 17 18 19 20 ...

Page 829: ...aise the head restraint pull it up without pressing the release button To lower the head restraint press the release button 1 on top of seatback and push the head restraint down To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever ...

Page 830: ...03 14 korando 2010 10 7500 13 SEAT Seatback folding Heated wire 2 Seat warmer accessories Heated wire Rear armrest LH RH ...

Page 831: ...03 15 SEAT korando 2010 10 7460 13 Seat belt assy FRT Height adj assy FRT s belt Dust cover FRT seat belt Screw Buckle assy FRT 1 2 3 4 5 ...

Page 832: ...03 16 korando 2010 10 7560 13 SEAT Seat belt assy RR 1st Double buckle assy RR 1st Tongue buckle assy RR 1st Dust cover RR 1st seat belt Screw 1 3 4 6 7 ...

Page 833: ...the front side driver seat passenger seat includes pretensioner function which rewinds the seat belt immediately to protect occupant s face and chest when a strong frontal collision occurs 1 Seat Belt Layout 3 point seat belts front seats 3 point seat belts for both sides or all rear seats 2 3 point seat belt only for rear center optional ...

Page 834: ...03 18 korando 2010 10 7560 13 SEAT Rear 3 point Rear center 2 point optional 2 Mounting Location Driver side 3 point Front passenger side 3 point ...

Page 835: ...03 19 SEAT korando 2010 10 7510 08 ...

Page 836: ...kg 6 to 9 months Seat belt U SU X 13kg 12 to 15 months Seat belt U SU X Forward seat 9 to 18kg 9 to 48 months Seatbelt ISOFIX U UF SU X Booster seat 15 to 25 kg 4 to 6 years Seat belt U X Booster cushion 22 to 36 kg 6 to 11 years Seat belt U X U General child restraint system which should be fixed with the seat belt approved by official institute UF SU General child restraint system which should b...

Page 837: ...tem the seat belt is not needed The lower anchor is not installed to the rear seat center The approved ISOFIX child restraint system can be mounted to the vehicle with ISOFIX system lower latch 2 EA and rear seatback anchor 1 EA When installing ISOFIX child restraint system all the seat belts in the rear seat should be inserted to the buckle The mounting latches and anchors for the ISOFIX are only...

Page 838: ...ting for fixing child restraint system on the back side of the rear seatback as shown in the figure Pass the belt of the child restraint over the seatback of the rear seat Connect the hook of the child restraint system belt to the anchor firmly and securely tighten the child restraint to the seat ...

Page 839: ...d and cross tip screwdrivers Do not use any similar tool Take care not to drop the sunroof assembly when removing it and do not keep it right up 1 2 3 4 5 Operating voltage 9 to 16 V Operating current open close Max 6 A At no load Approx 3 A Dark current Max 1 mA Roof motor operating speed at opening and closing 1 4 0 5 sec 100 mm Motor overload stop conditions Current for 25 A or higher and torqu...

Page 840: ...04 4 korando 2010 10 7340 00 SEAT Sunroof switch 1 SYSTEM LAYOUT Sunroof assembly TILT OPEN Sunroof motor control unit ...

Page 841: ...not in use The sunroof glass can be open in two steps and can also be tilted by the switch operation The sunroof switch is installed to the overhead console and tilts closes opens the sunroof TILT CLOSE OPEN Sun shade panel Sunroof glass Sunroof switch Opens the rear section of the sunroof only Closes the sunroof Opens the sunroof Sunroof glass Sun shade panel ...

Page 842: ...h manual sliding close The sunroof is closed as long as pulling down the switch Pull down the switch Push up the switch Open 2 step open Push up and hold the switch manual sliding open The sunroof is opened as long as pushing up the switch Push up the switch briefly 2 step auto sliding open When pushing up the sunroof switch briefly the sunroof is automatically opened by two third of its travel fi...

Page 843: ...en pulling down the sunroof switch with the sunroof closed The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted up Pull down the switch Push up the switch When leaving the vehicle make sure the sunroof is completely closed The sunroof may look closed but it might be tilted up ...

Page 844: ...s because of an influx in air through the window or sunroof and its resonance effect If this happens adjust by opening the window or sunroof To prevent any body parts from being trapped by the sliding sunroof an Anti Pinch Function automatically opens the sunroof when an object is trapped 4 Safety Anti Pinch Function Wind buffeting The anti Pinch function is deactivated just before the sunroof clo...

Page 845: ... pressing the switch it could cause a malfunction Especially in the winter never operate the sunroof if moving areas are iced Wait until the areas are deiced When leaving the vehicle unattended be sure to completely close the sunroof Otherwise there is a great risk of vehicle theft Or the interior of the vehicle will be wet when it rains or snows When the sunroof is slid to its complete open posit...

Page 846: ...te close and tilts up the sunroof The opening gap remarkably decreases for the sliding open or tilt up Operation of the sunroof switch does not do anything or work properly The operating process is not same as before due to discharged or disconnected battery When the switch is pushed up for more than 5 seconds with the sunroof is completely open the sunroof cannot completely be either closed or op...

Page 847: ...04 11 SEAT korando 2010 10 7340 00 4 CIRCUIT DIAGRAM ...

Page 848: ...05 3 BODY INTERIOR korando 2010 10 7110 00 5110 01 BODY INTERIOR ...

Page 849: ... assy FRT DR I S HDL Cable assy F DR s lock knob Holder cable Striker assy DR Shim DR striker Screw DR striker MTG Handle assy FRT DR O S Nut Rod FRT DR O S HDL Checker assy FRT DR Bolt Bumper DR overslam Handle assy FRT DR I S Cap DR I S HDL Screw 1 2 4 5 7 8 9 10 11 14 15 21 22 23 24 25 26 ...

Page 850: ... FRT DR trim Pnl assy A rest FRT DR trim Bezel FRT DR Reflector DR courtesy FRT Lens DR courtesy FRT Clip 1 2 4 5 7 8 11 Lamp assy DR courtesy Bulb Foam block FRT DR trim BRKT assy F DR pull HDL MTG Grommet Screw Screw Rivet Pull handle Cover FRT 15 16 17 20 24 25 26 30 ...

Page 851: ...05 6 korando 2010 10 7120 00 BODY INTERIOR Regulator F DR PWR WDW FRT Motor assy Power window FRT Glass run FRT DR window Nut 1 2 6 7 ...

Page 852: ...05 7 BODY INTERIOR korando 2010 10 7210 00 ...

Page 853: ...S HDL RR Cable assy R DR S lock knob Holder Cable Striker assy DR Shim DR striker Screw DR striker MTG Handle assy RR DR O S Nut Rod RR DR O S HDL Label DR child safety Checker assy RR DR Bolt Flange Bumper DR overslam Handle assy RR DR I S Cap DR I S HDL Screw 1 2 4 5 7 8 9 10 11 14 15 20 21 22 23 24 25 26 ...

Page 854: ...INTERIOR korando 2010 10 7215 00 Trim assy RR DR W strip RR DR trim PNL assy A rest RR DR trim Bezel RR DR Clip 1 2 4 5 11 BRKT assy R DR pull HDL MTG Grommet Screw Screw Rivet Pull handle Cover RR 20 24 25 26 30 ...

Page 855: ...05 10 korando 2010 10 7220 00 BODY INTERIOR Regulator R DR PWR WDW RR Motor assy Power window FRT Nut Glass run RR DR window Rail assy RR DR glass guide 1 2 4 6 7 ...

Page 856: ...010 10 7321 00 Trim assy T gate LWR Cover Latch Clip Grommet Screw Screw Rivet 1 2 3 12 13 14 Trim assy T gate UPR Trim assy T gate side Trim assy T gate side Clip Trim MTG Grip T gate LWR Cap T gate HDL Screw 15 16 17 18 20 21 23 ...

Page 857: ...05 12 korando 2010 10 7330 00 BODY INTERIOR ...

Page 858: ...30 00 Head lining assy Head lining assy Insulation Roof no2 Insulation ROOF no3 Insulation Roof no4 Fastener Tree type Coat hook assy Grip assy FRT Grip assy RR BRKT assy Grip MTG FRT BRKT assy Grip MTG RR Screw 1 2 3 4 5 7 8 10 11 20 21 23 ...

Page 859: ...05 14 korando 2010 10 7610 00 BODY INTERIOR ...

Page 860: ...ssy Glove Housing assy Glove box Molding assy CTR fascia Molding assy Side fascia Molding assy Side fascia PNL CTR fascia LWR PNL Side fascia PNL Side fascia PNL CTR fascia PNL assy Cluster fascia Louver assy Side A vent Louver assy Side A vent Louver assy CTR A vent Louver assy CTR A vent Tray assy CTR fascia LWR PNL Shroud UPR PNL assy Shroud LWR PNL assy LWR main Cover assy Crash pad side BRKT ...

Page 861: ...05 16 korando 2010 10 7630 00 BODY INTERIOR ...

Page 862: ...older Tray Main UPR Bezel Cup holder UPR Cover ARm rest hinge BRKT assy Console main CTR BRKT assy Console main RR LWR Cover assy FRT end console Mat Console main tray Guide Cup Ash tray Fascia Console UPR Cover Console FRT Fascia assy Console FRT Fascia Console UPR Cover assy TGS A T Tray assy Console FRT Screw Screw Nut Screw Rivet 1 3 4 5 6 7 9 10 11 12 13 15 16 20 22 24 25 31 32 36 37 38 39 41...

Page 863: ...05 18 korando 2010 10 7710 00 BODY INTERIOR ...

Page 864: ...BODY INTERIOR korando 2010 10 7710 00 Insulator Engine room Insulator Partition Insulator Dash UPR Nut Insulator Dash INR Mat assy Floor FRT Mat assy Floor CTR Mat Floor RR Hook Car MAT 1 2 3 5 6 11 12 13 15 ...

Page 865: ...05 20 korando 2010 10 7730 00 BODY INTERIOR ...

Page 866: ...y QTR LWR Cap QTR UPR Socket assy Power Cap Luggage cover MTG Hook assy Luggage Cover Luggage hook Guide Seat belt Grommet Screw Screw Screw Trim assy DR scuff FRT Trim assy DR scuff RR Clip Trim Dr scuff FRT OTR Trim DR scuff RR OTR Trim assy RR transverse Cover Luggage Clip Grommet Screw Screw Rivet Blanking cover RR transverse 1 2 3 4 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 2...

Page 867: ... assy Luggage room Net Luggage Lid assy Luggage Handle assy Latch UPR Housing Latch LWR BRKT assy Trim MTG Trim assy Luggage FRT Tray Luggage 1 2 4 5 6 11 12 13 Tray Luggage CTR Hook assy Luggage Screw Screw Grommet Screw Screw Rivet 14 16 20 21 22 23 ...

Page 868: ...o 2010 10 7770 00 Sunvisor assy Sunvisor assy Grommet Screw Retainer assy Sunvisor Mirror assy I S RR view 1 2 3 4 5 10 Cover I S mirror Console assy Over head Switch assy Sunroof Screw BRKT Over head console MTG 11 20 21 22 40 ...

Page 869: ... INTERIOR Anti pad Cowl UPR Anti pad FRT floor FRT Anti pad FRT floor CTR Anti pad FRT floor RR Anti pad FRT floor RR CTR 2 3 5 6 7 Anti pad RR floor FRT Anti pad Spare tire Anti pad RR floor RR OTR Anti pad RR wheel house INR 8 9 11 12 ...

Page 870: ...06 3 BODY EXTERIOR korando 2010 10 5110 01 WHITE BODY White body with sunroof 1 2 ...

Page 871: ...06 4 korando 2010 10 5120 00 BODY EXTERIOR ...

Page 872: ... Bush FRT subframe MTG Stopper Subframe MTG FRT UPR Stopper FRT subframe FRT LWR Bolt Body MTG Stopper Subframe MTG RR UPR Stay FRT subframe Bush RR subframe MTG FRT Stopper RR subframe MTG LWR Bush RR subframe MTG RR Bolt 1 2 3 5 6 7 8 9 10 12 ...

Page 873: ...06 6 korando 2010 10 5125 00 BODY EXTERIOR Member assy FRT H frame Member assy RR H frame 1 2 ...

Page 874: ...Brkt RR bumper MTG LWR Brkt assy Fender MTG LWR Pillar compl D OTR Housing assy Fuel filler PNL compl Q INR W HSE 2 3 4 6 7 8 PNL side OTR FRT PNL Side OTR RR Reinf assy RR DR striker PNL assy Cowl side INR PNL Wheel house RR OTR Pillar assy B INR 9 10 11 12 15 16 ...

Page 875: ...06 8 korando 2010 10 5510 00 BODY EXTERIOR PNL Roof Pnl Roof Rail assy Roof FRT Reinf assy Sunroof Rail Roof No1 CTR Rail Roof No2 CTR Rail Roof No3 CTR Rail assy Roof RR 1 2 3 4 5 6 7 9 ...

Page 876: ...06 9 BODY EXTERIOR korando 2010 10 5610 00 PNL compl FRT floor PNL Side sill INR 1 13 ...

Page 877: ...06 10 korando 2010 10 5620 00 BODY EXTERIOR PNL compl RR floor Member assy RR end Reinf RR floor corner PNL assy Back OTR 1 11 13 14 ...

Page 878: ...06 11 BODY EXTERIOR korando 2010 10 5710 00 PNL compl Engine room Beam assy FRT end LWR Member assy Head lamp Member FRT end UPR Bolt Member assy FRT end CTR 1 2 3 4 5 6 ...

Page 879: ...06 12 korando 2010 10 5720 00 BODY EXTERIOR PNL assy Fender apron PNL assy Fender apron Brkt Fender MTG FRT PNL Fender Pad Fender MTG sealing Bolt Seal Fender Reinf Fender 1 2 3 4 5 6 7 8 ...

Page 880: ...06 13 BODY EXTERIOR korando 2010 10 5730 00 PNL compl Dash cowl Member compl Cowl side UPR Cross member assy 1 2 3 ...

Page 881: ...er Hood over slam Seal assy Hood FRT sub Seal assy Hood RR Bumper Trunk lid over slam 1 2 3 4 5 6 7 8 10 12 13 16 Cable assy Hood latch release Clip F filr DR REL CBL Handle Hood latch release Screw Grille assy Cowl Screw Rivet Rod assy Hood stay BRKT Hood stay rod MTG Retainer Hood stay rod Nut Clip Hood stay rod Holder Hood stay rod 17 18 19 20 21 23 24 25 26 27 28 29 ...

Page 882: ...06 15 BODY EXTERIOR korando 2010 10 6210 00 PNL assy FRT DR Hinge assy FRT DR UPR Hinge assy FRT DR LWR Bolt Bolt 1 2 3 4 5 ...

Page 883: ...06 16 korando 2010 10 6310 00 BODY EXTERIOR PNL assy RR DR Hinge assy RR DR UPR Hinge assy FRT DR LWR Bolt Bolt 1 2 3 4 5 ...

Page 884: ...06 17 BODY EXTERIOR korando 2010 10 6410 00 PNL assy Tailgate Hinge assy Tailgate Bolt Nut 1 2 3 5 ...

Page 885: ...06 18 korando 2010 10 7090 00 BODY EXTERIOR Cable assy F filr DR REL Handle assy F filr DR REL DR assy Fuel filler Bolt Screw 1 4 6 7 8 ...

Page 886: ...10 7121 00 W strip FRT DR body side W strip assy FRT DR opening Cap W strip Clip W strip W strip assy F DR belt O S Screw Tape DR tooling hole sealing Tape FRT DR frame A Tape FRT DR frame B Vinyl seal FRT DR trim 1 2 3 4 5 6 7 9 10 11 ...

Page 887: ...y RR DR DR side Cap W strip Clip W strip W strip assy RR DR belt O S Screw 1 2 3 4 5 6 Tape DR tooling hole sealing Tape RR DR frame B Tape RR DR frame A Vinyl seal RR DR trim Cover assy RR DR trim UPR Cover RR DR DR side strip Molding assy RR DR delta Screw 7 9 10 12 13 17 18 19 ...

Page 888: ... korando 2010 10 7310 00 Latch assy T gate Bolt Striker assy T gate Screw DR striker MTG Lifter assy T gate Ball stud Bumper Trunk lid over slam Bumper assy T gate O slam CTR W strip T gate opening 1 2 3 4 20 21 28 29 30 ...

Page 889: ...06 22 korando 2010 10 7830 00 BODY EXTERIOR Blade assy RR wiper Arm assy T gate wiper Motor assy RR wiper Spacer assy T gate wiper Splash ring T gate wiper Nut Cap Wiper arm 1 2 3 5 6 7 9 ...

Page 890: ...010 10 7840 00 Glass assy Windshield Plate I S RR view mirror base Molding assy Windshield Dam Windshield Spacer assy Windshield glass 1 2 3 4 5 Glass FRT DR drop Grommet DR glass MTG Bolt DR glass MTG Glass assy T gate 10 12 13 20 ...

Page 891: ...06 24 korando 2010 10 7850 00 BODY EXTERIOR Mirror assy O S Mirror assy O S Glass holder assy O S mirr Screw Lamp assy Turn signal Cover O S mirror FRT Rivet Plastic 1 2 3 4 5 10 11 ...

Page 892: ...olding Intake Screw Absorber Energy FRT bumper Reinf FRT bumper CTR Cover Fog lamp FRT Blanking cover Fog lamp FRT Garnish License plate 1 2 3 4 5 6 7 8 9 10 Spring Nut Clip Lock Screw Screw Screw Scrivet Grommet Screw Screw rivet RR fascia MTG Brkt assy Side FRT bumper Bolt 11 12 13 14 15 16 19 21 22 24 ...

Page 893: ...scia RR bumper RR LWR Absorber Energy RR bumper Lamp assy Reflex reflector Screw Nut Clip Screw Spring Nut Screw 1 2 3 4 5 6 7 8 9 12 Bolt Grommet Screw Beam assy Impact RR bumper Scrivet Screw Bolt Grommet Screw BRKT assy Side RR bumper Nut 13 14 15 16 17 18 19 20 21 ...

Page 894: ...06 27 BODY EXTERIOR korando 2010 10 7910 00 Grille Radiator Screw Molding Radiator grille Screw 1 2 3 4 ...

Page 895: ...t Clip Side sill molding MTG Garnish assy FRT wheel arch Garnish assy RR wheel arch Clip DR molding MTG Garnish assy Side sill Clip Side sill molding MTG 1 2 3 4 5 10 11 Clip Side sill molding MTG LWR Screw Grommet Screw Clip DR garnish MTG Screw 12 13 14 15 16 17 ...

Page 896: ...06 29 BODY EXTERIOR korando 2010 10 7940 00 Molding assy Roof Molding assy Roof No1 Molding assy Roof No2 Rail assy Fashion Nut Spoiler assy Cover LWR Screw Garnish assy Tailgate 1 2 3 10 11 20 21 22 30 ...

Page 897: ...ndo 2010 10 7970 00 BODY EXTERIOR Cover assy FRT wheel house Screw Screw Cover Crankshaft pulley Cap nut Cover RR wheel house Under cover RR Nut Mud guard RR BRKT RR mud guard MTG Nut 1 2 4 5 6 10 15 16 20 21 22 ...

Page 898: ... REPAIR GENERAL INFORMATION 1 MAJOR DIMENSION 2 LIFTING POINTS 3 SEALING APPLICATION POINTS 4 DEADENER APPLICATION POINTS 5 UNDER COATING 6 MAJOR WELDING POINTS 7 MAJOR BODY DIMENSIONS 8 GAP CHART 3 4 6 11 12 13 23 31 ...

Page 899: ......

Page 900: ...07 3 BODY REPAIR korando 2010 10 5110 01 Top View Side View Front view Rear view 5110 01 BODY REPAIR 1 MAJOR DIMENSION ...

Page 901: ...07 4 korando 2010 10 5110 01 BODY REPAIR 2 LIFTING POINTS 1 2WD ...

Page 902: ...07 5 BODY REPAIR korando 2010 10 5110 01 2 4WD ...

Page 903: ...07 6 korando 2010 10 5110 01 BODY REPAIR 3 SEALING APPLICATION POINTS 1 Dash panel engine tunnel floor etc ...

Page 904: ...07 7 BODY REPAIR korando 2010 10 5110 01 2 White Body ...

Page 905: ...07 8 korando 2010 10 5110 01 BODY REPAIR ...

Page 906: ...07 9 BODY REPAIR korando 2010 10 5110 01 3 Front And Rear Door Panel ...

Page 907: ...07 10 korando 2010 10 5110 01 BODY REPAIR 4 Engine Hood Panel ...

Page 908: ...07 11 BODY REPAIR korando 2010 10 5110 01 4 DEADENER APPLICATION POINTS ...

Page 909: ...07 12 korando 2010 10 5110 01 BODY REPAIR 5 UNDER COATING ...

Page 910: ...07 13 BODY REPAIR korando 2010 10 5110 01 6 MAJOR WELDING POINTS 1 Cross Sectional View of Major Panels ...

Page 911: ...07 14 korando 2010 10 5110 01 BODY REPAIR 2 Side Panel ...

Page 912: ...07 15 BODY REPAIR korando 2010 10 5110 01 3 Front Panel ...

Page 913: ...07 16 korando 2010 10 5110 01 BODY REPAIR 4 Apron Panel ...

Page 914: ...07 17 BODY REPAIR korando 2010 10 5110 01 5 Dash Cowl Panels ...

Page 915: ...07 18 korando 2010 10 5110 01 BODY REPAIR 6 Front H Frame Panel ...

Page 916: ...07 19 BODY REPAIR korando 2010 10 5110 01 7 Front Floor Panel ...

Page 917: ...07 20 korando 2010 10 5110 01 BODY REPAIR 8 Rear Floor Panel ...

Page 918: ...07 21 BODY REPAIR korando 2010 10 5110 01 9 Rear End Panel ...

Page 919: ...07 22 korando 2010 10 5110 01 BODY REPAIR 10 Roof Panel ...

Page 920: ...07 23 BODY REPAIR korando 2010 10 5110 01 7 MAJOR BODY DIMENSIONS 1 Under Body Unit mm ...

Page 921: ...07 24 korando 2010 10 5110 01 BODY REPAIR 2 Vehicle Structure Unit mm ...

Page 922: ...07 25 BODY REPAIR korando 2010 10 5110 01 3 Side Structure Unit mm ...

Page 923: ...07 26 korando 2010 10 5110 01 BODY REPAIR 4 Windshield Glass Area Unit mm ...

Page 924: ...07 27 BODY REPAIR korando 2010 10 5110 01 5 Tail Gate Area Unit mm ...

Page 925: ...07 28 korando 2010 10 5110 01 BODY REPAIR 6 Front End Unit mm ...

Page 926: ...07 29 BODY REPAIR korando 2010 10 5110 01 7 Engine Compartment Unit mm ...

Page 927: ...07 30 korando 2010 10 5110 01 BODY REPAIR 8 Back Panel Unit mm ...

Page 928: ...07 31 BODY REPAIR korando 2010 10 5110 01 8 GAP CHART 1 Side Body Unit mm ...

Page 929: ...07 32 korando 2010 10 5110 01 BODY REPAIR 2 Front Unit mm ...

Page 930: ...07 33 BODY REPAIR korando 2010 10 5110 01 3 Rear Unit mm ...

Page 931: ......

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