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SSANGYONG Korando 2013, Manual

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SSANGYONG Korando 2013 Manual Download Page 823

06-6

2. MAJOR CHANGES

Center fascia switch 

▶

Center fascia switch 

- Center fascia switch design and layout changed
- Digital clock switch deleted 

Outside rearview mirror switch 

▶

Outside mirror switch 

- Changed from self-return type to push-lock type

Hazard warning flasher 

switch

TRIP reset switch

Digital clock

Windshield 

heating switch

Rear glass/outside 

rearview mirror 

heating switch

Windshield

heating switch

TRIP reset switch

Rear glass/outside 

rearview mirror 

heating switch

Hazard warning lamp switch

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Page 149: ...01 3 0000 00 Top view Side view Front side Rear view 1 MAJOR DIMENSION Unit mm ...

Page 150: ...ht side in the engine compartment passenger side 3 The certification label is affixed on the bottom of driver side B pillar 30 psi 2 VEHICLE IDENTIFICATION 1 The engine number 671 950 0 2 5000001 is stamped on the lower area of cylinder block in exhaust manifold side ...

Page 151: ...01 5 0000 00 VIN number Engine number ...

Page 152: ...01 6 3 SPECIFICATION Optional ...

Page 153: ...01 7 0000 00 Optional ...

Page 154: ...01 8 Optional ...

Page 155: ...NDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels when adding or replacing the fluids ...

Page 156: ...01 10 5 SCHEDULED MAINTENANCE SERVICES 1 Diesel Engine EU ...

Page 157: ...01 11 0000 00 ...

Page 158: ...01 12 ...

Page 159: ...01 13 0000 00 2 Diesel Engine General ...

Page 160: ...01 14 ...

Page 161: ...01 15 0000 00 ...

Page 162: ...01 16 3 Gasoline Engine ...

Page 163: ...01 17 0000 00 ...

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Page 168: ...01 3 0000 00 Front view Left side view 1 LAYOUT Right side view Rear view ...

Page 169: ...or Coolant temperature sensor IMV valve Magnetic triggering Crankshaft position sensor Vacuum pump Oil filter assembly Camshaft position sensor Power steering pump pulley Water pump pulley Alternator pulley Idler pulley No 1 A C compressor pulley Auto tensioner Idler pulley No 2 Isolation damper Oil pressure switch ...

Page 170: ...ssembly E VGT turbocharger Post CDPF pressure port Oil drain plug Left side 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 Front exhaust gas temperature sensor ...

Page 171: ... hazardous situation which if not avoided may result in minor or moderate injury or property damage However above references and cautions cannot be inclusive measures so should have habits of paying attentions and cautions based on common senses indicates information to assist maintenance and instructions 2 Equipment Korando is FF Front Engine Front Drive type vehicle and engine and powertrain sys...

Page 172: ...asher and self locking nut Replace them with new ones If reused normal functions cannot be maintained Store the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or mix the fasteners If necessary especially for inspection clean the removed parts completely Apply the oil or grease on the running and sliding surfeces before installation Use the spec...

Page 173: ...xhaust system including catalytic converter Inspect all the components and body frame near the exhaust system 4 Tires Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads may indicates the uneven tire inflation pressure or poor wheel balance 5 Steering and suspension system Inspect the front and rear suspension and the steering system for damage ...

Page 174: ...l the inlets with the plugs before removing the engine All the interference should be eliminated before removing the engine 3 Electric devices To prevent any damage to electric systems make sure to disconnect the negative cable from the battery and place the ignition switch to OFF position before servicing Use only the specified parts with same ratings when replacing the electric devices Check the...

Page 175: ...DI engine s fuel system there can be serious damages between HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system When working on the fuel line between priming pump and injector including return line always plug the openings with caps to p...

Page 176: ... UP POINTS Stand jack up points and installation status front side Jack up points for 2 post lift Jack up points for 2 post lift Supporting Jack up points and setup rear side Supporting Jack up points and setup front side ...

Page 177: ...uring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ...

Page 178: ...nt in this behicle Select YES YES FAN 2 relays Select 2 relays FAN Not defind Engine level control NO Engine level control system is not available in this vehicle Select NO YES SKM key NO with Smart key Select YES YES Glow plug Relay K Line AQGS is the standard equipment in this vehicle Select AQGS AQGS CAN A C NO Select the appropriate system YES Not defind Vehicle speed sensor CAN with ABS or ES...

Page 179: ...DURA lever M T M T DC lever DURA lever M T Electric power steering EPS YES Select the appropriate system NO Transfer case 2WD Select the appropriate system AWD E coupling Not defined Sedan Limousine Sedan RV Select Sadan RV Limousine Vehicle code Engine D32DT Select D20DTF D27DT D27DTP D20DTF EAS NO Select NO ECS 2 corner EAS 4 corner EAS Telematics NO Select NO YES Brake NO Select the appropriate...

Page 180: ... the appropriate system YES Transmission type M T Select the appropriate system DC AT DSI AT Vehicle code platform STAVIC Select KORANDO REXTON KORANDO KYRON ACTYON SPORT Not defined ECU coding status ECU not coded Select ECU coded ECU coded Signal not valid Not defined ...

Page 181: ...e 0 1 to 0 35mm Exhaust 0 1 to 0 35mm Camshaft position sensor Distance between Camshaft position sensor and sprocket 0 20 to 1 80mm Valve Clearance between valve and piston Intake Approx 0 7mm Exhaust Approx 0 8mm Valve recess Intake 0 6 to 1 0mm Exhaust 0 6 to 1 0mm Cylinder block Piston protrusion 0 475 to 0 745mm Piston ring TOP ring end gap 0 20 to 0 35mm 2nd ring end gap 0 35 to 0 50mm 3rd r...

Page 182: ...02 4 0000 00 Oil pressure switch Newly added oil pressure switch B instead of oil level switch A 2 MAJOR CHANGES Oil pressure switch ...

Page 183: ...mbly Changed appearance of right hand mounting assembly and its rubber for enhanced NVH performance Changed appearance and material of front rear mounting assemblies rubbers for enhanced NVH performance The mounting appearance has been changed but work procedure is same as the old one 2 4WD 2WD 4WD 2WD 4WD 2WD 4WD ...

Page 184: ...r center bolt M18 50 1 200 20Nm 180 20 660 720Nm Not re usable Oil pan M6 20 18 10 1Nm M6 35 2 10 1Nm M6 85 2 10 1Nm M6 120 2 10 1Nm M8 40 2 25 2 5Nm HP pump main nut M14 1 5 8 1 1 650 5Nm HP pump mounting bolt M8 55 3 25 2 5Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1Nm M8 60 4 25 2 5Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket bolt M8 13 5 1 25 2 5Nm Coolant temperatur...

Page 185: ... return pipe M6 16 turbo side 2 10 1Nm M6 16 block side 2 10 1Nm EGR valve M8 22 3 25 2 5Nm EGR pipe bolt Intake side M6 16 2 10 1Nm EGR pipe bolt EGR cooler side M8 25 2 25 2 5Nm Oil pressure sensor M24 1 Max 50Nm Component Size Quantity Tightening torque Nm Remark Total torque Hot water inlet pipe M6 12 2 10 1Nm Alternator M10 90 1 25 2 5Nm Lower M10 116 1 46 4 6Nm Upper A C compressor M8 85 4 2...

Page 186: ... position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8x25 3 25 2 5Nm Power steering pump M8 100 3 25 2 5Nm Mass balance shaft MBU M8 45 6 30 3Nm Cylinder head front cover M6 10 5 10 1Nm 품명 규격 볼트 수량 규정토오크 Nm 비고 총 토오크 Timing gear case cover M6 40 7 10 1Nm M6 45 1 10 1Nm M6 50 3 10 1Nm Cylinder head cover M6 35 21 10 1Nm Component Size Quantity Tightening torque Nm Remark Total to...

Page 187: ...02 9 0000 00 ...

Page 188: ...02 10 ...

Page 189: ...02 11 0000 00 ...

Page 190: ...02 12 ...

Page 191: ...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 2 Cylinder pressure leakage test If the measured value of the compression pressure test is not within the specifications perform the cylinder pressure leakage test Specified value Perform thi...

Page 192: ...easure how the piston is protruded from the upper side of the cylinder block 3 Piston protrusion check Specified value 0 475 to 0 745mm Measure it at both end positions in the axial direction of the crankshaft ...

Page 193: ... valve 0 6 to 1 0 mm Exhaust valve Measure the cylinder head height A 1 If the height is less than the limit the cylinder head must be replaced Insert the valves into the valve guides and measure the recesses 2 If the measured value is out of the specified range machine the valve seat as much as necessary until the specified value is achieved Valve recess a 0 6 to 1 0 mm 2 Cylinder head pressure L...

Page 194: ...ning and aligning work areas Do not allow the foreign material get into the fuel injection system When removing the engine use only the safety hook on engine and engine hanger Do not support the bottom of oil pan with a jack Engine and accessories Completely drain the engine oil coolant and fuel from engine before removal Before disassembling assembling the engine components carefully read the wor...

Page 195: ...m Do not allow the fluid and engine oil to make contact with the body paintwork and hoses If work on the fluid system such as fuel and oil working area should be well ventilated and smoking should be prohibited Gasket or seal on the fuel lubrication system should be replaced with new ones and bolts and nuts should be tightened as specified After removal installation works be sure to check whether ...

Page 196: ...m which uses single belt 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 ...

Page 197: ...uum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid This pump is single vane type and displacement is 210 cc rev The lubrication oil is supplied through the hole in hollow shaft Components Vacuum pump Pump capacity 210 cc rev Speed 375 to 3 000 rpm Lubrication temperature 40 to 155 C Oil 5W30 Drive type Driven by exhaust Camshaft solt Brake booster ...

Page 198: ...ng 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 train rods and torque reaction Additionally right mounting is hydraulic type and supports the engine vibration Components Left mounting assembly Location Upper side of transfer axle housing and body side member Location Front mounting Loc...

Page 199: ...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 Exhaust manifold Components ...

Page 200: ...LINDER 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 201: ...s 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 202: ...02 24 Vacuum pump drive Intake exhaust Camshafts Camshaft sprocket Finger follower HLA Components Cylinder head Camshaft position sensor HP pump drive gear Cylinder head gasket ...

Page 203: ... is single bush type Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke and lower chain drives oil pump to lubricate the engine And MBU Mass Balance shaft Unit drive gear drives MBU Components Chain lower bush Chain type single bush Chains 60 EA Mechanical type tensioner Operated by internal spring The timing links gold color on the timing chain are aligne...

Page 204: ...02 26 Intake exhaust Camshaft assembly Components Intake Camshaft HP pump drive gear Exhaust Camshaft Connected to vacuum pump ...

Page 205: ...02 27 0000 00 Timing gear cover case TGCC TGCC Oil seal Screw plug ...

Page 206: ...02 28 Mass Balance Unit MBU Fuel HP pump HP pump gear Crankshaft MBU drive gear MBU HP pump drive gear ...

Page 207: ...DTF engine improves the noise and vibration Especially the oil drainage is very easier than before And A C compressor bracket and the oil dipstick tube are mounted on the oil pan Components Oil drain plug Dust cover A C compressor bracket Oil dipstick tube hole ...

Page 208: ...SS BALANCE SHAFT UNIT MBU The balance shaft in MBU Mass Balance shaft Unit improves the NVH performance by decreasing the unbalanced force Components MBU drive gear Mass balance shaft unit Mass balance shaft unit ...

Page 209: ...e 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 starting the engine Wit...

Page 210: ...LOCK 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 211: ...g 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 tank Capacity 57 L Material Plastic Fuel sender Dual ...

Page 212: ...03 4 Part SGN NO Sub Sender Filter Suction port introduced replacing sub sender pre filter 2 MAJOR CHANGES Filter ...

Page 213: ...el 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 4 Clean the engine...

Page 214: ...e 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 components with clean a...

Page 215: ...0 00 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 216: ...k the low pressure and high pressure fuel systems before removing the components To run the system properly the electric system must be intact but for the DI engine the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device 2 Hydraulic system ...

Page 217: ...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 218: ...essure 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 219: ... for high pressure line Tool kit for low pressure line 2 Pre inspection Connections in fuel supply line Fuel level in fuel tank Air in fuel supply line air bubbles in fuel supply line or fuel Fuel leaks from fuel supply line low high pressure line Used the specified Fuel filter contamination ...

Page 220: ...ral 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 221: ...03 13 0000 00 4 Fuel System Check Procedure ...

Page 222: ...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 223: ...utton on the tester to check if the message TEST is displayed If the button is pressed again at 4 seconds after starting engine cranking the highest pressure is displayed on the tester 1 2 The fuel rail pressure value can be checked using a diagnostic device ...

Page 224: ... low pressure test and clean it thoroughly to prevent foreign materials from entering 1 2 Disconnect the key connector for fuel filter connection and connect both connectors to the fuel filter and hose 3 Start the engine and check visually for clogged low pressure fuel system excessive air or air entry If the fuel flow is not sufficient or air is in the fuel repair the leak area 4 5 ...

Page 225: ...urn 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 for 5 seconds Check the flow volume of injector backleak 4 5 If the value is out of the specified range replace the injector Flow volume...

Page 226: ...e hose of the container for measuring backleak to the return nipple of the injector Start the engine again and let the engine idle for 30 seconds Perform backleak test of fuel system with a diagnostic device after 30 seconds 3 4 5 This test consists of 4 cycles and the engine rpm reaches 3 500 rpm for 18 seconds in each cycle Check the amount of backleak collected into the container and confirm th...

Page 227: ...should be over 60 C Check the conditions of sensors and components in fuel system with scan tool Perform the diagnostic test as follows 1 2 3 Select the Vehicle Model and go to Diagnosis Mode Select Pressure Leak Test in Fuel System in Diagnosis Menu If the conditions are OK press Start The pressure leak test procedure is performed in 4 cycles The engine speed goes up to 3 500 rpm and down again f...

Page 228: ...o the fuel rail for test 3 Disconnect the return hose for HP pump and connect the clear hose and connect its the other end to the return port of the fuel rail for test 4 Connect the digital tester connector to the sensor connector of the fuel rail for test Crank the engine 2 times for 5 seconds after removing the IMV connector and fuel rail pressure sensor connector Read the pressure value display...

Page 229: ...ivated to protect the system It reduces the driving force restricts the engine speed rpm and stops engine operation Refer to Diagnosis section in this manual Engine CHECK Warning Lamp 3 The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or major electronic systems of the engine are not working properly As a result the engine s power output may decrease or the engine may...

Page 230: ... open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The below figure shows the clearance between internal operating elements The core elements of fuel system has very high...

Page 231: ... 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 lubrication of pu...

Page 232: ... 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 supply tube Fuel return ...

Page 233: ......

Page 234: ...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 235: ...emperature Engine ECU D20DTF Engine control by various signals High pressure pump Generates the high pressurized fuel and supply it Plunger type HP pump 1 800 bar Vane type transfer pump 6bar Accelerator pedal position sensor Detects driver s intention for speed up down Fuel filter assembly Supply clean fuel fuel heating water separation by priming pump ...

Page 236: ...y the injectors according to the injection signals The injection method is the same with the conventional method Fuel return by backleak which operates the needle valve The major difference is that the fuel return line is connected to the fuel filter inlet port not the HP pump venturi The pressure from the high pressure pump is increased to 1 800 bar from 1 600 bar and the pump is now installed to...

Page 237: ...03 29 0000 00 3 Input Output devices ...

Page 238: ...accelerator pedal depressed driver s will by receiving the electrical signals from the accelerator pedal sensor The mass air flow sensor detects the volume of intake air and sends the value to the ECU The major function of the ECU is controlling air fuel ratio to reduce the emission level EGR valve control by detecting instantaneous air flow change with the signals from the mass air flow sensor Al...

Page 239: ...03 31 0000 00 4 Flow Diagram of Fuel Supply System ...

Page 240: ...03 32 5 Circuit Diagram ...

Page 241: ...e conditions GEN Change every 15 000 km 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 W x H x T Tank material Plastic Molding Efficiency 80 Shorten the service interval under severe conditions such as driving on a dusty...

Page 242: ...ing the intake hoses and pipes which were disconnected to check the system or replace the air cleaner If the intake system is free of any faults check the EGR and PCV oil separator connected to the intake system The figure may be different from the actual engine Therefore read thoroughly below before replacing the parts 2 Abnormal Noise Caused by Poor Tightness of Intake System When the DI engine ...

Page 243: ...ke system is an open circuit system Therefore any malfunction may occur due to dust and dirt Most of the connections consist of hoses so the system cannot withstand high temperature and pressure Also it can be deformed or loosened easily because it is a clamp mounting system Thus when checking the engine basic inspections such as tightened status check and visual inspection for hose etc should be ...

Page 244: ... Engine Control 1 OVERVIEW The intake system for D20DTF engine is equipped with an electric throttle body which includes a flap This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off To be sure to get the optimized swirl in intake manifold the swirl valve and dual type port have been adopted And the improved HFM senso...

Page 245: ...04 7 0000 00 2313 15 HFM Hot Film Air Mass sensor HFM sensor version 6 For more information refer to Chapter Engine Control 2313 01 Air cleaner assembly and resonator ...

Page 246: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM ...

Page 247: ...04 9 0000 00 4 OPERATING PROCESS Work Flow ...

Page 248: ...eates the bowl type squish 2 Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal ...

Page 249: ...efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are dramat...

Page 250: ...04 12 5 CIRCUIT DIAGRAM ...

Page 251: ...05 3 0000 00 1 TROUBLESHOOTING 1 Work Flow ...

Page 252: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 253: ...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 254: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 255: ...00 1 SPECIFICATION Component Item Specification Turbocharger Max expansion coefficient 5 0 Max turbine speed 215 000 rpm Max temperature of turbine housing 800 Weight 7 2 kg E Actuator Operation duty cycle 300 Hz ...

Page 256: ...nute allowing oil to circulate to the turbocharger after the replacement When the engine is stopped abruptly after driving at high speed the turbocharger continues to rotate in condition where the oil pressure is at 0 In such condition an oil film between the journal bearing and the housing shaft journal section gets broken and this causes abrasion of the journal bearing due to the rapid contact T...

Page 257: ...ust gas opening Problems in turbocharger In case where the oil is smeared on only at the exhaust gas outlet section 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 Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and...

Page 258: ...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 negative pressure at the compressor section causing the oilleakage within the center housing a b No problem will occur with the turbocharger if above conditions are found in early ...

Page 259: ...erstand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects In case where oil pan oil pipe has been contaminated oil filter is defected and where adhesive of gaskets has been contaminated into the oil line 1 ...

Page 260: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 261: ...06 9 0000 00 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 262: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 263: ...here 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 level check for ...

Page 264: ...06 12 2 Work Flow for Troubleshooting ...

Page 265: ...06 13 0000 00 ...

Page 266: ...06 14 ...

Page 267: ...06 15 0000 00 ...

Page 268: ...06 16 ...

Page 269: ...ume efficiency Also the exhaust efficiency improves as the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger The E VGT system installed to the D20DTF engine variably controls the passages of the turbine housing to regulate the flow rate of the exhaust gas The actuator of E VGT is a DC motor actuator E Actuator which controls more quickly and precisel...

Page 270: ... 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 1 Features Features Benefits Folding and unfolding of the vane is controlled electrically Easy to get low speed air volume Rapid response time Electric control Improved low speed t...

Page 271: ...ne ECU D20DTF E VGT duty control Accelerator pedal position sensor Transfers accelerating demand to ECU Atmospheric pressure RPM signal HFM sensor Improves the engine power Coolant temperature sensor Operates the VGT according to engine warm up For more information about control logic refer to Chapter Engine Control ...

Page 272: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 273: ...s by controlling the turbine as follows 1 How it Works at Low Speed Normal turbocharger cannot get the turbo effect because the amount of exhaust gas is not enough and the flow speed is slow in a low speed zone but VGT allows the flow passage of exhaust to narrow resulting in increasing the flow speed of exhaust gas and running the turbine quickly and powerfully Therefore as VGT can intake more ai...

Page 274: ...dant exhaust gas can deliver a more increased energy to the compressor The output will increase in submission to the increase of intake air volume Control range Turbocharger driving mechanism Control method Effect Improved performance At high speed Expands the flow passage for the exhaust gas by unfolding the vanes The flow rate is increased due to the expanded passage Increased turbine impeller s...

Page 275: ... Taxi patrol service or delivery service extended idling and excessive driving with low speed Unit Description Specification Oil pump Lubrication system Gear pump forced circulation Type Internal gear Capacity 74 L at 4 000 rpm 3 bar Relief pressure 6 3 bar 0 3 bar Oil filter Type Fulle flow Paper element Engine oil Specified oil Quality class Ssangyong genuine engine oil Total Quartz INEO ECS 5W ...

Page 276: ...07 4 2 MAJOR CHANGES Oil pressure switch 0000 00 Oil pressure switch Newly added oil pressure switch B instead of oil level switch A ...

Page 277: ...nsufficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary 2 Replenishment If the level gets to the lower point open the filler cap on top of the cylinder block and add the genuine oil without exceeding the level of the upper mark Recheck the oil level after 5 minutes Regularly check the engine oil level and add Ssangyong genuine engine oil i...

Page 278: ...nal heat is generated on each lubrication section If this condition persists the bearing can be 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 2 Component Oil pressure switch Engine oil dipstick Oil pan Oil pump Oil filter module Oil cooler ...

Page 279: ...ooling 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 280: ...07 8 1 Operation Flow 2 OPERATING PROCESS ...

Page 281: ...he piston ring on the piston seals the cylinder The oil gets into the clearance in piston ring to secure the sealing for compression pressure and combustion gas 4 Anti corrosion The oil generates the thin film on the surface of components to prevent the material from contacting with air water and corrosive gas 5 Cleaning The oil transfers the residue of material due to friction oxidized substance ...

Page 282: ...al h Antifreeze Type Long life coolant SYC 1025 Mixing ratio water antifreeze 50 50 Cooling fan module Type Electric 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 90 Fully open temperature 100 Valve lift 8mm Capacity...

Page 283: ...proper 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 auxiliary reservoir or tank cap Replace the thermostat Replace the water pump Replace the radiator Replace the auxiliary reservoir or tank cap Cracks on the cylinder block or cylinder head Clogged ...

Page 284: ... MAX and MIN mark on the coolant reservoir Check the coolant level If the level is below the MIN mark immediately add coolant 1 2 Scalding hot coolant and steam could be blown out under pressure which could cause serious injury Never remove the coolant reservoir cap when the engine and radiator are hot Avoid any direct contact of the coolant to the painted body of the vehicle MAX MIN ...

Page 285: ...n Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank Connect the tester to the tank filler and apply pressure 1 4 bar Check all the coolant hoses pipes and connections for leaks when the pressure of the tester drops and replace or tighten if necessary 2 3 4 3 Thermostat Immerse the thermostat into the water Heat the water and check the valve opening...

Page 286: ...se burns by hot steam or water To open the coolant reservoir cap wrap the cap with a wet towel or thick cloth after the engine is cooled down sufficiently If cool water is added to the heated engine the engine or radiator can be deformed The anti freeze in the coolant can damage the painted surface so avoid the contact of the coolant to the painted body The anti freeze and water should be mixed in...

Page 287: ...at 100 and lets the coolant flow to the radiator to maintain the engine temperature 1 SYSTEM DESCRIPTION 1 Overview Coolant reservoir 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 Water pump pulley Impeller vane Sealing ...

Page 288: ...xchange heat with the radiator core fin Coolant temperature sensor Measures the coolant temperature and sends the result to the engine ECU Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core ...

Page 289: ...08 10 3 System Layout ...

Page 290: ...08 11 0000 00 ...

Page 291: ...ICATION Specification HPS EPS Alternator Crankshaft pulley Alternator Pulley 1 2 94 Normal output idling 2200 rpm 70 120 A 70 140A Regulator voltage 14 6 V Brush Length 12 5 mm Wear limit 7 mm Battery Type MF Capacity 90AH ...

Page 292: ...gear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measur...

Page 293: ...ted battery Replace Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace Defective ground of alternator circuit Repair Charge warning lamp does not go off aft...

Page 294: ...09 6 3 Checking Battery ...

Page 295: ...ixing current load capacity and time and varying voltage Determine battery capacity based on the amount of voltage drop when discharging a fixed load capacity 120 A for 5 seconds Connect the tester to the battery and read the display while applying a load for 5 seconds How to read display Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a batte...

Page 296: ...towing hook 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle whi...

Page 297: ... key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the battery surface using a rubber glove and a clean cloth wetted with soapy water If the charge warning lamp on the instrument cluster comes on while driving there is a malfunction in the charge...

Page 298: ...the electrical energy 1 SYSTEM DESCRIPTION 1 Overview The charge system is designed to supply electrical energy to the vehicle while driving and supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according...

Page 299: ... battery charger to the cold battery the amount of current the battery can accept initially is very small As the battery gets warmer it can accept more current Charging capacity Charging a battery with a low capacity charger takes longer time than charging with a high capacity charger Charging status Charging a fully depleted battery takes twice or more as long as charging a half depleted battery ...

Page 300: ...09 12 2 CHARGING OPERATION 1 With Smart Key System ...

Page 301: ...09 13 0000 00 2 Without SMART Key System ...

Page 302: ...09 14 3 CIRCUIT DIAGRAM ...

Page 303: ...09 15 0000 00 ...

Page 304: ...escription Specification Glow plug Rated voltage 4 4 V Maximum temperature 1100 C Operating temperature 1080 to 1100 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 305: ...10 4 GCU Glow plug Control Unit 2 TIGHTENING TORQUE No Name Tightening torque 1 Glow plug 15 1 5 Nm 2 Glow plug control unit bolt 10 1 0 Nm Glow plug ...

Page 306: ...s 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 control unit GCU ...

Page 307: ...10 6 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 308: ......

Page 309: ...10 8 3 Circuit Diagram ...

Page 310: ...10 9 1413 00 ...

Page 311: ...MS voltage Battery voltage 1 2 3 1 Characteristics of temperature and current in AQGS AQGS unit increases the glow plug temperature very rapidly 1 000 C in 2 seconds FET similar to transistor for each cylinder in AQGS unit pre heats the glow plug If the glow plug temperature reaches to target temperature the temperature is controlled by duty ratio 1 2 3 AQGS PWM Control Actual voltage pattern AQGS...

Page 312: ...y the preheating request from the engine ECU before starting The time for pre heating is controlled by the ECU If the input voltage VB is 11 5 V or less GCU supplies the battery voltage for preheating time T1 If the input voltage VB is greater than 11 5 V GCU supplies the voltage of 11 5 V for preheating time T1 The preheating time may vary according to the conditions Input voltage VB V Pre heatin...

Page 313: ...30 seconds Step 1 Step 3 if no cranking signal is received after the step 1 During 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 preheating request from the engine ECU Emergency glow If no CAN signal is...

Page 314: ...10 13 1413 00 Normal operating mode This shows the components of preheating system in the pre heating and the post heating steps ...

Page 315: ...10 14 When there is no engine cranking signal after turning the ignition key ON ...

Page 316: ...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 317: ...switch or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replace Loose corroded or damaged battery cable Repair or replace Faulty starter Starter does not stop Faulty starter Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring gear Replace ...

Page 318: ...or 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 319: ...e engine immediately if it receives the engine cranking request 2 when pressing the Engine Start Stop button 1 2 3 4 5 6 Engine cranking request 1 when pressing the Engine Start Stop button shortly in normal conditions Engine cranking request 2 when pressing the Engine Start Stop button again after first press or when pressing the Engine Start Stp button for more than 3 seconds Engine start during...

Page 320: ...11 7 1461 00 2 With SMART key system ...

Page 321: ...11 8 3 Without SMART key system ...

Page 322: ......

Page 323: ...11 10 2 Circuit Diagram 1 With SMART key system ...

Page 324: ...11 11 1461 00 ...

Page 325: ...11 12 2 Without SMART key system ...

Page 326: ...11 13 1461 00 ...

Page 327: ...ISE indicator comes on according to the working conditions 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 di...

Page 328: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 329: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 330: ...12 6 2 Components Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ECO 4 22 4 82V ...

Page 331: ...ipped vehicle When the desired speed is reached press CRUISE ON 3 switch of cruise control lever The system is readyreadyreadyready to activate the cruise control function To activate the cruise control function push up 1 the ACCEL switch of the cruise control lever Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an ...

Page 332: ...ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 333: ...n release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 38 km h When you push down the cruise control switch RESUME function starts GSL only 1 2 3 4 3 Tap down while the cruise control system is running Push down the DECEL switch of the cruise control lever less than 0 5 second per one...

Page 334: ...se control lever 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 The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 335: ...own the cruise control lever again To cancel the ECO cruise mode while in operation push down the cruise control lever again The ECO cruise mode is canceled and the indicator goes out What is ECO Cruise mode In this mode the smooth acceleration to the set cruise speed can be achieved by optimized fuel consumption Control lever ECO indicator ON Blinking Push down the lever O Push down it again O ...

Page 336: ...8 km h When pushing the ON OFF switch of the cruise control lever When ESP is activated When applying the parking brake while driving When using the clutch in order to shift M T only To cancel the cruise control function pull the cruise switch toward you GSL only 1 2 3 4 5 6 7 Keep the main cruise control switch in the neutral position when not using the cruise control And the cruise control syste...

Page 337: ...eleration pedal intervention DSL only When the cruise control lever is failed DSL only When the brake switch and the brake light switch input signal are implausible 1 2 3 4 And the cruise control system cannot be operated again in driving state In this case you should stop the vehicle and turn off the ignition switch and then turn it on again After you do that you can use the cruise control system...

Page 338: ...Item E EGR valve Motor EGR response time 50 mS Driven by DC motor Valve EGR gas flow rate 120 Kg h Position sensor Sensing type Hall sensor Supply voltage 5V 10 Signal range 5 95 Max current consumption 15mA E EGR cooler Cooling capacity 8 3 kW or more Coolin fin type Wavy fin Coller type U shaped ...

Page 339: ...acity reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decreased Benefits of E EGR valve Improved accuracy and response through electr...

Page 340: ...uxiliary map values EGR pipe Transports the exhaust gas from the EGR cooler and EGR bypass valve to the intake duct E EGR cooler and bypass valve The cooler lowers the high temperature 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 E EGR valve Rece...

Page 341: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 342: ...ompensation 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 E EGR to regulate the opening extent of the EGR valve and sends the feedback to the potentiometer 1 Operating conditions Intake air temperature between 10 and 50 Atmospheric pressure 0 92 bar or more Engi...

Page 343: ...ssion Regulation Euro V Front Area 182 41cm Size DOC 124 X 158 X 78L DPF 124 X 158 X 194L CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 4 2L Material of Filter AT Aluminum Titanium Alloy ...

Page 344: ...turn off the engine while the vehicle is running Do not shift the gear selector lever to neutral when going downhill Do not use improper engine oil or fuel additives Do not drive for a long time when the warning lamp is illuminated Make sure no flammable material such as dry grass or tissue paper contacts with the catalyst filter while the vehicle is parked For the vehicles used in urban traffic d...

Page 345: ...ase 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 When this condit...

Page 346: ...sive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp comes on and the engine power is decreased to protect the system To solve this problem blow soot between the engine and exhaust system several times and erase the related DTC Then check if the same DTC is regenerated again If so check...

Page 347: ...h the oxidation process of CO and HC And the DPF Diesel Particulate Filter collects PM Particle Matter and is regenerated to reduce the quantity of particulates HC and CO But there is a limitation in reducing the emission of exhaust gas for each system so the CDPF which combines these two system is applied ...

Page 348: ...M collected by reading the pressure difference between before and after the CDPF Electric throttle body Regulates the rate of air intake CDPF DOC DPF Front temperature sensor Protects the turbocharger Rear temperature sensor Measures the temperature of fuel combustion 2 COMPONENT Oxygen sensor ...

Page 349: ...emperature exceeds 600 the life of CDPF can be reduced So the amount of fuel post injection is decreased If the temperature drops under 600 the rate of regeneration can be decreased So the amount of fuel post injection is increased Differential pressure sensor This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF Electric throttle va...

Page 350: ...started for regeneration The amount of fuel post injection is controlled by the exhaust gas temperature measured by the rear temperature sensor If the temperature is less than 600 the amount of post injection is increased to increase the regeneration temperature Otherwise the fuel injection amount is decreased or the fuel is not injected When the engine is running with low load the intake air amou...

Page 351: ...lues of before and after the CDPF The pressure difference between before and after the CDPF is measured by the differential pressure sensor If PM is collected in the CDPF the pressure difference between before and after the CDPF exceeds the specified value Rear EGT sensor Measures the temperature of DPF The DPF burns the soot with hot exhaust gases regeneration at around 600 and the rear EGT senso...

Page 352: ...mperature and burns the collected PM at approx 600 C Oxidation DOC When the exhaust gas enters into the CDPF assembly its CO HC and PM are reduced by the redox reaction of the DOC The remaining PM is filtered and collected in CDPF and the temperature of the exhaust gas is increased to between 450 and 500 C 5 OPERATING PROCESS Configuration and principle of operation The exhaust gas passed through ...

Page 353: ...14 13 1114 00 6 OPERATING TEMPERATURE ...

Page 354: ...14 14 7 ELECTRIC CIRCUIT DIAGRAM ...

Page 355: ...ngines diesel and gasoline Problems when using non designated engine oil for CDPF 3 Decreases the life span of engine oil due to accumulated ash in DPF around 30 Decreases the fuel economy due to friction resistance exhaust gas resistance and frequent recycling process of DPF The fule containing high sulfur may cause the same problems 2 Do Not Use the Fuel Containing High Sulfur Producing white sm...

Page 356: ... distance from last generation up to now Display regeneration history distance time stored until now in figure Index 0 4 The regeneration distance time is stored up to the last 5 events in sequence and the oldest one will be deleted if the number of events is exceeded 5 times The currently displayed index value indicates where the regeneration information will be stored in the future and the just ...

Page 357: ... the CDPF automatically when the driving distance reaches about 1 000 km or longer The more high speed driving the greater value is The times of regeneration is displayed cumulatively 23 Times which CDPF re regeneration start is requested 0 When the regeneration should be stopped and started again according to the exhaust gas temperature start condition and vehicle speed during CDPF regeneration t...

Page 358: ...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 selection A T 1 ON ...

Page 359: ...ve Electronic throttle body T MAP sensor Temp Pres Injector C3I Oxygen sensor Front exhaust gas temp sensor Glow plug Knock sensor 2 Oil pressure switch 1 MAJOR COMPONENT Rear exhaust gas temp sensor Camshaft position sensor ...

Page 360: ...15 5 0000 00 Coolant temp sensor HFM air mass temperature Fuel temp sensor Differential pres sensor D20DTF ECU IMV E EGR bypass valve E EGR valve Fuel rail pres sensor GCU Glow plug control unit ...

Page 361: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 362: ...r E EGR valve posi sensor Oxygen 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 ...

Page 363: ...EGR cooler bypass valve 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 SKM TCU Self diagnosis ...

Page 364: ...ectives Operating temperature range of ECU is normally 40 to 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circu...

Page 365: ...ngine 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 coolant temperature b Fuel...

Page 366: ...ing 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 which are liable...

Page 367: ...etermined 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 injected fuel becomes high...

Page 368: ...el 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 chooses the smaller o...

Page 369: ...d when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the fault the system activat...

Page 370: ...f 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 calculated Finall...

Page 371: ...er 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 little vibration and ...

Page 372: ...tablish 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 main injection 1 2...

Page 373: ...naled is a percentage of the maximum possible value of the ratio Because of the severity of the recovery process engine shut down the etection must be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too much Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and ...

Page 374: ...erated 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 eventually the ...

Page 375: ...15 20 b Input Output for variable swirl valve ...

Page 376: ...d creates the bowl type squish d Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizon...

Page 377: ...tion e Features Swirl and air intake efficiency To generate the swirl the intake port should be serpentine design This makes the resistance in air flow The resistance in air flow in engine high speed decreases the intake efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl a...

Page 378: ...o high during strong swirl the injection angles might be overlapped Therefore the system may decreases the fuel injection pressure when the swirl is too strong Anti knock methods Shorten the ignition timing by pilot injection lessen the fuel injection volume during ignition delay period Increase engine speed Maintain intake sir temperature with intercooler or glow plug device Increase intake air p...

Page 379: ...r difference with the previous EURO 4 type is that the DC motor with improved response rate according to the EURO 5 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 e...

Page 380: ...15 25 0000 00 c Input Output of E EGR system ...

Page 381: ...e rpm Used as the signal for determining EGR operating range Coolant temperature When the coolant temperature is low NOx is decreased but PM could be increased So to reduce PM decrease EGR ratio when the coolant temperature is low Intake air mass and temperature HFM sensor measures the intake air mass to calculate the actual EGR volume If the air mass is larger than programmed value in map EGR rat...

Page 382: ...rdingly 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 383: ... Turbine turbocharger system in D20DTF engine uses the venturi effect that controls the flow rate of exhaust 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 C...

Page 384: ...15 29 0000 00 c Input Output for E VGT system ...

Page 385: ...r operation and the boost temperature is used for calculating the precise density E VGT provides higher engine power with faster reaction speed compared to conventional VGT Operating wave Vane Control Low speed range In low speed range retract the vane to increase boost pressure The vane has low duty and the unison ring moves to retract the vane in weak PWM signal High speed range The unison ring ...

Page 386: ...rent from the one that used for gasoline engine The combustion in diesel engine is controlled by fuel injection volume Therefore the wide band oxygen sensor should be used in diesel engine This sensor measures the air fuel ratio in very wide range and is also called full range oxygen sensor The wide band oxygen sensor measures the oxygen density in exhaust gas and sends it to ECU to control the EG...

Page 387: ...15 32 c Input Output for oxygen sensor ...

Page 388: ...en 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 389: ...s in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools The heat from automatic 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 th...

Page 390: ...15 35 0000 00 c Input Output for cooling fan and A C compressor ...

Page 391: ...8 bar Refrigerant pressure HI 105 Coolant temp 115 HI 115 Coolant temp OFF cut A C compressor OFF conditions Coolant temperature below 20 or over 115 Approx 4 seconds after starting the engine Engine rpm below 650 rpm or over 4500 rpm When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 30 kg then ON below 21 4 kg The output voltage from refrigerant pressure ...

Page 392: ...o two temperature values measured at the coolant temperature sensor 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 ...

Page 393: ...perature 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 394: ...rature 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 395: ...d prevents it from being started by unauthorized 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 compone...

Page 396: ...CU 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 397: ...15 42 Smart key slot Smart key Start motor Meter cluster BCM SKM D20DTF ECU c Components for immobilizer with Smart key system Components For antenna refer to Chapter SKM ...

Page 398: ...ot to check if it has valid crypto code If it is valid ECU start to control the engine when pressing the Engine Start Stop button 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 Smart key approval When pressing the Engine Start Stop button or depressing the brake pedal without Smart key inserted into the k...

Page 399: ... engine the low emission vehicle is getting popular This vehicle is equipped 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 ...

Page 400: ...15 45 0000 00 c Input Output for CDPF control ...

Page 401: ... pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is accumulated and the post injection is performed to raise the temperature of exhaust gas The amount of fuel injected is determined according to the temperature of exhaust gas detected by the rear temperature sensor If the temperature is below 600 C the amount o...

Page 402: ...cumulating 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 life of filter may...

Page 403: ... 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 SKM Smart Key Module TPMS Tire Pressure Monitering S...

Page 404: ...Glow Control Unit S102 W H Floor RH Inside RH Fender S202 Main wiring Backside Cluster LH Cowl Cross Member S204 Main wiring Backside Cluster Upper ICM Relay Box S205 W H Main Backside Audio CTR Cowl Cross Member S206 W H Floor LH Under Driver Seat S401 W H Floor LH Beside PAS Unit Inside LH QTR Trim ...

Page 405: ...15 50 3 Input Output for CAN communication ...

Page 406: ...01 3 0000 00 Right side view Left side view Rear view Front view 1 LAYOUT ...

Page 407: ...ater pump pulley A C compressor Crankshaft pulley Oil pan assembly Rear View Camshaft position sensor Breather nipple Purge control solenoid valve Coolant temperature sensor Electronic throttle body T MAP sensor MCC complete VIS solenoid valve Cylinder head cover Dual mass flywheel Crankshaft position sensor Hydraulic tensioner assembly ...

Page 408: ...ld Heat protector Front oxygen sensor WCC complete Crankshaft pulley Oil pan drain plug Rear oxygen sensor Coolant outlet port Injector assembly Fuel rail T MAP sensor Purge control solenoid valve Electronic throttle body VIS solenoid valve Oil dipstick gauge Oil filter assembly Thermostat assembly Oil pressure sensor ...

Page 409: ...is manual and follow the instructions carefully Signal words such as WARNING CAUTION and NOTE have special meanings indicates information to assist maintenance and instructions However above references and cautions cannot be inclusive measures so should have habits of paying attentions and cautions based on common senses indicates a potentially hazardous situation which if not avoided may result i...

Page 410: ...tained Store the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or mix the fasteners If necessary especially for inspection clean the removed parts completely Apply the oil or grease on the running and sliding surfeces before installation Use the specified sealant and gasket to prevent leakage if necessary Tighten the fasteners to the specified...

Page 411: ...xhaust system including catalytic converter Inspect all the components and body frame near the exhaust system 4 Tires Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads may indicates the uneven tire inflation pressure or poor wheel balance 5 Steering and suspension system Inspect the front and rear suspension and the steering system for damage ...

Page 412: ...t can be caused by mistakes during service and to provide the optimized performance and safety after service works the service technicials must keep the basic cautions and service guidelines below These could be easily forgotten during service works Engine has a lot of precise components The specified tightening torque and correct procedures should be kept during service works And the working area...

Page 413: ...ints and setup rear side Jack up points and setup front side 2 JACK UP POINTS Stand jack up points and installation status front side Jack up points for 2 post lift Jack up points for 2 post lift Supporting Supporting ...

Page 414: ...ue 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 Plastics Tighten to 20...

Page 415: ... I MIL treatment OBD II MIL treatment E OBD MIL treatment KOBD Engine E20 Select E20 E23 E28 E32 E36 Body Sedan Select Sedan Limousine 4 CODING 1 Variant Coding Description Selection Coding Unleaded leaded Unleaded Select the appropriate system Leaded Cruise control No system Select the appropriate system Cruise control ACC Undefined Vehicle speed Max 180kph Selec 190kph 190kph 200kph 210kph Tire ...

Page 416: ...ect lever BTRA lever M T M T lever A T DURA lever DC lever DURA lever M T lever EPB Not equipped Select Not equipped Equipped Enable RON conection RON 89 Select RON 95 RON 91 RON 93 RON 95 RON 97 RON 98 RON 100 Not defined MIL MIL not illuminate Select MIL illuminate MIL illuminate Engine fan Relay Select Relay PWM Coding is completed NO Select YES YES ...

Page 417: ...hicle Chairman Select KORANDO C W200 REXTON Musso Kyron KORANDO C KORANDO old Actyon Sport Vehicle code transmission M T M T M T A T NAGI HPT NAGI HPT BTRA A T ION 6 speed A T NAG2 A T TPMS Not equipped Select the appropriate system Equipped EBS ABS ESP Not equipped Select the appropriate system ABS TCS ESP Telematics Not equipped Select Not equipped Equipped ...

Page 418: ...01 15 0000 00 Description Selection Coding EAS Not equipped Select Not equipped ECS 2 Corner EAS 4 Corner EAS Domestic Export Domestic Select the appropriate system General export EU export ...

Page 419: ...meter Coding Parameter Range Remark Fuel characteristic 1 6 Idle RPM P 50 127 Idle RPM D 50 127 CO correction 6 945 6 8907 Pedal progress coding 1 3 Idle RPM P cold condition 50 127 Idle RPM D cold condition 50 127 ...

Page 420: ... play Intake 0 1 0 35 mm Exhaust 0 1 0 35mm Valve timing Intake valve open BTDC 35 10 Intake valve close ABDC 14 62 Exhaust valve open BBDC 40 40 Exhaust valve close ATDC 12 12 Journal bearing Diameter 24mm Width 17 mm Oil clearance 0 037 0 074 mm Intake exhaust valve Lift of intake valve Max 9 0 mm Lift of exhaust valve Max 8 0 mm Length of intake valve 115 0mm Length of exhaust valve 114 0mm Con...

Page 421: ...1 0 X 30 20 10 1 0 Nm Crankshaft center bolt M18 X 1 5 X 50 1 200 20 Nm 90 10 Flywheel bolt M10 X 1 0 X 22 8 45 5 Nm 90 10 Connecting rod bolt M9 X 1 0 X 52 8 40 5 Nm 90 10 Cam Cap bolt 1 M6 X 1 0 X 35 4 10 1 0 Nm Cam Cap bolt 2 5 M6 X 1 0 X 30 16 10 1 0 Nm Solenoid valve bolt M5 X 0 8 X 22 1 8 1 Nm Intake manifold bolt M8 X 1 25 X 32 5 25 2 5 Nm 2 TIGHTENING TORQUE Name Size Quantity Tightening t...

Page 422: ...ner lower bolt M10 X 1 5 X55 1 65 5 Nm Water pump pulley bolt M6 X 1 0 X12 4 10 1 Nm Thermostat bolt M6 X 1 0 X22 3 10 1 Nm Coolant outlet port bolt M6 X 1 0 X22 3 10 1 Nm Coolant pipe mounting bolt M6 X 1 0 X14 3 10 1 Nm Bypass hose clamp M24 2 3 0 5 Nm EPS idler pulley 1 25 2 5 Nm Engine mountinf stud bolt 2 50 5 0 Nm Engine front mounting bolt M10 X 45 3 60 6 0 Nm Engine front mounting bolt M10...

Page 423: ...e stand and engine crane 1 ton To prevent the engine from abruptly starting during service in engine compartment never allow anybody to stay in the vehicle Make sure to disconnect the negative cable from the battery to prevent any damage to electric systems Make sure to clean the working area and to prepare the necessary tools before service works Always place the ignition switch to OFF position i...

Page 424: ...F use the angle tightening as a final step 1 Clean the mating surfaces before tightening 2 Place the marks with paint to tighten by angle if the angle wrench is not available Exhaust system Wear the protective gloves before removing the exhaust pipe The exhaust pipe is very hot immediately after stopping th engine Check if the exhaust pipe is fully cooled down before servicing the exhaust system C...

Page 425: ...Used engine cotains the hazardous material that may cause the skin cancer Do not allow the used engine to make contact with your skin Make sure to wear the protection gloves and goggle when handling the engine oil If contact happens rinse affected areas immediately with plenty of water Do not wash it with gasoline or solvent If irritation persists consult a doctor Improperly disposed engine oil ca...

Page 426: ...elt Overview There are two types of belt system EPS Electric Power Steering and HPS Hydraulic Power Steering In the vehicle with ESP instead of power steering pulley the idle pulley is installed on the engine The belt system is a single belt drive system which uses single V belt with 6 grooves This design provides the long life span and minimizes the belt slip and noise Components With idle pulley...

Page 427: ...spring hydraulic damper lever arm and tension pulley To transfer the tension to the belt from the hydraulic tensioner in small working space in G20DF engine the belt system uses the longer lever arm Overview Location and Components Hydraulic tensioner assembly Components No Name 1 Tensioner pulley cap 2 Tensioner pulley mounting bolt 3 Tensioner pulley 4 Lever arm 5 Hydraulic tensioner bolt 6 Hydr...

Page 428: ...nsioner automatically adjusts the belt tension to provide the reliability and durability for the system And the belt tension is decreased to minimize the friction loss and improve the belt operating noise Overview Location Crankshaft pulley CRS Timing mark ...

Page 429: ...ounting Right mounting assembly Location Engine block side and body side member Location Right mounting Left mounting assembly Location Upper side of transaxle housing and body side member Location Left mounting Rear mounting assembly Location Rear side of transaxle housing and front side of sub frame Location Rear mounting ...

Page 430: ...Bracket Insulator Type Rubber type mounting Function support torque reaction Left mounting Bracket Insulator Type Rubber type mounting Function support power train rod support torque reaction Rear mounting Bracket Insulator and D damper Type Hydraulic type mounting Function support power train rod power train bounce vibration absorber support torque reaction ...

Page 431: ...inder block This contains the combustion chamber intake and exhaust ports valve running housing and oil gallery And this also contains the water jacket to dissipate the heat from the combustion chamber Location Top of cylinder head Bottom of cylinder head Intake side Exhaust side ...

Page 432: ...02 15 1211 01 Closed roof water jacket improving coolimg efficiency Intake side Exhaust side Cylinder head oil gallery ...

Page 433: ...02 16 Components Exhaust camshaft OCV Finger follower HLA Intake camshaft Intake camshaft CVVT gear Camshaft position sensor ...

Page 434: ...thing system with PCV valve for recirculation of blow by gas The blow by gas is induced into the intake manifold through the breather nipple and PCV Valve To improve the sealing performance new bolt pattern is introduced And to prevent the freezing the PCV valve is tilted with 9 to the below direction Location Breather nipple PCV valve ...

Page 435: ...tains the cam octagon cam OCV gallery cam position rotor The camshaft operates the intake and exhaust valves Location Exhaust camshaft Intake camshaft Timing marks Align the timing marks A on the camshaft flange and camshaft cap when installing the intake exhaust camshaft ...

Page 436: ...y introducing the roller type finger follower Valave installation angle 17 Decreased running amount by compact design increased valve following movement in high speed and improved fuel economy by decreased friction loss 2 Layout and components Intake camshaft assembly Exhaust camshaft assembly Valve stem seal Valve upper spring seat Valve guide Hydraulic lash adjuster Exhaust valve assembly Valve ...

Page 437: ...head gasket is installed between cylinder block and cylinder head to seal the combustion gas from the combustion chamber engine oil and coolant Overview Location Cylinder head gasket 3 Layer MLS Gasket Thickness 0 7 mm Compressed PFP Max 85 bar ...

Page 438: ...e and operated by hydraulic pressure and spring in tensioner Timing chain Chain type Silent chain type Links 146 ea Tensioner rail Installed between exjaust camshaft sprocket and crankshaft sprocket Crankshaft sprocket Teeth 21 ea Oil pump sprocket Teeth 28 ea Exhaust camshaft sprocket Teeth 42 ea Intake camshaft sprocket CVVT Teeth 42 ea OCV Controls the hydraulic circuit to control the intake ca...

Page 439: ...tion Shielding the chain noise Timing gear case cover prevents the oil from leaking The crankshaft front seal and the engine mounting bracket are installed on the timing gear case cover Timing gear case cover Do not touch the inner lip of crankshaft front seal installed on the timing gear case cover ...

Page 440: ...chain tensioner In G20DF engine the hydraulic auto tensioner is used to keep the tension for chain drive system of engine The auto tensioner is operated by the spring in tensioner and the hydraulic pressure 2 Hydraulic Auto Tensioner Oil gallery ...

Page 441: ...02 24 3 Oil Pump Chain Tensioner Layout and Location Oil pump chain tensioner Operated by spring in tensioner Tensioner type Compensating and absorbing the impact Static and dynamic force spring ...

Page 442: ... A Timing chain B Oil pump chain 4 Timing Chain and Gear Timing chain Simple layout provides the optimized timing Decreased chain vibration and noise Single stage layout minimized chain load Teeth 146 ea Teeth 58 ea ...

Page 443: ...nd reduces the chain wear The chain rail is normally made of PA Polyamide nylon and PA66 and PA46 are used for the chain rails in G20DF engine For the tensioner rail PA46 is used to provide high anti wear function and high strength since the load to the rail is huge Ther is an open area for shoulder bolt hole in the clamping rail The chain rails are installed by shoulder bolts Tensioner rail Insta...

Page 444: ... the engine to the powertrain system Additionally DMF decreases the rattling noise in transaxle and the vehicle vibration by reducing the differences of torque and rotational speed due to the combustion in engine The drive plate initially drives the powertrain system by using the power from the start motor when starting the engine The drive plate is installed on the crankshaft and is engaged to th...

Page 445: ...ularity increases more less pulsation absorbing effect Transaxle protection function Reduces the torsional vibration to powertrain transaxle by reducing the irregularity of engine Compression stroke Combustion stroke Small changes from engine k Damper increases the torque changes to clutch Large changes from engine j Damper decreases the torque changes to transaxle by absorbing the impact Torque c...

Page 446: ...response by using 2 stage type spring Strengthens the torque response in all ranges low medium and high speed by applying respective spring constant at each range Stable revolution of the primary and secondary wheel by using planetary gear Works as auxiliary damper against spring changes Less heat generation due to no direct friction against spring surface Plastic material is covered on the spring...

Page 447: ...piston pin and snap ring The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy Overview Layout and Components Top Bottom Oil ring Piston ring No 1 ring Piston pin No 2 ring Snap ring Piston ...

Page 448: ...er 2 ring Scrapes the engine oil on the cylinder bore and prevents the leaked combustion gas from 1 ring from leaking into the crank chamber Oil ring Scrapes the engine oil on the cylinder bore B Piston pin Connects the piston the connecting rod and transfers the linear movement of piston to connecting rod to convert it to rotating energy Piston ring Piston ring end gap mm 1 end gap 0 170 0 320 2 ...

Page 449: ...stall the piston rings with the X mark on the ring facing upwards Position the end gap of 1 ring at 180 away from the end gap of 2 ring Position the end gap of oil ring at 180 away from the end gap of coil spring and position the end gap of oil ring at 90 away from the end gap of 2 ring 1 cylinder ...

Page 450: ...ement of crankshaft The big end is connected to connecting rod bearing and the crank pin journal and the small end is connected to the piston pin Components Connecting rod Piston pin bush Connecting rod Connecting rod upper bearing Connecting rod lower bearing Connecting rod cap Connecting rod cap bolt A B C D E F ...

Page 451: ...ection of connecting rod bearing Select the bearing shell combination according to the table below Conrod_UPR Grade Conrod_LWR Grade Clearance Red Blue 0 005 0 050 Yellow Yellow 0 005 0 050 Blue Red 0 005 0 050 ...

Page 452: ...02 35 1130 01 Overview Crankshaft is installed on the cylinder block The crankshaft converts the reciprocative movement of piston to the rotatinal movement Layout and Components Crankshaft ...

Page 453: ...별 베어링 선택 Pin punch mark Color Diameter of crankshaft main journal in cylinder block mm Blue 62 500 62 506 Yellow 62 506 62 513 Red 62 513 62 519 Mark Color Diameter of crankshaft main journal mm B Blue 57 960 57 965 Y Yellow 57 955 57 960 R Red 57 950 57 955 W White 57 945 57 950 V Violet 57 940 57 945 Engine name Main journal bearing 1 2 3 4 5 G 2 0 D F R R W W R ...

Page 454: ...is made of special cast iron and contains the major components such as cylinder head crankshaft and piston assembly There are oil and coolant galleries to lubricate and cool the engine Components Plug screw water jacket plug 70Nm Expansion plug intake 4 Spring pin A C mounting Oil gallery oil filter assembly Ctankshaft position sensor mounting Plug screw oil gallery plug Spring pin RR seal mountin...

Page 455: ...ngine oil Coolant Coolant and oil flows Cylinder head Cylinder block water jacket Coolant pump Coolant pipe Thermostat Supply line to cylinder head Oil pump Supply line to PCJ Main bearing Oil filter assembly ...

Page 456: ...ilter type Dry filter element Filtering area 0 225 m Service interval Clean every 7 500 km Change every 15 000 km Air cleaner assembly Weight 1 45 kg Operating temperature 25 Capacity 7L Shorten the service interval under severe conditions such as driving on a dusty road or offroad ...

Page 457: ...04 4 2 LAYOUT Intake Manifold Assy Bolt T MAP sensor Bolt Intake Manifold Brkt 1 2 3 4 5 Bolt Electric Throttle Body Bolt Acoustic Cover 6 7 8 9 ...

Page 458: ... Insulator Collar Spring Clamp Resonance Duct Resonance O Ring Air Cleaner MTG NO 1 Air Cleaner MTG Bolt 1 3 5 6 7 8 9 10 11 Snorkel Assy Water Portector Resonator Assy RR Fascia MTG Screw Rivet Bolt Nut Screw Air Cleaner to Engine Hose Assy 12 13 14 17 18 19 20 21 ...

Page 459: ...oduced in the intake manifold It provides the Long Runner in low speed and the Short Runner in high speed And to reduce the internal pulsation in the intake manifold the Runner 1 and 2 are located in symmetry position with Runner 3 and 4 To reduce the air resistance the throttle body is tilted b 2 COMPONENTS VIS solenoid valve ...

Page 460: ...04 7 0000 00 Purge control solenoid valve Blow by hose PCV valve Electronic throttle body Air cleaner element ...

Page 461: ...04 8 When Long Runner is operating When Short Runner is operating 3 OPERATING PROCESS Intake air flows ...

Page 462: ...04 9 1740 01 4 INPUT OUTPUT DEVICES ...

Page 463: ...04 10 5 CIRCUIT DIAGRAM ...

Page 464: ...soline Fuel injection MPI Muilt Point Injecter type Fuel supply Returnless Fuel System Fuel tank Capacity 57 L Material Plastic Fuel sender Dual sender type Fuel filter Service interval Change every 100 000 km Fuel pump Pressure 3 8 bar Injector Color Black Capacity 187 2 g min ...

Page 465: ...sy Heat shield assy Sub sender assy Main fuel pump assy Fuel filler assy Fuel filler cap assy Feed tube assy Return tube assy 1 3 4 5 6 7 8 9 10 Suction tube assy Harness wiring assy Fuel pump plate cover O ring clamp Nut Nut Screw 11 12 13 14 20 21 22 23 ...

Page 466: ...03 5 2221 01 Fuel Filter Assy Bolt Fuel Return Pipe Fuel Supply pipe Fuel Vapor Pipe Assy Canister Compl Fuel line Holder Fuel line Holder 1 2 3 4 6 9 14 15 ...

Page 467: ... controls the fuel injection in each injector electronically According to the engine loads the engine ECU draws or cuts off the evaporated gas in canister into the combustion chamber The fuel system consists of fuel tank fuel lines fuel pump and fuel pressure regulator Fuel supply line to sub tank Fuel return line Fuel supply line Maintain 3 8 bar ...

Page 468: ......

Page 469: ...03 8 Fuel pump and fuel sender assembly 2 COMPONENTS Canister Fuel filter Fuel tank assembly Primary fuel sender Fuel tank assembly Fuel neck hose Canister Fuel filter ...

Page 470: ...03 9 2221 01 Engine ECU Engine compartment Injector Purge control solenoid valve Fuel rail Secondary fuel sender ...

Page 471: ...03 10 3 SCHEMATIC DIAGRAM OF FUEL FLOWS ...

Page 472: ...ates the accelerator pedal based on the input signals from various sensors and controls the overall operation of the vehicle The ECU receives the signals from various sensor through data line and performs effective airfuel ratio control based on these signals ...

Page 473: ...05 3 1745 01 1 TROUBLESHOOTING ...

Page 474: ...05 4 2 LAYOUT Exhaust Manifold Assy Exhaust Manifold Gasket Hex Flange Nut Heat Protector Assy Hex Bolt M6 X 1 X 25 Heat Protector Assy Hex Bolt M8 X 1 25 X 16 1 2 3 4 5 6 7 ...

Page 475: ...ssy UCC Compl Muffler Complete RR Exhaust FRT Heat Protector CTR Muffler Heat Protector RR Muffler Heat Protector Clamp Gasket 1 2 3 4 5 6 7 8 9 Hanger Hanger Hanger Nut Nut Bolt Gasket Ring Nut CTR Muffler Complete 10 11 12 13 14 15 16 19 20 ...

Page 476: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 477: ...ondition For detailed description see the corresponding section The fuel evaporative gas is a gas evaporated to the atmosphere in the section between the fuel tank and fuel line and its main component is hydrocarbon HC The fuel evaporative gas is temporarily stored in the canister and it is drawn to the engine through the throttle body when the purge control solenoid valve is open according to the...

Page 478: ...05 8 PCV valve 2 COMPONENTS Engine ECU WCC Engine CHECK lamp Blow by hose Exhaust manifold ...

Page 479: ...05 9 2414 00 Rear oxygen sensor Exhaust No 2 Exhaust No 1 Exhaust No 3 main muffler UCC Front oxygen sensor ...

Page 480: ...05 10 3 WORK FLOW IN EXHAUST SYSTEM ...

Page 481: ...05 11 1745 01 4 INPUT OUTPUT DEVICES ...

Page 482: ... 7 kΩ Center electrode Iridium alloy Ground electrode Platinum alloy Electrode clearance 1 1 mm Change interval 160 000 km Ignition coil Primary operating current 7 0 5A Generated voltage primary secondary Max 400 V 5 20 kV Ignition type Independent ignition type Ignition sequence 1 3 4 2 ...

Page 483: ...06 4 2 LAYOUT Ignition Coil Bolt Spark Plug 1 2 3 ...

Page 484: ...ned by the signals from camshaft position sensor and crankshaft position sensor This ignition system controls the electronic ignition timing received from the engine ECU To control the ignition timing precisely the ECU use the information below Engine load Coolant temperature Intake air temperature Engine rpm Camshaft position sensor CPS Crankshaft position sensor CKS If the signal from the camsha...

Page 485: ...06 6 2 COMPONENTS Ignition coil Camshaft position sensor Knock sensor Injector Spark plug ...

Page 486: ...06 7 1443 01 Electric throttle valve T MAP sensor Accelerator pedal position sensor Coolant temperature sensor Engine ECU Crankshaft position sensor ...

Page 487: ...06 8 3 INPUT OUTPUT DEVICES ...

Page 488: ......

Page 489: ...06 10 4 CIRCUIT DIAGRAM ...

Page 490: ...06 11 1443 01 ...

Page 491: ...sary Remember to check the engine oil level and shorten the cycle to replace the engine oil under severe driving conditions The engine oil filter element should be changed at the same time with the engine oil Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountaino...

Page 492: ...ax Min 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 Operating vehicle with insufficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary Regularly check the engine oil level and add S...

Page 493: ...Pump Assy Seal Ring Oil Pan Bolt Drain Plug Bolt Oil Pump Chain Oil Pump Chain Tensioner Assy 1 6 8 10 11 21 22 24 Bolt Oil Dipstick Tube Assy Oil Dipstick Gauge Assy O Ring Bolt O Ring Sealant Dust Cover 25 31 32 33 34 37 44 45 ...

Page 494: ...07 6 Oil Filter Assy Oil Filter Cover Oil Filter Element Kit Drain Plug 1 2 9 10 O Ring Oil Filter Bypass Valve Assy Oil Filter Housing Gasket Bolt Oil pressure switch 11 26 30 31 35 ...

Page 495: ...uns frictional heat is generated on each lubrication section If this condition persists the bearing can be 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 2 COMPONENTS Engine oil dipstick Oil jet Engine oil pan Oil pump Oil filter module ...

Page 496: ... 8 1 Operation Flow 3 OPERATING PROCESS CVVT Cam journal bearing Main oil gallery in cylinder block Oil pressure switch Oil filter assembly Oil supply Oil pump Main journal bearing Chain tensioner Oil jet ...

Page 497: ...low type Cross flow Antifreeze Type SYC 1025 LLC Mixing ratio 50 50 water antifreeze Cooling fan module Type Electric Capacity 180 W 120 W Control type Series low speed Parallel high speed Coolant reservoir Min capacity 1 6 L Circulation Closed roof type Pressure cap Screw type 1 4 bar Thermostat Type Wax pallet type Opening temperature 90 Fully open temperature 100 Valve lift 8mm ...

Page 498: ...he thermostat sealing Coolant leakage 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 ...

Page 499: ... temperature is too low Thermostat is stuck open Replace the cooling fan or repair the related circuit Improper operation of cooling fan Replace the sensor or repair the related wiring Defective temperature sensor or faulty wiring Change the thermostat ...

Page 500: ...and MIN mark on the coolant reservoir If the coolant level is below the MIN mark immediately add coolant A B Coolant reservoir MAX MIN 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 ...

Page 501: ... burn Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank Connect the tester to the tank filler and apply pressure 1 4 bar Check all the coolant hoses pipes and connections for leaks when the pressure of the tester drops and replace or tighten if necessary B C D 3 Thermostat Immerse the thermostat into the water Heat the water and check the valve ope...

Page 502: ...urns by hot steam or water To open the coolant reservoir cap wrap the cap with a wet towel or thick cloth after the engine is cooled down sufficiently If cool water is added to the heated engine the engine or radiator can be deformed The anti freeze in the coolant can damage the painted surface so avoid the contact of the coolant to the painted body The anti freeze and water should be mixed in pro...

Page 503: ...er Pump Assy Bolt Water Pump Pulley Bolt Thermostat Assy Bolt Coolant Outlet Port Assy Bolt 1 2 3 4 7 8 9 10 Coolant Pipe Assy Bolt Bypass Hose Clamp Deaeration Pipe Assy Bolt Bolt Deaeration Hose Clamp 11 12 13 14 15 16 17 18 ...

Page 504: ...08 10 Cooling Radiator Assy Fan Shroud Assy Cover Radiator Seal Side Screw 1 2 3 4 5 Insulator Module MTG LWR Module MTG UPR Brkt Assy Screw Protector Eroom Hot Air Screw Fastener 7 8 9 10 11 12 ...

Page 505: ...d Hose Assy Deaeration Rsvr Hose Assy Deaeration Eng Clip Deaeration Tube mtg WDT_Spring_Clamp_M45 WDT_Spring_Clamp_M50 1 2 3 4 5 6 7 8 9 WDT_Clamp_M24 WDT_Clamp_M30 Clip_Closed_CT_M25 Bolt Tapping Clamp_Spring_M14 Screw Tank Assy Reservoir Cap Reservoir Tank 10 11 12 13 14 15 16 17 ...

Page 506: ...each area of the engine Coolant reservoir 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 1 OVERVIEW The coolant system is to keep the engine temperature stable 2 COMPONENTS ...

Page 507: ...and sends the result to the engine ECU Radiator Radiates the heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core PWM fan Circulates the fresh air forcibly to exchange heat with the radiator core fin Coolant outlet port ...

Page 508: ...08 14 3 COOLANT FLOW DIAGRAM Heater return Water pump Thermostat Bypass ...

Page 509: ...8 15 2112 01 Coolant outlet port to radiator to water pump bypass to cabin heater to coolant reservoir Coolant temperature sensor mountinh boss from cylinder head Gasket A B C D E F G Coolant outlet port ...

Page 510: ...TION Unit Description Specification Alternator Type HPS EPS Crankshaft pulley Alternator pulley 1 2 66 Normal output idle 2200rpm 70 140A Regulator voltage 12V Brush Length 12 5mm Wear limit 7 0mm Battery Type MF Capacity 90AH ...

Page 511: ...09 4 2 LAYOUT 1 Alternator Alternator assembly Bolt 1 2 ...

Page 512: ...able assembly Cable positive Cable assembly Battery ground Bolt Earth Cap Terminal Connector Battery 1 2 3 5 6 8 9 10 Nut Nut Cab Earth Box assembly Battery sub Fuse MID 80A Clamp Battery cable Grommet Ring terminal Grommet Ring terminal 17 18 20 21 22 23 24 25 ...

Page 513: ...ear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measure...

Page 514: ... Replace Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace Defective ground of alternator circuit Repair Charge warning lamp does not go off after starting...

Page 515: ...09 8 2 Battery Inspection ...

Page 516: ...t 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 Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a battery charger Green area Normal Red...

Page 517: ...ok 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle while accele...

Page 518: ...he terminals are corroded clean them with a wire brush or sandpapers Always disconnect the battery cables with the ignition key removed When disconnecting the battery cables with the ignition key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the ...

Page 519: ...constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change Body ground B wiring Alternator The alternator charges the battery and supplies power to each electric ...

Page 520: ...09 13 1452 01 2 CHARGING OPERATION 1 Vehicle without Smart key system ...

Page 521: ...09 14 2 Circuit Diagram ...

Page 522: ...09 15 1452 01 ...

Page 523: ...11 3 1462 01 1 SPECIFICATION Unit Description Specification Start motor Capacity 12V 1 4kw Engagement Meshed type Rotating direction Clockwise Solenoid operating voltage Max 8V Weight 2 5kg ...

Page 524: ...11 4 2 LAYOUT Starter Bolt 1 2 ...

Page 525: ...h 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 Repair or replace Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring ...

Page 526: ...otor 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 ...

Page 527: ...11 7 1462 01 2 OPERATING PROCESS ...

Page 528: ...11 8 3 CIRCUIT DIAGRAM ...

Page 529: ...11 9 1462 01 ...

Page 530: ...ISE indicator comes on according to the working conditions 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 di...

Page 531: ...den change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roads yy Do not use in heavy traffic yy Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries The described speed value may vary slightly depending on the road conditions ...

Page 532: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 533: ...12 6 2 Components Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DES RES 0 7 1 1V ACC SET 1 6 2 0V CANCEL 2 52 2 92V ECO 4 22 4 82V ...

Page 534: ...ipped vehicle When the desired speed is reached press CRUISE ON 3 switch of cruise control lever The system is readyreadyreadyready to activate the cruise control function To activate the cruise control function push up 1 the ACCEL switch of the cruise control lever Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an ...

Page 535: ...ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 536: ...n release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 38 km h When you push down the cruise control switch RESUME function starts GSL only 1 2 3 4 3 Tap down while the cruise control system is running Push down the DECEL switch of the cruise control lever less than 0 5 second per one...

Page 537: ... of Set Speed RESUME To cancel the cruise control function pull the cruise switch toward you The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 538: ...ver To activate the ECO cruise mode push down the cruise control lever again To cancel the ECO cruise mode while in operation push down the cruise control lever again The ECO cruise mode is canceled and the indicator goes out What is ECO Cruise mode In this mode the smooth acceleration to the set cruise speed can be achieved by optimized fuel consumption ...

Page 539: ...8 km h When pushing the ON OFF switch of the cruise control lever When ESP is activated When applying the parking brake while driving When using the clutch in order to shift M T only To cancel the cruise control function pull the cruise switch toward you GSL only 1 2 3 4 5 6 7 Keep the main cruise control switch in the neutral position when not using the cruise control And the cruise control syste...

Page 540: ...eleration pedal intervention DSL only When the cruise control lever is failed DSL only When the brake switch and the brake light switch input signal are implausible 1 2 3 4 And the cruise control system cannot be operated again in driving state In this case you should stop the vehicle and turn off the ignition switch and then turn it on again After you do that you can use the cruise control system...

Page 541: ...25kg h Throttle position angle TA 0 Full Open 78 Close Engine torque Nm varies according to engine conditions Injection time Ms Battery voltage V 13 5V 14 1V Accelerator pedal position 1 V 0 3 4 8 V Accelerator pedal position 2 V 0 3 2 4 V Oxygen sensor mV 0 5 V OCV Oil Control Valve 0 100 VIS solenoid valve 1 ON 0 OFF A C compressor switch 1 ON 0 OFF Full load 1 ON 0 OFF Knocking control 1 ON 0 O...

Page 542: ...15 4 Spark plug OCV Oil Control Valve Rear oxygen sensor MCC complete Knock sensor Injector Oil pressure switch Ignition coil 1 MAJOR COMPONENTS PVC valve ...

Page 543: ...urge control solenoid valve G20DF engine ECU Coolant Temp sensor Camshaft position sensor Crankshaft position sensor T MAP sensor VIS solenoid valve Electronic throttle body Magnetic trigger ring Front oxygen sensor ...

Page 544: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU ...

Page 545: ...osition sensor Crankshaft position sensor Front oxygen sensor Knock sensor G20DF Engine ECU Electronic throttle body Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal CAN ABS ESP Instrument cluster TCU Oil pressure switch Oil pressure warning lamp T MAP sensor ...

Page 546: ... Valve 3 Components for ECU Output Start motor Injector VIS solenoid valve Purge control solenoid valve G20DF Engine ECU Ignition coil CAN ABS ESP unit BCM E coupling unit EPS Instrument cluster SKM TCU Diagnostic tool Cooling fan module ...

Page 547: ...a among electrical systems automatic T M and brake system in the vehicle fluently And the diagnostic tool can be used to diagnose vehicle 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 2 Control Functions Controls by operating stages To make optimum combustion un...

Page 548: ...the emission gas ECU determines the injection volume and timing 2 Components Input Components Accelerator pedal position sensor Front oxygen sensor Coolant temperature sensor Crankshaft position sensor Camshaft position sensor Knock sensor T MAP sensor Electronic throttle body Output Components ...

Page 549: ...15 11 0000 00 3 Input Output for Injection Volume Control ...

Page 550: ...15 12 4 Basic Injection Volume Map ...

Page 551: ...ingle ignition system Each spark plug is operated independently by the ECU and one ignition coil and spark plug are provided for each cylinder 2 Components Input Components Crankshaft position sensor Accelerator pedal position sensor Knock sensor Camshaft position sensor Electronic throttle body Output Components ...

Page 552: ...15 14 3 Input Output for Ignition System ...

Page 553: ...ition timing control can be performed faster than the control through the throttle valve Fuel cut off in deceleration The ignition timing is retarded temporarily to prevent abrupt increase of the torque when the combustion is restarted Intake air temperature coolant temperature The ignition timing is retarded to prevent knocking if the intake air temperature or coolant temperature is high The igni...

Page 554: ...15 16 5 Warm Up of Catalytic Converter 1 Components Input Components T MAP sensor Coolant temperature sensor Crankshaft position sensor Output Components ...

Page 555: ...ioner compressor operation The air conditioner control unit sends the air conditioner operation signal to the ECU to increase the throttle valve opening amount in order to prevent reduction of the engine speed when the air conditioner compressor is in operation at idling 3 Warm up Control Operating Conditions To make the catalytic converter reach a operating temperature the ignition timing is reta...

Page 556: ...rating temperature 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 180W 120W in G20DF engine ECU controls the electric cooling fans with three cooling fan relays to improve the engine torque and air condit...

Page 557: ...15 19 0000 00 3 Input Output for Cooling Fan and A C Compressor ...

Page 558: ...frigerant 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 over 118 Approx 4 seconds after starting the engine When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 32 kg then ON below 26 0 kg Output voltage according to refrigerant pressure The output voltag...

Page 559: ...r 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 2 Components Conditions for cooling fan Immobilizer antenna Immobilizer key Start motor Instrumen...

Page 560: ...CU communicate with the immobilizer key to check if it is valid crypto code If it is valid ECU start to control the engine when turning the ignition switch to START position The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again ...

Page 561: ...PS Electronic Power Steering Unit BCM Body Control Moudule SKM Smart Key Moudule CAN system communicates with the system units in vehicle It consists of P CAN and B CAN according to the communication speed P CAN B CAN SKM Instrument cluster BCM Disgnostic connector P CAN ECU ABS ESP TCU E coupling EPS unit Terminal resistance installed on ECU and BCM ...

Page 562: ...S101 Floor wiring LH Under fuse relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind instrument cluster cowl cross member S202 Main wiring Behind instrument cluster cowl cross member S205 Floor wiring LH Under driver s door scuff ...

Page 563: ...15 25 0000 00 3 Input Output for CAN communication ...

Page 564: ...01 3 0000 00 Top view Side view Front side Rear view 1 SPECIFICATIONS Unit mm 1 Dimensions ...

Page 565: ...right side in the engine compartment passenger side 3 The certification label is affixed on the bottom of driver side B pillar 30 psi 1 The engine number 671 950 0 2 5000001 is stamped on the lower area of cylinder block in exhaust manifold side 2 Identifications ...

Page 566: ...01 5 0000 00 VIN NO Engine NO ...

Page 567: ...01 6 2 SPECIFICATION option ...

Page 568: ...01 7 0000 00 ...

Page 569: ...01 8 3 RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong genuine fluids Use of non recommended products could cause damage to the unit Keep the specified capacity and service interval ...

Page 570: ...01 9 0000 00 4 SCHEDULED MAINTENANCE SERVICES ...

Page 571: ...01 10 ...

Page 572: ...01 11 0000 00 ...

Page 573: ......

Page 574: ...s GEN Clean every 7 500 km change every 15 000 km But shorten the service interval under severe conditions Air cleaner assembly Weight 1 5kg Operating temperature 30 100 Capacity 8L Intercooler Core material Aluminum Size 510X122X67 WxHxT Tank material Plastic Molding Efficiency 80 Exhaust system Turbocharger assembly Max temperature of turbine housing 780 Diameter of turbine housing ø40 0 Diamete...

Page 575: ......

Page 576: ...02 5 0000 00 T MAP sensor Turbocharger CDPF 1 MAJOR COMPONENTS D20DTF Low CO2 ECU Intercooler assembly Air cleaner assembly ...

Page 577: ...02 6 2 COOLANT FLOWS IN COOLING SYSTEM ...

Page 578: ...02 7 0000 00 ...

Page 579: ...ine is equipped with a throttle body which includes a flap This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off The intake manifold contains the swirl control valve and dual port system to make the optimum turbulence The T MAP sensor is located on the left top of the intake manifold and the HFM sensor for precise co...

Page 580: ...r Mass Sensor HFM sensor version 6 Refer to Chapter Engine Control Air cleaner assembly Its volume is increased and air flowing efficiency is improved Intercooler assembly Its volume is increased and cooling efficiency is improved ...

Page 581: ...40A 6500rpm 25 13 5V Battery Capacity 90Ah 20hr Reserve capacity 180 minutes Starting current when engine cooed 710A Weight 23kg EBS Electronic Battery Sensor Resolving power 1mA Operating voltage 7 18V Operating temperature 40 105 Communication LIN 2 0 Unit Description Specification ...

Page 582: ...attery capacity 12V 90Ah Alternator capacity Delphi 120A Delphi 140A Alternator Changed the diameter of belt pulley Front view Changed the regulator and control logic Rear view EBS None Monitoring the battery conditions voltage current temperature and SOC 2 COMPARISON ...

Page 583: ...r dirt with a wire brush or sand paper and then wash out with lukewarm soapy water 2 Measuring the Voltage Drop Measuring at battery terminal Measure the voltage between battery terminal and wiring clamp Specified value below 0 3V If the terminals are corroded clean and retightening them If the specified tightening torque cannot be kept replace the clamp Terminal Terminal Terminal 4 5 Nm Terminal ...

Page 584: ...ting bolt for corrosion and looseness If there is a poor contact due to corrosion or paint wipe out the contact area and retighten it Wiring mounting bolt to body ground 17 Nm Measuring the battery voltage Stop the engine and wait for 20 minutes Measure the voltage between terminal and terminal with the ignition switch OFF and all electric devices OFF Specified value over 12V ...

Page 585: ...out of the specified value check the terminal and clamp for looseness Checking the charge warning lamp Turn off all electric devices and put the ignition switch ON Pre warning Check if the charge warning lamp goes out If the charge warning lamp does not go off inspect the electric circuit Start the engine and check if the charge warning lamp keeps off 1 2 3 ...

Page 586: ... INSPECTION CHARGING CURRENT Perform the basic inspection Setting up the testers Preparation Set up the ammeter and voltmeter as shown in the figure 1 Make sure to set up the tester while keeping its polarity ...

Page 587: ...0 rpm 1 Specified value 60 of rated current limit Turn the ignition OFF after inspection Disconnect the negative cable from the battery and remove the testers ammeter and voltmeter 2 3 Characteristic curve output from alternator The output current may not reach the limit value due to various parameters high temperature or electric load etc Thus do not perform the inspection with fully charged batt...

Page 588: ...n Turn the ignition ON and measure the voltage on the voltmeter 1 Start the engine and turn all electric devices OFF Increase the engine speed to 2 700 rpm and maintain the speed Measure the voltage when the output current from alternator decrease below 30A 2 3 Specified value over 12V Specified value 11 5 15 5V Make sure to set up the tester while keeping its polarity ...

Page 589: ... inspect the affected circuit 1 Specified value below 0 05A 6 INSPECTION DARK CURRENT Perform the basic inspection Setting up the tester Preparation Disconnect the negative cable from the battery Set up the ammeter as shown in the figure above 1 2 1 When Using Multi tester Connect the probe to ground wiring and probe to terminal of battery ...

Page 590: ... up the ammeter and MSM as shown in the figure above 1 2 2 When Using MSM Connect the negative cable to the battery 3 Make sure to set up the tester while keeping its polarity Measure the current while removing the fuses one by one If the current drops sharply when a certain fuse is removed inspect the affected circuit ...

Page 591: ... replacement required 7 INSPECTION BATTERY Perform the basic inspection all electric devices OFF Battery tester 1 Voltage Check without load Connect one measuring clamp to terminal of battery first then connect the other one to terminal Disconnect the clamps in the reverse order 1 Read the measurement 2 ...

Page 592: ...ection for less than 5 seconds 1 Read the measurement 2 Specified value 7 9V Red Over discharged or faulty 9 11V Yellow Charging required 11 13V Normal To identify the battery capacity with the voltage drop V value discharge the fixed load capacity 120A for a certain period 5 seconds ...

Page 593: ...warning lamp ON condition Turn the ignition ON Engine stopped Open or short circuit of L terminal wiring open or short internal circuit of alternator fixed control of 13 8V Open or short circuit of F terminal wiring no feedback output signal 1 2 3 ...

Page 594: ...03 16 1 LAYOUT D20DTF Low CO2 D20DTF ECU Battery sensor EBS Alternator ALT Meter cluster charge warning lamp ...

Page 595: ...SOC to engine ECU with LIN communication Engine ECU outputs the information from EBS and regulating control signal PWM according to the engine load conditions to L terminal on alternator Engine ECU controls the magnetic resistance between stator coil and rotor coil by controlling the current in rotor coil according to PWM duty value The alternating voltage induced to stator coil is converted to di...

Page 596: ...asic control logic according to the driving conditions Engine ECU determines the engine loads according to the fuel injection volume and engine speed It charges the battery by increasing the generating voltage during deceleration To improve the fuel economy by reducing the alternator load during acceleration engine ECU decreases the generating voltage and consumes the battery voltage ...

Page 597: ...p Overview Meter cluster charge warning lamp The meter cluster receives the charge warning lamp ON signal from ECU through CAN line Charge warning lamp ON conditions Pre warning When DTC related EEM set Open or short circuit in alternator Circuit diagram ...

Page 598: ...03 20 4 CIRCUIT DIAGRAM ...

Page 599: ... lamp 1 EXTERIOR LAMP SYSTEM LAYOUT Headlamp High beam Tail lamp DRL EU Front fog light Tail lamp High mounted stop lamp Stop lamp License plate lamp Turn signal lamp Stop lamp Rear fog light EU Reflector Front view Rear view Headlamp Low beam Back up lamp ...

Page 600: ...01 4 Headlamp Puddle lamp Front fog light Side repeater Turn signal lamp Headlamp High beam Headlamp Low beam Tail lamp DRL EU ...

Page 601: ...01 5 0000 00 High mounted stop lamp License plate lamp Rear combination lamp Vehicle with spoiler Vehicle without spoiler Back up lamp Stop lamp Tail lamp Turn signal lamp Stop lamp Rear fog light EU ...

Page 602: ...01 6 Front room lamp Glove box lamp Sun visor lamp 2 INTERIOR LAMP SYSTEM LAYOUT ...

Page 603: ...01 7 0000 00 Luggage lamp Door courtesy lamp Center room lamp ...

Page 604: ...embly Drive door main switch Outside rearview mirror switch FATC switch Steering wheel remote control switch Passenger door switch Lower main panel switch Start stop switch Cruise control switch Multifunction switch 3 SWITCH SYSTEM LAYOUT ...

Page 605: ...tch Overhead console switch Front seat heating and ventilation switch With heating and ventilation switch With heating switch Driver power seat switch Center room lamp switch Rear door switch RH Rear door switch LH Tailgate switch ...

Page 606: ...01 10 4 SCHEMATIC DIAGRAM FOR WIRING AND ELECTRICAL DEVICES 1 Wiring Harness Arrangement ...

Page 607: ...01 11 0000 00 2 Electrical Devices Mounting Locations ...

Page 608: ...01 12 3 Connector Ground And Splice Pack Connector ...

Page 609: ...01 13 0000 00 Ground Splice pack ...

Page 610: ... the same time and the SKM SMART Key Module communicates with the instrument cluster and BCM through B CAN 1 CAN Configurations P CAN B CAN Abbreviations Meaning Function GCU Glow Control Unit Glow Control Unit EPS Electronic Power Steering Unit Electronic Power Steering Unit BCM Body Control Module Body Control Module SKM Smart Key Module Smart Key Module TPMS Tire Pressure Monitering System Tire...

Page 611: ... Glow Control Unit S102 W H Floor RH Inside RH Fender S202 W H Main Backside Cluster LH Cowl Cross Member S204 W H Main Backside Cluster Under ICM Relay Box S205 W H Main Backside Audio CTR Cowl Cross Member S206 W H Floor LH Under Driver Seat S401 W H Floor LH Beside PAS Unit inside LH QTR Trim ...

Page 612: ......

Page 613: ...e which has the correct amperage rating If you use a fuse with higher capacity than the specification the component can be damaged or catch fire Do not drop or appy excessive impact to sensors and relays 80 10 A 15 A Make sure to turn OFF the ignition switch and other lamp switches before disconnecting or connecting the negative battery cable Otherwise semiconductor parts can be damaged ...

Page 614: ...ity of the connector terminal with a circuit tester connect the tester probe to the terminal at the harness side For a sealed type connector connect the probe to the terminal through the hole in the rubber cap of the wiring Take care not to damage the insulation of the wires Insert the probe until it contacts the terminal completely When inspecting the airbag system make sure to use a diagnostic d...

Page 615: ...k 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 tightly at regular intervals Secu...

Page 616: ...beam Changed to PCB type D Rear glass heated mirror relay Changed to PCB type E Cooling fan high speed relay Changed to Micro type F Blower motor relay Changed to Micro type G Cooling fan low speed relay Changed to Micro type H Cooling fan relay Changed to Micro type I Fuel heater relay Changed to Micro type J PTC1 heater relay Changed to Micro type K Power window relay Changed to Micro type L Sta...

Page 617: ...7 8410 00 8410 02 Changed connector position Change position of connectors A B and D 8410 02 Changed connector D Connector D changed 32 pin 40 pin 8410 02 Interior fuse box Interior fuse box label changed ...

Page 618: ...de of the instrument panel and rear of the instrument cluster 3 off in total The capacities and its names for each fuse and relay are marked on the each fuse and relay box cover The label attached on each fuse box indicates only major fuses and relays For detailed information see the power distribution circuit diagram 1 OVERVIEW 2 SYSTEM LAYOUT ...

Page 619: ...to 18 0 V Should be operated normally within this range Operating temperature 30 80 Should be operated normally within this range Storage temperature 40 to 85 Max operating humidity 95 Dark current BCM without SKM 7 0 mA or less BCM with SKM 4 0 mA or less All switches turned OFF Key removed entering sleep mode after all doors are locked ...

Page 620: ...PEN 12 Passenger door open switch OPEN GND CLOSE OPEN 13 Rear LH door open switch OPEN GND CLOSE OPEN 14 Rear RH door open switch OPEN GND CLOSE OPEN 15 Tailgate switch OPEN GND CLOSE OPEN 16 Hood switch OPEN GND CLOSE OPEN 17 Sunroof switch OPEN GND CLOSE OPEN 18 headlamp switch ON GND OFF OPEN 19 Folding unfolding switch ON GND OFF OPEN 20 Crash door LOCK UNLOCK switch ON GND OFF OPEN 21 Crash s...

Page 621: ...er switch ON IGN OFF OPEN 33 Rear washer switch ON IGN OFF OPEN 34 AUTO light switch OPEN GND CLOSE OPEN 35 Tail lamp switch ON GND OFF OPEN 36 AUTO hazard warning lamp switch ON GND OFF OPEN 37 Left turn signal lamp switch ON GND OFF OPEN 38 Right turn signal lamp switch ON GND OFF OPEN 39 Hazard warning lamp switch ON GND OFF OPEN 40 DRL switch ON GND OFF OPEN 41 Rear fog lamp switch ON IGN OFF ...

Page 622: ...jar O O 3 Tail lamp control Tail lamp switch ON warning O O Tail lamp warning display X O Tail lamp AUTO switching off O O 4 Door ajar warning Door ajar control X O Door ajar warning O O 5 Seat belt control Seat belt warning O O Seat belt reminder O O 6 Sunroof warning Sunroof warning O O Sunroof warning display X O 7 Room lamp control Door coupled room lamp dim control O O Room lamp AUTO switchin...

Page 623: ...nal O X Door LOCK UNLOCK control by smart key X O Door LOCK UNLOCK control by door handle switch passive entry X O AUTO door LOCK control O O AUTO UNLOCK upon receiving air bag deployment signal O O 12 Panic alarm Panic alarm control by REKES key signal O X Panic alarm control by smart key signal X O 13 Tailgate control Tailgate open control for vehicles without SKM O X Tailgate open control for v...

Page 624: ... 18 Fog lamp control Fog lamp control O O 19 Immobilizer function Key coding O X CHALLENGE O X CAN information O X 20 Folding unfolding control Folding unfolding control O O AUTO folding unfolding control O O 21 Approach lamp control Approach lamp control for vehicles without SKM O X Approach lamp control for vehicles with SKM X O 22 SKM warning control SKM buzzer control X O 16 System power sleep...

Page 625: ...y theft deterrent mode signal and passive entry signal etc to the BCM to control each module The signals for engine running and stopping controls are sent to the EMS ECU through the P CAN For the vehicles without SKM the BCM receives door LOCK UNLOCK signal by smart key theft deterrent mode signal and passive entry signal etc directly from the modules to control them The BCM controls the engine ru...

Page 626: ... folding unfolding and operates the external buzzer once AUTO folding unfolding unsetting Pressing the manual folding switch for 3 seconds or more again unsets the AUTO folding unfolding and operates the external buzzer twice AUTO folding unfolding setting The manual folding switch is not pressed AUTO folding unfolding unsetting The manual folding switch is pressed ...

Page 627: ...03 11 8710 01 REKES key The design of REKES key has been changed Folding key type ...

Page 628: ...les through the hard wire and CAN communication and controls the body electronic system and chassis of the vehicle 2 SYSTEM CONFIGURATION 1 Vehicles With SKM SKM BCM Internal buzzer chime Smart key ICM box Internal buzzer chime Warning horn External buzzer SKM buzzer Mounting location Component Mounting location Component ...

Page 629: ...03 13 8710 01 2 Without SKM BCM Internal buzzer chime REKES key Immobilizer ICM box Internal buzzer chime Warning horn Mounting location Component ...

Page 630: ...03 14 3 INPUTS AND OUTPUTS ...

Page 631: ...iper speed can be adjusted with this switch as follows when the wiper switch is in AUTO position FAST increases wiper speed SLOW decreases wiper speed 6 AUTO washer switch When the AUTO washer switch is pressed the washer fluid is sprayed once and the wiper is operate 4 times Then the fluid is sprayed once again with 3 wiping operations 7 When the switch is fully turned washer fluid will be spraye...

Page 632: ... is activated 0 1 seconds T1 after the MIST switch is turned ON The wiper LO relay is deactivated when the MIST switch is turned OFF and the wiper motor parking signal is input A B C D Operation 1 The wiper HI relay is activated when the MIST switch signal is input If no signal from the MIST switch is input the wiper LO relay is activated ...

Page 633: ...03 17 8710 01 Operating process IGN ON ...

Page 634: ...e T2 the windshield washer motor is activated The windshield wiper LO relay is activated 0 5 seconds T1 after the windshield washer switch is turned ON When the windshield washer switch is turned OFF the windshield wiper LO relay is deactivated after the windshield wiper motor rotates 3 times T3 A B C D Operation 1 washer switch pressed for 0 1 to 0 59 seconds ...

Page 635: ...er LO relay is deactivated after the windshield wiper motor rotates once T5 and then the windshield wiper is operated intermittently after the rest time T6 The ignition is turned ON with the wiper AUTO switch ON The windshield wiper LO relay is activated 0 5 seconds T1 after the windshield washer switch is turned ON for 0 6 seconds or more T3 C D Operation 2 windshield washer switch pressed for 0 ...

Page 636: ...03 20 Operating process IGN ON and wiper AUTO switch in ON position Priority of operation Windshield washer switch Wiper AUTO switch ...

Page 637: ...N The rear washer motor is activated when the rear washer switch is turned ON The rear washer motor is deactivated when the rear washer switch is turned OFF A B C Operation 1 Operating process IGN ON Priority of operation Windshield washer switch Rear washer switch ...

Page 638: ... windshield washer motor is activated for 1 5 seconds T3 A B C D Operation 1 The input from the AUTO washer switch during the washer coupled wiper operation is overridden The input from the AUTO washer switch during the AUTO washer coupled wiper operation is ignored The input from the AUTO washer switch during the speed sensitive intermittent wiper operation is ignored When the signal from the int...

Page 639: ...03 23 8710 01 ...

Page 640: ...03 24 Operating process IGN ON and wiper AUTO switch in OFF position ...

Page 641: ...switch or AUTO light switch in the AUTO position The data from the rain sensor is recognized as 2 consecutive data Operation when data is recognized Data OFF Lo HI relay output OFF Low speed signal LO relay output ON ON for at least 1 revolution HI relay output OFF High speed signal HI relay output ON ON for at least 1 revolution LO relay output ON The washer input is overridden during continuous ...

Page 642: ...tates once T1 initially when the windshield wiper LO relay is activated regardless of the rain sensor communication D E Operation 2 The ignition is turned ON with the wiper AUTO switch in the ON position The windshield wiper LO relay is not operated F G Operation 3 The rain sensor did not detect rain drops after Operation 2 Operation 4 The rain sensor detects rain drops after Operation 2 The ignit...

Page 643: ...03 27 8710 01 ...

Page 644: ...03 28 Operating process IGN ON ...

Page 645: ...sensor coupled operation T2 However if the washer switch signal is received the washer relay is activated and wiper relay remains activated when the data coupled with rain sensor indicates continuous wiper operation A B C D Operation 1 The rain sensor coupled data is not continuous wiper operation Basic conditions Intermittent operation with IGN ON and wiper AUTO switch in ON position Even though ...

Page 646: ...03 30 Operating process Intermittent operation with IGN ON and wiper AUTO switch in ON position ...

Page 647: ... of rain is not detected by the rain sensor The windshield wiper LO relay is not operated A B Operation 1 Increasing the speed level ex speed level 0 level 1 Basic conditions IGN ON Wiper AUTO switch ON Wiper motor in parking position If the speed level is changed more than 1 stage within 2 seconds the windshield wiper motor runs only one cycle ...

Page 648: ...03 32 Operating process IGN ON Wiper AUTO switch ON Wiper motor in parking position ...

Page 649: ...eration 1 When the wiper motor parking signal stopped at GND Abnormal wiper parking signal stop IGN The wiper system sends the corresponding signal of current status for 2 seconds T2 with IGN ON and wiper AUTO switch ON After the 2 seconds T2 the system outputs the signal of the stopped status The wiper motor is operated only when the request signal from the rain sensor is received A B Operation 1...

Page 650: ...03 34 Operating process IGN ON Wiper AUTO switch ON Wiper motor in parking position ...

Page 651: ...lfunction The wiper AUTO switch speed level is adjusted speed level 3 level 2 The wiper LO relay is operated once T1 A B Operation 1 rain sensor installed improperly signal received from the rain sensor Basic conditions IGN ON and wiper AUTO switch in ON position ...

Page 652: ...ain sensor signal The AUTO switch speed level is adjusted ex speed level 4 level 3 The wiper LO relay is operated once T1 A B Operation 1 no signal detected signal received from the rain sensor Basic conditions IGN ON and AUTO switch ON ...

Page 653: ...03 37 8710 01 Operating process IGN ON Wiper AUTO switch ON ...

Page 654: ... sensitivity AUTO switch rest time AUTO switch level Level Resistance Remarks 0 3 kΩ or less FAST 25 8 kΩ to 13 KΩ 50 18 kΩ to 30 KΩ 75 35 kΩ to 43 KΩ 100 45 kΩ or more SLOW There are HYSTERISIS ranges between the levels The wiper remains activated for the time remaining when the AUTO switch is turned OFF during the speed sensitive wiper operation The intermittent operation is reactivated when the...

Page 655: ...er operates 3 or 4 times with high speed abruptly Symptom 3 Check if the wiper speed control switch is set to the fast side The fast stage has the highest sensitivity and is very sensitive to the small change of amount of rain drops Therefore adjust the knob to lower the sensitivity level The wiper continues work even if the windshield glass is dry Symptom 4 Check the wiper blade for wear If the w...

Page 656: ...s activated when the HI relay is activated If the ignition turned OFF while the wiper is operated the wiper stops operating when the wiper motor parking signal is input If no wiper motor parking signal is input during the wiper LO HI operation the wiper relay continues working If no wiper parking signal is input for 3 seconds of wiper AUTO operation wiper relay is deactivated after 5 seconds failu...

Page 657: ...03 41 8710 01 ...

Page 658: ...s of 0 02 sec ON 1 38 sec OFF A Operation 1 When the ignition key is removed or the driver door is closed while the internal buzzer chime is activated for up to 10 seconds the buzzer is deactivated B Operation 2 5 IGNITION KEY REMINDER The 2 operations stated above are not available after the ignition is turned ON C Operation 3 This function overrides the tail lamp switch warning function ...

Page 659: ...03 43 8710 01 Operating process Mounting location for internal buzzer chime Internal buzzer chime The internal buzzer chime is fitted inside the BCM ...

Page 660: ...oor LOCK switch is in LOCK position within 0 5 seconds T1 after the door is closed with the ignition key inserted The UNLOCK signal is output for 0 5 seconds T2 immediately after the LOCK signal output C D Operation 2 The door LOCK switch is in LOCK position after the driver door is opened with the ignition key inserted The door UNLOCK signal is not output when the ignition key is removed during t...

Page 661: ...03 45 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 662: ... is output for 0 5 seconds T1 immediately after the LOCK signal output A B Operation 1 All doors are closed during the UNLOCK output The UNLOCK output continues C D Operation 2 When the ignition key is inserted the ignition key reminder is operated E Operation 3 Except tailgate and hood Operating process This function does not work if the vehicle speed is over 10 km h ...

Page 663: ...03 47 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 664: ...OFF while the internal buzzer chime is activated or the driver door is closed The internal buzzer chime is deactivated immediately C D Operation 2 6 TAIL LAMP CONTROL The 2 operations stated above are not available after the ignition is turned ON E Operation 3 The sunroof and ignition key reminder warnings override this function If the tail lamp switch is turned ON from OFF while the internal buzz...

Page 665: ...03 49 8710 01 Operating process IGN OFF ignition key removed ...

Page 666: ...ed OFF automatically when the driver door is opened and then closed with tail lamp switch ON B C Operation 2 When the ignition is turned ON ignition key inserted after the operation 2 the tail lamp relay is turned ON D Operation 3 The ignition is turned OFF or the ACC is turned ON ignition key removed After the tail lamp is turned ON the lamp relay is not turned OFF automatically when the driver d...

Page 667: ...03 51 8710 01 Operating process IGN OFF ignition key removed ...

Page 668: ...arts to flash C D E Operation 2 The warning lamp remains on when the vehicle speed decreases to 10 km h or less V2 F Operation 3 The warning lamp flashes under the condition of operation 2 Operation 4 The door ajar warning lamp flashes The lamp goes out when the open door is closed The lamp flashes again whenever a door is opened G H I The door ajar warning lamp goes out when the open door is clos...

Page 669: ...03 53 8710 01 Operating process IGN ON ...

Page 670: ... chime sounds and the driver seat belt warning lamp comes on for T2 again E F Operation 3 The ignition is turned OFF while the internal buzzer chime and seat belt warning lamp are activated The internal buzzer chime and seat belt warning lamp are deactivated G H Operation 4 8 SEAT BELT CONTROL The driver seat belt is fastened while the internal buzzer chime and seat belt warning lamp are activated...

Page 671: ...03 55 8710 01 ...

Page 672: ... operated as follows F Priority of internal buzzer chime operation Seat belt reminder ignition key reminder sunroof warning tail lamp warning hazard warning flasher on turn signal indicator GEN The seat belt reminder is operated when the vehicle is driven at 25 km h or more with IGN ON and alternator in High status engine running and driver seat belt is not fastened If the vehicle speed is decreas...

Page 673: ...03 57 8710 01 Operating process IGN ON ...

Page 674: ...roof is closed while the internal buzzer chime is activated The internal buzzer chime is deactivated The internal chime buzzer is not activated again after the operation 1 and it is activated again when the operation 1 is performed after the ignition is turned ON C D Operation 2 9 SUNROOF WARNING LAMP CONTROL The sunroof open warning T2 overrides the tail lamp ON warning T3 E Operation 3 ...

Page 675: ...03 59 8710 01 Operating process IGN OFF ignition key removed ...

Page 676: ...es out when the REKES LOCK signal is received in theft deterrent mode When the key hole lamp and immobilizer signals are received simultaneously the immobilizer signal overrides the key hole lamp signal When the immobilizer confirmation is failed regardless of the key hole lamp operation condition it flashes for 11 seconds at intervals of 0 5 sec ON 0 5 sec OFF When the ignition is turned ON in vi...

Page 677: ...03 61 8710 01 Operating process ...

Page 678: ...ont defogger heated wire for 12 minutes T1 When the front defogger heated wire switch is turned ON the front defogger is activated for only 6 minutes T3 This operation is not available when the front defogger is turned off by turning off engine IGN OFF or front defogger heated wire switch D E Operation 3 If the engine is running at low speed with IGN OFF or IGN ON the front defogger heated wire is...

Page 679: ...03 63 8710 01 Operating process Engine running Alternator High ...

Page 680: ...03 64 Front defogger heated wire switch ...

Page 681: ...ter the output of the rear defogger heated wire for 12 minutes T1 When the rear defogger heated wire switch is turned ON the front defogger is activated for only 6 minutes T3 This operation is not available when the rear defogger is turned off by turning off engine IGN OFF or front defogger heated wire switch D E Operation 3 If the engine is running at low speed with IGN OFF or IGN ON the rear def...

Page 682: ...03 66 Operating process Engine running Alternator High ...

Page 683: ...03 67 8710 01 Rear defogger heated wire switch ...

Page 684: ...signal by the REKES key is received D E Operation 3 The room lamp stays on when a door is opened during fading out The lamp goes out or fades out when the door is closed F Operation 4 12 ROOM LAMP CONTROL When the room lamp switch is in the door coupled position and the driver passenger rear door is opened the room lamp comes on The room lamp goes out automatically after 10 minutes of illumination...

Page 685: ...03 69 8710 01 Operating process Door coupled front room lamp switch in ON position ...

Page 686: ...he room lamp is turned off automatically the room lamp automatic switching off signal is sent to the instrument cluster before entering sleep mode B C Operation 2 preventing battery discharge When the ACC is turned ON or ignition is turned ON with the ignition key inserted the room lamp is activated D Operation 3 When the room lamp cut off operation is activated the BCM sends cut off operation sig...

Page 687: ...vated When the theft deterrent mode is deactivated the hazard warning lamp flashes once In theft deterrent mode if a door tailgate or engine hood is not opened within 30 seconds after the door is unlocked by a remote controller the doors are locked with the hazard warning lamp and buzzer activated lamp flashes twice and buzzer sounds once the theft deterrent mode is activated again 13 REMOTE KEYLE...

Page 688: ...g the status signals from the driver door knob switch passenger door knob switch rear LH RH door knob switch and central door LOCK UNLOCK switch through the wiring If all doors are unlocked 5 times within 1 minute after door LOCK signal output because of faulty door knob switch and door open switch the doors are forced to lock and not allowed to unlock However the UNLOCK conditions are met the UNK...

Page 689: ...03 73 8710 01 Operating process The door LOCK UNLOCK relay is installed inside the actuator ...

Page 690: ...en one of the door LOCK detection switches is in LOCK position with the ignition turned OFF all doors are unlocked automatically When the central door switch LOCK is operated with all doors unlocked and any door ajar the door LOCK relay is activated followed by UNLOCK relay to prevent the door LOCK by misoperation Door LOCK detection switch The switch is installed inside the door actuator and dete...

Page 691: ...03 75 8710 01 Operating process The door LOCK UNLOCK relay is installed inside the actuator ...

Page 692: ...nds T2 The door UNLOCK conditions are met the turn signal lamp is operated once for 1 second D E Operation 2 All doors closed Hood closed Tailgate closed Door LOCK detection switch in LOCK state The turn signal lamp flashes 2 times at intervals of 0 5 sec ON 0 5 sec OFF C Operating process for vehicles without SKM Do not operate the REKES key with the ignition key inserted or for 1 second after th...

Page 693: ...03 77 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 694: ...l lamp is turned ON for 0 5 seconds and then turned OFF for 0 5 seconds and this operation is repeated 2 times A B C Operation 1 SKM receives UNLOCK signal through B CAN with IGN ON IGN OFF or ACC ON BCM outputs UNLOCK relay signal for 0 5 seconds T3 The turn signal lamp is operated once for 1 second D E F Operation 2 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 695: ...03 79 8710 01 Operating process for vehicles with SKM ...

Page 696: ...n A B C Operation 1 when driver door locked The ignition is turned OFF or ACC is turned ON When the door handle switch is operated the door LOCK UNLOCK signal is sent to the BCM through B CAN The SKM operates the turn signal lamp twice at intervals of 0 5 sec ON 0 5 sec OFF after 0 5 seconds T2 of door LOCK relay operation D E F Operation 2 when driver s door unlocked Operating process for vehicle...

Page 697: ...03 81 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 698: ...et by this function or the ignition is turned ON to OFF even when there is no LOCK output while the vehicle is driven at over 30 km h under LOCK condition If a door is unlocked after the 5 times of LOCK output the door is regarded as malfunctioning If there is a malfunctioning door the AUTO door LOCK is not activated but the LOCK operation by the central door LOCK switch is available If a malfunct...

Page 699: ...03 83 8710 01 Operating process for vehicles without SKM The door LOCK UNLOCK relay is installed inside the actuator ...

Page 700: ... T2 When turning IGN OFF during 5 seconds T3 of unlock relay signal output Signal from unlock relay is input for the rest of the time B C D E Operation 2 The room lamp comes on when the air bag deployment signal is input except when the room lamp switch is turned off The hazard warning lamp flashes when the air bag deployment signal is input Resetting the auto door unlock function turns off the ba...

Page 701: ...ctions during or after the UNLOCK output by the air bag signal are ignored However the LOCK control is carried out when the ignition switch is turned to the OFF position The same request during the LOCK UNLOCK output is ignored However the UNLOCK by the air bag deployment signal or operation by the smart key is carried out When LOCK and UNLOCK outputs occur at the same time the LOCK output is carr...

Page 702: ...and warning horn are activated by REKES panic function The REKES panic LOCK and panic signals are received The panic function is interrupted and other functions are activated by the corresponding command C D E Operation 2 The theft deterrent alarm is activated The panic function is interrupted and theft deterrent alarm is set F G Operation 3 during operation 1 15 PANIC ALARM CONTROL The panic alar...

Page 703: ...03 87 8710 01 Operating process ...

Page 704: ...function is interrupted and theft deterrent alarm is set G H Operation 3 during operation 1 The panic function is activated by the signals from SKM The hazard warning lamp and warning horn are activated by smart key panic function operation 1 The followings occur D E Operation 2 The panic button of the smart key is pressed When other function signal is received the command is executed while the pa...

Page 705: ...03 89 8710 01 Operating process ...

Page 706: ...gate open relay is activated for 1 second A B Operation 1 The tailgate open relay is activated The vehicle is driven at 3 km h or more with the driver door locked or IGN ON The tailgate open relay is deactivated immediately C D E Operation 2 The vehicle is driven at 3 km h or more with IGN ON The tailgate open relay is not activated when the tailgate open switch is pressed F G Operation 3 16 TAILG...

Page 707: ...03 91 8710 01 Operating process When the driver door is unlocked with the power OFF ACC ON or IGN ON ...

Page 708: ...the BCM through B CAN The BCM activates the tailgate open relay after the valid smart key verification In theft deterrent mode only the theft deterrent for tailgate is deactivated Operation 4 The tailgate open signal is input by the smart key when the vehicle is not in stationary or the power is not turned OFF The BCM keeps the tailgate open relay ready to operate for 30 seconds If the signal from...

Page 709: ...03 93 8710 01 Operating process in theft deterrent mode ...

Page 710: ... one or more doors open The LOCK relay is activated followed by activation of UNLOCK relay H I Operation 3 REKES LOCK signal is received with the tailgate and hood open Only the LOCK relays of the closed doors except hood and tailgate are activated The system does not enter theft deterrent mode If the open tailgate and hood are closed The system enters the theft deterrent mode after operating the ...

Page 711: ...03 95 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 712: ...03 96 Operating process IGN OFF ACC ON All doors including hood and tailgate closed ...

Page 713: ...lgate is opened in theft deterrent mode The LOCK switch of any door including tailgate is set to UNLOCK in theft deterrent mode Any door except tailgate and hood is closed and then opened after 30 seconds of alarming The hazard warning lamp and warning horn are activated for 30 seconds at intervals of 0 5 sec ON 0 5 sec OFF Theft deterrent alarm deactivation conditions for vehicles without SKM Any...

Page 714: ...ter the theft deterrent mode F G H Operation 2 The tailgate and hood are open The door LOCK signal is received through B CAN If all doors including hood and tailgate are closed door LOCK relay is activated The system does not enter theft deterrent mode If the open tailgate and hood are closed The system enters the theft deterrent mode after operating the hazard warning lamp twice and external buzz...

Page 715: ...03 99 8710 01 The door LOCK UNLOCK relay is installed inside the actuator ...

Page 716: ...d the theft deterrent mode is deactivated after the hazard warning lamp once and external buzzer SKM buzzer twice operations If UNLOCK signal by the smart key is received after the deactivation of theft deterrent mode the hazard warning lamp relay and external buzzer SKM buzzer are turned ON When the tailgate open signal by the smart key or tailgate open switch is received only the theft deterrent...

Page 717: ...LOCK signal by smart key is received b Tailgate open signal by smart key is received c UNLOCK signal by door switch is received d Tailgate open switch signal is received e IGN ON signal is received f Panic function is activated When the ignition is turned ON while the theft deterrent alarm is activated the alarm is deactivated immediately When the theft deterrent alarm is activated in theft deterr...

Page 718: ...rning lamp flashes and the warning horn is activated A B C Operation 1 The theft deterrent alarm is activated The conditions for deactivation of theft deterrent alarm are met The hazard warning lamp and warning horn are deactivated The theft deterrent alarm is deactivated because the conditions are not met and the system enters the theft deterrent mode D E F G Operation 2 ...

Page 719: ...03 103 8710 01 Operating process Theft deterrent alarm activated ...

Page 720: ...w relay is turned ON for 30 seconds T1 A B C D Operation 1 The power window relay is turned OFF immediately when the driver passenger door is opened E Operation 2 during 30 seconds T1 of power window relay ON The system enters theft deterrent mode The power window relay is turned OFF immediately F G Operation 3 18 POWER WINDOW RELAY CONTROL ...

Page 721: ...amp tail lamp or power window is already activated or all doors are closed for continuous 30 seconds after the door UNLOCK under the conditions stated in 1 the system waits in normal mode If the lamps or power window is deactivated and no change is detected for 6 seconds after all doors are closed the system enters the sleep mode 3 When the front room lamp is ON the system turns of the room lamp i...

Page 722: ...2 and the internal buzzer sounds at intervals of 0 3 sec ON 0 3 sec OFF D E Operation 2 The LH RH turn signal lamp is activated only with IGN ON F Operation 3 20 FLASHER FUNCTION The LH RH turn signal lamp flashes 3 times once the corresponding lamp switch is turned ON When the LH turn signal lamp switch is turned OFF during the 3 times flashing the turn signal lamp goes out after the flashing ope...

Page 723: ...03 107 8710 01 ...

Page 724: ...han 3 A or more than 7 A detection signal is input while the lamp is ON The hazard warning lamp flashes 100 times per minute T2 and the internal buzzer sounds at intervals of 0 3 sec ON 0 3 sec OFF D E Operation 2 Hazard warning lamp functions at B or more The allowed time difference between the LH and RH turn signal lamp operations is within 0 1 seconds The hazard warning lamp overrides the turn ...

Page 725: ...03 109 8710 01 ...

Page 726: ... turn signal lamp switch is pressed during the AUTO hazard warning lamp operation The corresponding turn signal lamp is activated after this AUTO hazard warning lamp operation B C D Operation 2 The AUTO hazard warning lamp can be controlled only with IGN ON The input from the AUTO hazard warning lamp switch is ignored during the turn signal lamp operation by the turn signal lamp switch Priority of...

Page 727: ...03 111 8710 01 ...

Page 728: ...arning lamp The BCM activates emergency hazard warning lamp operation when receiving emergency braking signal from the ESP ABS Priority of operation Manual operation of hazard warning lamp Emergency stop signal Emergency AUTO hazard warning lamp AUTO hazard warning lamp Operation 3 Emergency AUTO hazard warning lamp Manual operation of hazard warning lamp During operation 2 emergency AUTO hazard w...

Page 729: ...03 113 8710 01 ...

Page 730: ...mergency braking flasher ON signal from the ESP ABS When the emergency stop signal is input through the P CAN the hazard warning lamp flashes with the frequency of 4 Hz and the internal buzzer sounds at 1 25 Hz P CAN signal during operation Emergency Stop EBL_INFO 0 0 Hazard Warning Lamp unrequested ...

Page 731: ...urned on When pressing the rear fog lamp switch again during the operation The rear fog lamps are turned off A B C D Operation 1 If the headlamp is turned off or IGN2 switch is turned to OFF position The rear fog lamps are turned off The rear fog lamps are not turned on automatically without operating the rear fog lamp switch E F G Operation 2 ...

Page 732: ... is activated by the folding switch The folding switch is turned OFF The unfolding relay is activated after 0 1 seconds T2 E F G Operation 3 21 OUTSIDE REAR VIEW MIRROR FOLDING UNFOLDING The AUTO folding unfolding function is not available when the folding switch is ON The AUTO folding unfolding function is available when the folding switch is OFF The control logic is the same for folding to unfol...

Page 733: ...lamp ON Thirty seconds after the lamp ON C D E Operation 2 Puddle lamp OFF conditions 22 APPROACH PUDDLE LAMP Approach lamp control for vehicles with SKM The lamp is illuminated for 30 seconds when UNLOCK signal by the smart key or door handle switch is received in theft deterrent mode The lamp is illuminated when the driver door is opened after the ignition is turned OFF A B Operation 1 Puddle la...

Page 734: ...03 118 Priority of BCM buzzer control 23 BUZZER CONTROL External buzzer SKM buzzer Internal buzzer chime Warning horn Internal buzzer chime ...

Page 735: ...EKES key and immobilizer unit in the key box through wireless communication The immobilizer unit and BCM check the encrypted codes received through hard wire communication to start the engine Stays on Communication failure between immobilizer and EMS ECU Flashes Immobilizer coding failure once per second 2 System Diagram ...

Page 736: ...he immobilizer unit requests the transponder verification through the antenna The transponder sends the encrypted message to the immobilizer control unit The immobilizer unit compares the encrypted message received from the transponder to the coded value through the logic circuit If they are identical it requests the transponder approval When the ignition is turned ON the EMS ECU requests immobili...

Page 737: ...er PCB Battery replacement Remove the battery cover with a flat bladed screwdriver to replace the battery Transponder replacement Remove the battery cover to remove the battery Remove the key plate after removing the rubber cover and screws Remove the side cover and main cover Replace the transponder Main cover Spring ...

Page 738: ...er system Do not drop the key or subject it to impact the key as it may damage the transponder inside the key The engine cannot be started using a key with damaged transponder In the following cases you may experience starting problem or a system error can occur 1 2 3 4 5 6 5 Cautions for immobilizer When two or more ignition keys come into contact with each other s or the key is close to any devi...

Page 739: ...3 920 MHz 0 015 kHz PWM Frequency bandwidth 15 kHz 2 kHz or less Modulation type FSK Frequency Shift Keying Receive distance RF 10 m or more without obstacles LF 1 2 m without obstacles Smart key Component Item Specifications Smart key Electric Operating voltage 2 7 V to 3 3 V Operation temperature 20 to 60 Battery type CR2032 Smart key wireless RF Radio Frequency transmission LF Low Frequency rec...

Page 740: ...consumption Max 1 2 A Operating temperature range 30 to 80 Door handle switch Rated voltage 5 0 V Voltage range 6 0 V to 16 0 V Rated current 5 to 20 mA Operating temperature range 30 to 80 Component Item Specifications External buzzer SKM buzzer Operating voltage 7 5 V to 14 5 V Operation temperature 30 to 80 Sound pressure level 83 dB ...

Page 741: ......

Page 742: ...cates vehicle status with LED illumination and flashing 1 OVERVIEW The SKM Smart Key Module system is equipped to only the vehicles with smart key and is to prevent theft and enhance the driver experience When the driver presses a door handle switch carrying a smart key this system checks the smart key information and driver door status and locks unlocks the doors passive function The vehicle can ...

Page 743: ... for valid smart key searching outside vehicle passive entry and KEY IN OUT SKM exterior antenna Door handle switch Interior rear antenna Mounting location Component LF transmission for valid smart key searching inside vehicle passive start and KEY IN OUT Interior center antenna Mounting location Component ESCL Mounting location Component The ESCL Electric Steering Column Lock is a device which lo...

Page 744: ...04 8 3 INPUT OUTPUT DIAGRAM ...

Page 745: ...ctivated The system searches a smart key only in the actuation area of a switch which the signal is input driver passenger door handle switches and tailgate open switch 4 PASSIVE ENTRY MANAGEMENT 1 Passive Function The passive entry actuation area refers to the area where passive LOCK UNLOCK can be performed by pressing the switch on the driver or passenger door handle with a smart key carried by ...

Page 746: ...functions may occur when generating radio waves around the smart key or vehicle or attaching a electronic device which generates radio waves on the smart key or vehicle 2 Passive start actuation area Starting the engine by pressing the START STOP switch with the gear selector lever in P or N position and the brake pedal depressed START STOP switch LED green after the driver has entered the vehicle...

Page 747: ...verification signal RF verification from the smart key is sent to the REKES antenna of the SKM The SKM sends the Passive LOCK signal to the BCM through the B CAN if the verified smart key is found outside the vehicle The BCM receives the signal from the SKM and controls the door LOCK actuator and turn signal lamp The buzzer sounds once and hazard warning lamp flashes twice when the system enters t...

Page 748: ...M through the B CAN if the verified smart key is found outside the vehicle The BCM receives the signal from the SKM and controls the door UNLOCK actuator and turn signal lamp The buzzer sounds twice and hazard warning lamp flashes once when the theft deterrent mode is deactivated 1 2 3 4 5 6 If no smart key is identified as being outside the vehicle the passive UNLOCK process is stopped and restar...

Page 749: ...the outside vehicle Theft deterrent mode deactivated outside searching after inside searching The driver door is locked and the system in the theft deterrent mode The tailgate open switch signal is received The BCM sends the valid smart key verification request signal to the SKM The SKM verifies if a smart key is outside the vehicle using the corresponding rear bumper antenna LF verification The S...

Page 750: ...es within 10 minutes The SKM starts to search a smart key 30 seconds after sending the 1st puddle lamp operation signal If a smart key is found the SKM sends the 2nd operation signal 10 minutes timer terminated Re entering theft deterrent mode after deactivation Duration Function Time sec 1st within 5 days Normal monitoring time 1 25 2nd within 5 to 14 days Increasing monitoring time 1 5 3rd 14 da...

Page 751: ...on The REKES UNLOCK signal is sent when the UNLOCK button on the smart key is pressed briefly 0 1 sec or more The SKM receives the REKES UNLOCK signal and sends the REKES UNLOCK request signal to the BCM through B CAN The BCM outputs the door UNLOCK signal according to the signal received from the SKM 1 2 3 Tailgate open operation The ignition is turned OFF ON or ACC is turned ON The tailgate open...

Page 752: ...ic request signal to the BCM through B CAN The BCM controls the panic alarm and hazard warning lamp 1 2 3 4 When the panic button on the smart key is pressed again during the panic alarm operation the SKM sends the panic operation command to the BCM to stop the panic alarm When the theft deterrent activation command is received from the BCM the panic alarm is stopped and the theft deterrent siren ...

Page 753: ...icle All smart keys in the vehicle including the one that output the REKES LOCK are memorized as silent smart keys and the passive UNLOCK is not available with these keys 1 2 3 Silent smart key function Passive UNLOCK not available Passive start power control available REKES function available 1 2 3 Cancellation of silent smart key When the theft deterrent mode is deactivated the silent smart key ...

Page 754: ... LOCK theft deterrent mode activation request signal is sent by a smart key outside the vehicle The smart key activated door LOCK is not found in the vehicle The system memorizes all smart keys found inside the vehicle as deactivated ones 1 2 3 Smart key deactivation actuation area Passive entry not available Passive starting power control not available REKES function not available 1 2 3 Cancellat...

Page 755: ...arried out without a smart key under the verified conditions 30 seconds after the verification Input conditions Verification conditions Smart key searching completed after the following conditions are met Close signal input after any door opened Brake switch signal input START STOP switch signal input After emergency slot inserted After IGN OFF 1 2 3 4 5 Power changed to IGN ON after valid pre ver...

Page 756: ...mmobilizer verification is not deactivated until the ignition is turned to ON OFF or ACC ON The immobilizer is not deactivated when the key out warning condition is met while the engine is running 8 START POWER MODE CONTROL The ignition status is changed to OFF ACC ON IGN ON and engine cranking by one START STOP switch 30 seconds has been passed after the immobilizer verification timer IGN1 OFF No...

Page 757: ...04 21 8712 03 Power control and engine start diagram ...

Page 758: ...gine after checking the engine warming up If the engine cranking request2 signal is sent the EMS cranks the engine without checking the engine warming up 5 6 Engine cranking request1 engine start after warming up When the START STOP button is pressed briefly under the start conditions the vehicle starts to warming up and then the engine is started after a certain amount of time warming up indicato...

Page 759: ...gain the ignition status is changed from ACC to Power OFF DTC set When the START STOP button is pressed and held with IGN ON the ignition status is changed to OFF When the START STOP button is pressed briefly the ignition status is changed to ACC ON 3 ACC ON to Power OFF The SKM changes the ignition status to OFF from ACC ON when the engine START STOP button is pressed with the brake pedal release...

Page 760: ...try to LOCK or UNLOCK operation the power transition and start is not still possible after automatic retry and the warning lamp comes on 1 ESCL LOCK Control When the ESCL is unlocked and the followings are met at normal condition If the driver door is open or closed with ignition key OFF the electric steering motor performs the steering column lock If the theft deterrent mode is activated by the L...

Page 761: ...e up to 2 times automatically If the LOCK retry occurs 3 times in succession the ESCL JAM warning is triggered Reactivates when the ESCL UNLOCK conditions are met by pressing the START STOP switch When the UNLOCK retry occurs after ESCL UNLOCK command the command will be overridden without retry 5 After the command is overridden the ESCL JAM warning is triggered Reactivates when the UNLOCK conditi...

Page 762: ...igure Indicator status OFF OFF Amber Red OFF Green Red Flash Illuminatio n control OFF TIME Controlled by SKM LED The indicator flashes 5 times at intervals of 0 5 sec ON 0 5 sec OFF when an error occurs When all the doors are closed with B the indicator does not flash START STOP switch indicator control START STOP switch indicator ON OFF Door coupled function When the driver door is opened the in...

Page 763: ... the SKM sends the smart key not detected warning signal to the BCM and instrument cluster through B CAN The BCM activates the buzzer for up to 10 seconds at intervals of 0 5 sec ON 0 5 sec OFF and turns on the smart key warning indicator on the instrument cluster If a smart key is found no operation is performed 1 2 3 4 5 Any door except the driver door is opened and then closed The smart key not...

Page 764: ...3 4 5 6 Smart key inside vehicle warning The ignition is turned ON or OFF or the ACC is turned ON A verified smart key found only in the vehicle including emergency slot with all doors including tailgate closed The passive LOCK signal is input without a valid smart key from the outside the vehicle The SKM sends the theft deterrent mode signal to the BCM through B CAN and the verified smart key is ...

Page 765: ...e transponder verification signal for 10 seconds If low smart key battery is detected during the verification process for ignition status change or engine start the SKM sends the signal for smart key battery low voltage warning to the BCM and instrument cluster through the B CAN for up to 10 sec until the warning condition is deactivated Smart key battery discharge confirmation and deactivation If...

Page 766: ...nditions will be met if jam is occurred when the electric steering motor is locked unlocked Failure Detecting Conditions When the UNLOCK retry occurs after ESCL LOCK command the ESCL LOCK is performed The UNLOCK retry is possible up to 2 times automatically If the UNLOCK retry occurs 3 times in succession the ESCL NOT LOCKED warning is triggered Reactivates when the ESCL LOCK conditions are met Wh...

Page 767: ...oon as the signal ESCL UNIT STATUS OK is received by the ESCL restart when the ESCL UNLOCK or LOCK activation conditions are met again by pressing the START STOP switch to change the ignition status within 10 seconds or after 10 seconds triggering the warning 8 ESCL FAIL warning The SKM monitors the ESCL and transmits the warning active command to the BCAN for 10 seconds through the BCAN signal ES...

Page 768: ...ey inserted into the slot is detected with IGN OFF and the driver s door open 12 SKM alert priority 1 Smart key out alarm Outside 1 2 Smart key reminder alarm Outside 3 Smart key verification failure alarm Inside 2 4 Transponder verification fail alert Inside 5 Smart key battery low voltage alert Inside 6 Transmission position alert Inside 7 SKM error alert Inside 8 Brake alert Inside 9 Clutch ale...

Page 769: ...irming the encrypted coding When the START STOP switch is pressed with the smart key inserted into the immobilizer slot because of the smart key battery discharge the SKM communicates with the EMS ECU through P CAN and the ECU starts to control the engine only the signal is valid A valid key verification time is provided for 10 seconds and the engine can be started during this time If pressing the...

Page 770: ... verification process is performed again When the ignition is turned ON the EMS ECU sends the challenge message to the SKM through the P CAN This is to verify whether the transponder of the smart key is valid If the verification fails it transmits the re verification signals 3 times for 2 seconds If 3rd re verification fails the verification is deactivated for 10 seconds and re activated after tha...

Page 771: ...operating voltage DC 7 V 18 V Inspection voltage DC 13 5 V Operating temperature 30 80 Storage temperature 40 85 Dark current IGN OFF 1 mA 12 V Measurement condition at 25 60 seconds after that ignition is turned off and stabilized data get IGN ON Max 2 A 12 V Measurement condition at 25 during DTC check mode ...

Page 772: ...els If there is any fault is displayed without other messages If the driver press the TRIP switch to change to the tire pressure display mode the tire pressure is displayed If the tire pressure is normal Tire Pressure OK is displayed If the tire pressure is abnormal the tire in question blinks then comes on depending on how the abnormality is severe on the display screen 2 MAJOR CHANGES 1 TPMS Glo...

Page 773: ...nloaded no occupant 32 psi at 20 Lower than minimum tire pressure Corresponding status lamp comes on if tire pressure is 24 psi or less Excessive tire pressure Corresponding status lamp blinks with shading reverse at interval of 0 4 seconds if tire pressure is 50 psi or higher Low tire pressure Corresponding status lamp comes on if tire pressure is 24 psi or less Sudden tire pressure loss Correspo...

Page 774: ...type Supervision type Display gear stage for manual transmission Informs appropriate shift time for manual transmission This means that you should shift up to 3rd gear 2nd gear or lower currently This means that you should shift down to 3rd gear 4th gear or higher currently The system operates normally when the indicator lamp looks not being gone out completely ...

Page 775: ...nd shows the messages above if the relevant systems are faulty 4 ESCL 5 LCD display Status Old New LCD display Bar graph border maintained when adjusting illumination brightness Average fuel economy and instant fuel economy displayed simultaneously Auto cruise indicator and supervision cluster DOT LCD graphic added for gasoline engine newly adopted DOT LCD winter mode deleted ...

Page 776: ...05 8 6 TPMS Global Warning Lamp Added Status Standard type Supervision type ECO indicator Warming up indicator Diesel Gasoline Diesel Gasoline ...

Page 777: ...ypes in the instrument cluster used for KORANDO C SVC super vision and STD standard While the SVC type has three LCD screens DOT LCD GAGE SEG LCD and ODO SEG LCD the STD type has one LCD screen 2 LAYOUT SVC ODO SEG LCD GAGE SEG LCD GAGE DOT ...

Page 778: ...05 10 Engine RPM gauge Speedometer STD LCD ...

Page 779: ...05 11 8010 01 1 SVC 3 DESCRIPTION OF WARNING LAMPS INDICATORS ...

Page 780: ...05 12 2 STD ...

Page 781: ...en the tail lamp is switched on This indicator comes on when the ignition switch is turned to the ON position and will go off when the glow plugs are sufficiently heated This indicator comes on when the water level in the fuel filter exceeds a certain level This lamp comes on when the headlamp high beam is operated This indicator comes on when the fog lamp switch is operated after the tail lamps c...

Page 782: ...nsor and cluster When the coolant temperature is 120 C or higher this lamp blinks at an interval of 1 second a message is displayed the warning sounds once through the speaker and the buzzer sounds at an interval of 0 5 seconds This lamp comes on when any door is open or not closed completely both STD and SVC class This lamp comes on when the ignition switch is pressed ON It keeps coming on if the...

Page 783: ...tive This lamp comes on when the start switch is ON or when the battery level is low For EEM warning lamp is controlled according to CAN signal This lamp comes on when the ignition switch is turned to ON position and then goes off if the engine oil level is normal If the engine oil level warning lamp comes on while driving check the engine oil level and oil leakage This indicator comes on when the...

Page 784: ... is operated This indicator comes on the immobilizer transponder is not certified This lamp comes on when the parking brake is applied or the brake fluid is insufficient If this lamp doesn t go off after the parking brake is released check the brake fluid level first and then fluid leakage This warning light comes on when the ignition switch is turned to ON and should go out if the system is norma...

Page 785: ...es off when the brake pedal is depressed auto cruise deactivated This warning lamp comes on when the 4WD LOCK switch is pressed This indicator goes off when pressing the switch again This warning lamp comes on when the 4WD system is defective This indicator comes on when the hazard warning flashers are switched on applies to STD class This indicator comes on when the ECO cruise system is activated...

Page 786: ...ent cluster The winter mode is used to start off on a slippery road with the 2nd gear If the switch is pressed again the winter mode is deactivated and system returns to standard mode This indicator comes on when the ignition switch is turned to the ON position and goes off when the passenger s seat belt is fastened The left turn signal indicator blinks if the light switch is pushed down to the le...

Page 787: ...on when the ignition switch is turned to ON and should go off in a few seconds If the TPMS is defective this warning light comes on This warning light comes on when the ignition switch is turned to ON and should go off in a few seconds If the tire pressure is too low this warning light blinks for 70 seconds and then ON This indicator indicates the proper gear shifting time Shift up to 3rd gear cur...

Page 788: ...05 20 1 SVC 4 OPERATING PROCESS 2 STD ...

Page 789: ...05 21 8010 01 3 Display Sequence Display sequence for STD main LCD SVC DOT LCD ...

Page 790: ...AFC IFC ILLUMINATION TPMS OUT TEMP Over 1 seconds Reset function Trip A B AFC Illumination 6 to 1 level unit of outside temperature Over 3 seconds Ready Mode change Illumination OUT TEMP ODO If the Trip Reset switch is not pressed within 3 seconds after getting into the illumination mode and the ambient air temperature mode the LCD changes to next mode The factory setting mode is DTE Distance To E...

Page 791: ... is switched on All input signals can be input 4 seconds after the pre warning system check indicator starts illuminating Only the symbol and DOT LCD are illuminated initially if the SKM Smart Key Module or door B CAN signal is received while B power is supplied If the ignition is switched on with the LCD illuminated the DOT LCD and the symbol follow the side fascia panel When the step 1 2 and 3 a...

Page 792: ...ched off the message GOOD BYE is displayed for 2 seconds and disappears The other LCDs go off as soon as the ignition is switched off The dial and pointer dim down for 2 seconds and go off at the same time when the DOT LCD goes off 7 ...

Page 793: ...ht 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 ignition switch ON OFF operation ...

Page 794: ...ination level DOT LCD ODO gauge LCD dial pointer Day Night Day Night B B CAN Wake UP Initial time Level 6 Level 6 OFF however level 6 for initial operation with B IGN1 ON After initial time Maintain previous level Maintain previous level OFF however maintains previous level for initial operation with B IGN1 ON IGN 1 Level 1 25 5 25 5 Level 2 40 12 40 12 Level 3 55 19 55 19 Level 4 70 26 70 26 Leve...

Page 795: ...05 27 8010 01 1 SVC Symbols in SVC 5 System Analysis ...

Page 796: ...05 28 Symbols in SVC via CAN ...

Page 797: ...osition IGN ON detecting time 40 80 ms after turning ignition switch to ON position 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 798: ...05 30 2 STD Symbols in STD ...

Page 799: ...osition IGN ON detecting time 40 80 ms after turning ignition switch to ON position 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 800: ...05 32 Symbols in STD via CAN ...

Page 801: ...05 33 8010 01 ...

Page 802: ...ulated by using the value of pulse per 1 km which is programmed in the EEPROM Applicable maximum driving speed is 300 km h If the vehicle speed goes over the limit ODO and Trip meter does not operate any more and the pointer indicates the maximum km h MPH The pulse count information is sent from the speed module according to the speed CAN data that matches the speed frequency ...

Page 803: ...e first time Press and hold mode switch for more than 1 sec Maximum Odo value If the signal indicating actual vehicle speed above 300 km h is received the data is not accumulated Function Signal Remark Input data Speed signal Display type 6 digits LCD Display range 0 999999 km mile Hold Resolution 1 km mile Maximum Odo value If the signal indicating actual vehicle speed above 300 km h is received ...

Page 804: ...m mile Display interval every 1 seconds 1 DTE Distance To Empty Mode The DTE distance to empty function is an estimation on how much further the vehicle can be driven with the fuel remaining in the tank based on the previous driving pattern fuel economy 7 Display Mode STD Class Odometer Display Data Storage STD SVC ...

Page 805: ... or higher after refueling A For auto reset Drive at speed of 1 km h or higher after refueling Menu is not reset when pressing TRIP switch for more than 1 sec Changed to manual setting when pressing TRIP switch for more than 5 sec B For manual reset Menu is not reset when driving at speed or 1 km h or higher after refueling Menu is reset when pressing TRIP switch for more than 1 sec Changed to aut...

Page 806: ...range 0 0 20 ℓ 100km km ℓ 0 0 50 MPG Resolution DOT 0 2174 ℓ 100km km ℓ per Bar 0 5435 MPG per Bar Display interval every 200ms 25 SVC 3 Instant Fuel Consumption Mode The LCD display indicates the instant fuel consumption for 2 seconds calculated based on driving distance and fuel consumption for last 2 seconds Function Signal Remark Display type 3 digits LCD Display range 0 0 99 9 MPG ℓ 100 km km...

Page 807: ...re s status and warns a driver for dangerous situations At initial start more than 20 minutes have elapsed after ignition off the tire pressure is not determined It can be displayed after 10 minutes of driving at speed of 20 km h or higher Standard type Pressing the TRIP switch at the illumination brightness mode shows the items in the following order TPMS front TPMS rear Status Operating conditio...

Page 808: ...igher Low tire pressure Corresponding status lamp comes on if tire pressure is 24 psi or less Sudden tire pressure loss Corresponding status lamp blinks with shading reverse at interval of 0 4 seconds if tire pressure changes more than 3 psi per 1 minute at speed of 0 km h or above Imbalance between left and right tire pressure Corresponding status lamps blink alternately at interval of 1 0 second...

Page 809: ...both STD and SVC class regardless of FATC type automatic or manual For SVC class the driver set only the unit between and on the DOT LCD the ambient temperature is displayed on the SEG LCD Function Signal Remark Display type 3 digits LCD Display range Resolution 1 1 30 90 22 194 31 33 maintain 30 91 93 maintain 90 STD SVC ...

Page 810: ...nstrument cluster buzzer output If there are multiple signals at a time the operation should be completed by the priority Priority Item Buzzer output time Operating condition ON OFF 1 PAS See PAS 2 ESP 0 1sec 0 1sec Instrument cluster buzzer output signal is received from ABS ESP 3 Engine overheat warning lamp 0 5sec 0 5sec Engine overheats 120 or higher 4 Water separator warning light 0 5sec 0 5s...

Page 811: ...f diagnosis 1 Sensor Operating Process The ultrasonic sensors transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it in the following order L C R Self diagnosis is performed once when the ignition is switched on gear shift lever in R position If the system is defective Fail due to open sensor or communication problem the information for the failed sensor is sent to...

Page 812: ...d the PAS returns to undetected condition Process while re inputting After timeout the process is performed normally if the signal required for display is received from beginning to end not detectable if the signal is received in the midst of process 1 2 Exception error handling Buzzer interval when measuring distance ...

Page 813: ...erage fuel consumption indicates average fuel control Reset Press and hold the Trip switch for more than 1 second Instant fuel consumption indicates fuel consumption for a short periods TRIP switch Illumination brightness indicates tail lamp brightness control Brightness control Press and hold the Trip switch for more than 1 second Start up screen LCD display shows this message for 2 seconds after...

Page 814: ... door with engine OFF and Smart key inserted in the Smart key holder This message informs the driver that the brake pedal should be depressed and the ignition switch be pressed in order to start the engine if the ignition is switched to ACC mode for more than one time when the driver keeps pressing the ignition switch without depressing the brake pedal LCD display shows this message when you press...

Page 815: ...y obstacle is detected in the rear of the vehicle when the shift lever is moved to R position with IGN ON each sensor shows its position and distance If any error is detected during initial diagnosis it is displayed as Other than that is operated in the same way as the PAS distance measurement mode Cruise control This message comes on when the cruise control system is activated This message comes ...

Page 816: ...open with the ignition in the OFF position and the key removed Low fuel level This message comes on when the remaining fuel is insufficient ESP check This message comes on when the ESP system is faulty ABS check This message comes on when the ABS system is faulty Engine oil level check LCD display shows this message when the engine oil level is low Have the system checked at Ssangyong Authorized S...

Page 817: ...This message helps the driver to predict the driving direction since the tire alignment is displayed on the instrument cluster The images on the left show that the tires are aligned to the left When the tires are aligned to the right the image is symmetrical vertically Tire alignment is displayed between level 0 and level 5 depending on the alignment degree when the ignition switch is turned to ON...

Page 818: ...05 50 5 SELF DIAGNOSIS PROCESS 1 Self Diagnosis Process Mode ...

Page 819: ...arning lamp and indicator lamp All the warning lamps and indicator lamps come on by MICOM control CAN communication and they blink if faulty However the wired type symbols such as air bag LH RH turn signal indicators hazard warning flasher high beam front fog lamp do not come on 3 Miscellaneous When entering into the self diagnosis mode the instrument cluster illumination output will be 100 All th...

Page 820: ... 3 A relay load Turn signal lamp switch 0 1 A relay load AUTO hazard warning flasher switch 0 1 A relay load Multifunction wiper switch Wiper switch LO 0 1 A relay load HI 0 1 A relay load AUTO 0 22 0 05 A relay load Fixed Max 0 1 A relay load AUTO washer switch 0 1 A relay load Washer switch 0 1 A relay load Wiping speed control switch Max 25 mA Mist switch 0 1 A relay load Rear wiper washer swit...

Page 821: ...witch DC 12V 0 1A max 30 mA Rear glass and outside rearview mirror heating switch DC 12V 0 1A max 30 mA Power window main switch Item Specification Power window main switch Rated voltage DC 12 V Operating voltage DC 9 to 16 V Rated load AUTO switch 0 7 A motor load AUTO MANUAL switch 10 A motor load Window lock switch 10 A motor load Door unlock switch 0 4 A motor load Power window sub switch Item...

Page 822: ...3 3 KΩ 5 0 4 to 1 0 V MODE 6 KΩ 5 1 1 to 1 4 V MUTE 9 9 KΩ 5 1 5 to 1 8 V SEEK UP 16 7 KΩ 5 1 9 to 2 25 V SEEK DOWN 31 3 KΩ 5 2 26 to 2 64 V TIP 670 Ω 5 TIP 1 08 KΩ 5 Bluetooth hands free 64 7 KΩ 5 2 66 to 3 0 V Front seat heating and ventilation switch Item Specification Front seat heating and ventilation switch Driver seat heating switch 12V 0 1A max 30 mA Driver seat ventilation switch 12V 0 1A...

Page 823: ...earview mirror switch Outside mirror switch Changed from self return type to push lock type Hazard warning flasher switch TRIP reset switch Digital clock Windshield heating switch Rear glass outside rearview mirror heating switch Windshield heating switch TRIP reset switch Rear glass outside rearview mirror heating switch Hazard warning lamp switch ...

Page 824: ...nd step 1st step OFF Switch with heating LO HI same as conventional switch Front seat heating ventilation switch 2 level of driver seat heating and ventilation 2 level of passenger seat heating Driver seat heating switch 2nd step 1st step OFF Driver seat ventilation switch 2nd step 1st step OFF Passenger seat heating switch 2nd step 1st step OFF Seat heating and ventilation unit switch application...

Page 825: ...l switch passenger Door panel switch rear IP panel switch Steering wheel switch Front console switch Trunk switch Headlining switch 1 2 3 4 5 6 7 8 This helps to enable the driver to drive the vehicle safely and comfortably by operating the switch for the driving situation ...

Page 826: ......

Page 827: ...tside mirror switch Heater and A C control switch auto Start stop switch Steering wheel remote control switch Center fascia switch Passenger door switch Lower main panel switch Cruise control switch Multifunction switch Switch layout ...

Page 828: ...h RH Front seat heating and ventilation switch With heating and ventilation switch With heating switch Rear door switch and heating switch LH Driver power seat switch Tailgate switch Luggage lamp switch Center room lamp switch Overhead console switch ...

Page 829: ...driver anti trap system and driver window safety function Driver window safety function The anti trap system enables the driver s window to automatically reverse when something is caught in the window as it is closing When the sensor detects an obstacle the window will be lowered immediately The anti trap safety system is available only for the driver s window equipped with the automatic rolling u...

Page 830: ...The window moves upwards or downwards while this switch is operated Rear RH window switch The window moves upwards or downwards while this switch is operated Driver door window switch The driver s door window switch has Auto down Auto up function The window can be controlled within 30 seconds by activating the power window relay even after turning off the ignition switch However if any of front do...

Page 831: ...ower window relay is turned ON The power window relay keeps ON for 30 seconds even when stopping the engine However the power window relay is turned OFF when opening a front door When locking the door activation of theft deterrent mode the power window relay is immediately turned OFF 1 2 3 ...

Page 832: ... door locks The BCM controls the lock unlock switch using the door lock unlock relay This is a same control type with Auto door lock function that locks the doors when the vehicle speed exceeds 30 km h see circuit diagram 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 u...

Page 833: ...K from LOCK position BCM sends the UNLOCK signal for 0 5 seconds 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 regardless of the door lock switch positions All doors stay unlocked when receiving the door lock signal ...

Page 834: ...n of driver door lock switch for 0 5 seconds The central door dock switch is not available when the system is in theft deterrent mode When turning the ignition off all doors are automatically unlocked if any of the door lock knob switches is in LOCK position 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 835: ... the switch to get a desired view C It is mounted to the door trim and can be adjusted to up down left or right so that the driver can obtain a clear view of the rear of the vehicle depending on the driver s physical condition The driver can fold the outside rearview mirror when passing by the narrow road or parking the vehicle Do not fold or unfold the outside rearview mirrors manually since the ...

Page 836: ...u turn the folding switch to the OFF position with the folding relay activated the unfolding relay is activated for 0 1 second 1 2 3 Folding unfolding control The control logic is the same for folding to unfolding operation and unfolding to folding operation The AUTO folding unfolding function is not available when the folding switch is ON The AUTO folding unfolding function is available when the ...

Page 837: ...y when the switch is operated A It is mounted to the door trim and can open or close only the window at the door 4 Rear Door Power Window Sub Switch It is mounted to the door trim and can open or close only the window at the door Rear seat heating switch When you press the switch the heating is operated and indicator lamp comes on Power window switch The window is operated only when the switch is ...

Page 838: ... the coolant heated by the engine heat to the heater This allows the driver to maintain the indoor comfortable conditions throughout the year Temperature control dial AUTO switch LCD display Fan speed dial A C switch A B C D E ON OFF switch Defroster mode switch Indoor temperature sensing part Air source selection switch Air distribution switch F G H I J Fan speed dial A C switch MAX A C switch De...

Page 839: ...The mode is switched in the following order each time the switch is pressed Vent mode Bi level mode Foot mode Defroster Foot mode LCD display AUTO switch When pressing this switch AUTO is shown on the display and the fan speed and air distribution mode are adjusted automatically to keep interior temperature to the set temperature Defroster mode switch This is used to remove the condensation from t...

Page 840: ...to the fresh air mode at the same time MAX A C switch This is designed for increasing driver comfort When the switch is pressed the indicator comes on and the air conditioner starts at the same time and vent and recirculation modes are selected automatically Defroster foot mode switch If the switch is pressed the indicator comes on while the air flows to the footwell and the windshield Defroster m...

Page 841: ...g the switch for the driving situation It consists of the windshield heating switch TRIP RESET switch rear glass outside rearview mirror heating switch and hazard warning flasher switch Windshield heating switch TRIP RESET switch Rear glass outside rearview mirror heating switch Hazard warning flasher switch A B C D ...

Page 842: ...omy Illumination level Tire pressure with TPMS Ambient air temperature for STD Trip A Trip B Distance to empty Average fuel economy Instant fuel economy Illumination level Tire pressure with TPMS Ambient air temperature for SVC Press and hold this button to initialize reset Trip A Trip B and average fuel consumption adjust illumination level or change the unit of temperature Description Rear glass...

Page 843: ... 12 minutes when the switch is pressed with the engine started Press the switch again to stop the operation The output is ON only for 6 minutes when turning on the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once This function is available only when the engine is running Operation curve ...

Page 844: ...inutes when the switch is pressed with the engine started Press the switch again to stop the operation The output is ON only for 6 minutes when turning on the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once This function is available only when the engine is running Operation curve ...

Page 845: ...initialize reset Trip A Trip B and average fuel consumption adjust illumination level or change the unit of temperature Description The factory setting is DTE mode Display Mode Switch Detecting time Function Briefly and hold Below 1 second 60 to 980 ms STD Mode change Odo Trip A Trip B DTE Average fuel consumption Instant fuel consumption Illumination level Ambient air temperature SVC Mode change ...

Page 846: ...tch status Pressing the switch again turns off the turn signal lamps The turn signal lamp does not operate while the hazard warning flasher operates Hazard warning flasher switch 4 Hazard warning flasher switch The hazard warning flasher blinks during emergency hazard warning lamp control and air bag deployment signal activation ...

Page 847: ...ain Panel Switch Rear fog lamp switch EU ONLY Steering wheel heating switch HLLD Headlamp Leveling Device 4WD LOCK switch ESP OFF switch This helps the driver to drive the vehicle comfortably by operating the switch for the driving situation ...

Page 848: ...ch The ESP OFF switch is of push return type which is used to stop or resume the ESP function 4WD LOCK switch This switch is of push lock type which enables to increase decrease the torque to the rear wheels in AWD mode HLLD Headlamp Leveling Device The headlamp aiming can be adjusted by using this dial type switch Rear fog lamp switch EU ONLY This switch is of push return type which sends ON OFF ...

Page 849: ...vehicle enters into the 4WD AUTO mode automatically If it is below 35 km h the vehicle returns to the 4WD LOCK mode 4WD mode operation table 4WD LOCK switch Vehicle speed Drive mode Deactivated 4WD AUTO Unlimited 4WD AUTO Activated 4WD LOCK 40 km h or higher 4WD AUTO Activated 4WD LOCK Below 35 km h 4WD LOCK 4WD 4WD stands for Four Wheel Drive and drives all the wheels to maximize the vehicle s dr...

Page 850: ...tch is a constant open type instant contact switch and grounded to IGN1 The default setting is ESP ON and it is turned on and off each time the switch is pressed If the driving wheels are slipping on snowy or icy roads the engine rpm may not increase even when you depress the accelerator pedal and accordingly you may not be able to move your vehicle In this case stop the ESP function by pressing t...

Page 851: ...ESP operation blink under diagnostic mode indicator lamp ON in instrument cluster impossible to communicate with CAN module ESP warning lamp module The ESP warning lamp shows self diagnosis result of ESP function and whether there is a fault The ESP warning lamp comes on when ...

Page 852: ...n panel In that signal voltage from the steering wheel heating controller which is installed in the steering wheel is grounded This is used as an operation signal for the steering wheel heating system The indicator in the switch comes on when it is operated Steering wheel heating switch 3 Operation process ...

Page 853: ...wer seat switch 1 Power seat switch Driver side 4 Power Seat Switch Assembly Seat sliding Seatback reclining Seat height adjustment A B C Seat sliding Seatback reclining Seat height adjustment Power seat switch ...

Page 854: ...udio remote control switch RH Audio remote control switch LH 1 Audio Remote Control Switch 4 STEERING WHEEL SWITCH MUTE MODE switch Volume UP DOWN switch SEEK UP DOWN switch Handsfree switch Tip switch D Tip switch D ...

Page 855: ...tch Change down CD mode Select next previous track and FF REW Radio mode Change frequency UP or DOWN Press and hold to auto search MUTE MODE switch To eliminate the sound MUTE briefly press this switch To change the audio mode Radio CD USB AUX Radio press and hold this switch Handsfree switch To make receive end a call press and hold this switch ...

Page 856: ... washer switch The multifunction switch contains the auto washer and wiper switch front fog lamp switch and auto hazard warning flasher switch For the vehicle with air bag since the contact coil is fitted to the upper part of the multifunction switch and ESP steering wheel angle sensor is fitted to upper part of the contact coil pay attention to when removing and fitting or checking the wiring ...

Page 857: ...light analyzed by the automatic light sensor Lights OFF High beam ON To turn on the headlamp high beam push the lever towards the instrument cluster with the headlamp low beam on Right turn signal lamp blinks 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 switch To turn on the fo...

Page 858: ... downward when the windshield wiper switch is in AUTO position Fast Fast interval Slow Slow interval Wipers are not in operation Operates automatically according to the vehicle speed and amount of rainfall Continuous wipe fast operation Continuous wipe slow operation MIST OFF AUTO LO HI Auto washer switch If pressing the switch when the wiper switch turns to the OFF position washer fluid is spraye...

Page 859: ...ou release the lever TYPE B 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 Rear wiper is not in operation TYPE A INT Rear wiper operation Intermittent ON Rear wiper operation Normal Speed Rear wiper operation When the switch is fu...

Page 860: ... The cruise control switch has a fivefold switch in it The engine ECU can determine the current driving condition since the resistance varies depending on the operation of the switch The cruise control system is operated at vehicle speed of between 38 km h and 150 km h The manual transmission is operated in the range of 3rd gear or higher This function can be used at the following traffic conditio...

Page 861: ...ch side There is another horn installed at the bottom of the battery tray side in the engine compartment for theft alarm Operating the horn switch on the steering wheel applies the power to the horn relay to operate both horns Dual horn The theft deterrent horn is controlled by the BCM in armed mode regardless of the horn relay operation Horn dual horn Horn switch ...

Page 862: ...ressing the switch a third time will turn off the operation Pressing the desired side of the switch heats the seat cushion and seatback or activates the seat ventilation function The temperature of the seat is kept uniform by cutting off or connecting power through thermistor fitted in the seat The seat heating and ventilation unit controls the rpm of the motor using PWM control to operate the sea...

Page 863: ...O 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 separate seat warmer unit to control the temperature of the seat heating system 2 Front Seat Rear Seat Heating Switch Overview Driver and Passenger Seats LO HI Rear Seats ON OFF LH RH Th...

Page 864: ...d operation switch ON When closing the driver or passenger door the front room lamp comes on for 2 seconds and then dims down for 3 seconds door coupled operation switch ON The front room lamp turns on off depending on the operation of the front room lamp ON OFF switch spot switch Front room lamp switch Door coupled operation switch Sunroof switch Front room lamp connector Sunroof connector ...

Page 865: ...cally opened Opening is carried out in 2 steps In first step the area 5 cm behind the sunroof is not opened Push up the switch once again in order to open the sunroof completely The sunroof operation stops if you operate the switch during its operation 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...

Page 866: ... immediately When receiving the door unlock signal with IGN OFF key removed and door closed the overhead console room lamp center room lamp come on for 30 seconds For specification with the SKM the lamps come on by the REKES unlock or passive unlock signal When receiving the door unlock signal again while the lamps stay on by the REKES or passive unlock signal the overhead console center room lamp...

Page 867: ...closing the driver door or closing the sunroof during indoor buzzer operation the buzzer stops its operation immediately When closing the driver door or sunroof and opening again during warning operation the sunroof warning does not work If the condition is met after the ignition switch is turned to ON position again the indoor buzzer sounds for 10 seconds with the interval of 0 02s ON 1 58s OFF T...

Page 868: ...06 51 8510 00 Tailgate open switch 7 TAILGATE SWITCH ...

Page 869: ...ilgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h during its operation When the tailgate switch on smart key is pressed in theft deterrent mode or with the smart key detected by the exterior antenna the SKM verifies the smart key and disarms the tailgate only When the tailgate is open and closed the system enters into the theft deterr...

Page 870: ... 10W Door courtesy lamp 2 5W Description Numbers Specification Headlamp High beam 2 H1 55W Low beam 2 H7 55W Turn signal lamp 2 P21W Position lamp LED Front fog light 2 H16 19W Rear fog light 2 21W Side repeater LED Rear combination lamp Tail lamp LED Turn signal lamp 2 PY21W Back up lamp 2 W16W Stop lamp 2 P21W License plate lamp 2 W5W High mounted stop lamp LED Puddle lamp 2 LED ...

Page 871: ...ng Diode or Luminescent Diode LED is a semiconductor diode that emits incoherent narrow spectrum light when electrically biased in the forward direction of the p n junction as in the common LED circuit In short it is an element that converts electric signals into light signals Yellow blue red and white LEDs are currently available The followings are the advantages of LED It is not glaring and does...

Page 872: ... its function changed 2 lamp system 4 lamp system Headlamp high low beam dualized and tail lamp changed to LED type Fog lamp Fog lamp design changed Headlamp high low beam Turn signal lamp Tail lamp Turn signal lamp Tail lamp DRL EU Headlamp high beam Headlamp low beam ...

Page 873: ...lamp Rear combination lamp design and its function changed Tail lamp stop lamp changed to LED type Backup lamp Turn signal lamp Stop tail lamp Rear fog light Tail lamp Stop lamp Rear fog light EU Turn signal lamp Backup lamp Stop lamp ...

Page 874: ...07 7 8310 00 Indoor Front door courtesy lamp Door courtesy lamp design changed due to modified front door trim ...

Page 875: ...r lamp combination lamp license lamp high mounted stop lamp and reflex reflector lamp Side lamp outside turn signal lamp and puddle approach lamp 2 Layout Front side Outside turn signal lamp and puddle lamp Headlamp Fog lamp Turn signal lamp Headlamp high beam Headlamp low beam Puddle lamp Outside turn signal lamp Fog lamp Tail lamp DRL EU ...

Page 876: ...ear combination lamp Rear side License plate lamp Reflex reflector lamp High mounted stop lamp Vehicle with spoiler Vehicle without spoiler Tail lamp Stop lamp Rear fog light EU Turn signal lamp Backup lamp Stop lamp ...

Page 877: ...mp according to the signal from the AUTO light sensor through LIN communication when the multifunction switch is in AUTO position Headlamp low beam Headlamp high beam DRL Day Time Running Light DRL is the function to turn on the high beam and tail lamp without any intervention from the light switch DRL turns off the lamps when turning off the light switch This is an additional safety device to pre...

Page 878: ... 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 1 2 Tail lamp auto turn off When opening and closing the driver door after turning off the ignition with the tail lamp ON the tail lamps go off automatically The tail lamps come on again when inserting the ignition key without SKM an...

Page 879: ...ge The BCM communicates with the auto light sensor when the ignition is turned on and turns on or off the tail lamp and headlamp automatically according to the signals from the sensor when the multifunction switch is set to AUTO light The BCM communicates with the rain sensor even if the multifunction switch is in tail lamp Auto light switch Automatic light sensor unit ...

Page 880: ...ontrol by BCM The rain sensor AUTO light module communicates with BCM with IGN ON When the AUTO light switch is in the AUTO position the BCM controls the tail lamp and headlamp according to the LIN communication data ...

Page 881: ...7 14 4 License lamp operation process When the corresponding lamp comes on and goes off by operating the tail lamp AUTO light high beam and low beam on the multifunction switch the license lamp also does ...

Page 882: ......

Page 883: ...07 16 Headlamp ...

Page 884: ...07 17 8310 00 ...

Page 885: ...07 18 Headlamp W VSM ...

Page 886: ...07 19 8310 00 ...

Page 887: ...07 20 Tail lamp circuit diagram ...

Page 888: ...07 21 8310 00 ...

Page 889: ...ted by the fog lamp switch only when the headlamp tail lamp is operating The front and rear fog lamps go off when turning the ignition switch or headlamp tail lamp switch to the OFF position Front Rear EU only Rear fog light Front fog lamp ...

Page 890: ...07 23 8310 00 Fog lamp circuit diagram ...

Page 891: ...er minute The BCM determines that there is an open circuit if the load is 3 0 A or less and there is a short circuit if the load is 7 0 A or more When turning ON the turn signal switch the lamp blinks 3 times by the BCM 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 blinki...

Page 892: ...de repeater lamp operates only when IGN1 is ON If the side repeater lamp fails while it is illuminated the BCM cycles the lamp and buzzer 100 times per minute The lamp automatically flashes 3 times when the multifunction switch is turned on If the switch is turned off during this operation the lamp flashes 3 times and then goes off If the switch is turned off and then on during the 3 times of auto...

Page 893: ...07 26 Turn signal lamp circuit diagram ...

Page 894: ...07 27 8310 00 ...

Page 895: ...ch fitted to the brake pedal and releasing the brake pedal turns off it 9 Backup lamp operation process When shifting the TGS lever into the R position with the ignition switch ON the backup lamps come on If the lever is placed in other positions the lamps go off High mounted stop lamp Rear combination stop lamp Backup lamp ...

Page 896: ......

Page 897: ...07 30 Stop lamp circuit diagram ...

Page 898: ...07 31 8310 00 ...

Page 899: ...07 32 Stop lamp W VSM circuit diagram ...

Page 900: ...07 33 8310 00 ...

Page 901: ...07 34 Backup lamp circuit diagram ...

Page 902: ...l or outside door handle switch 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 Approach lamp ON 1 Lamp control for models without SKM When receiving the UNLOCK signal in the theft deterrent mode the approach lamps come ON fo...

Page 903: ...07 36 Front room lamp Glove box lamp Sun visor lamp 1 Layout 2 INTERIOR LAMPS ...

Page 904: ...07 37 8310 00 Center room lamp Luggage lamp Door courtesy lamp ...

Page 905: ... is pressed the front room lamp and center room lamp are illuminated for 2 sec and then fade out for 3 sec If a door except the tailgate is opened and then closed while the room lamp is fading out the room lamp is illuminated for 2 sec and then fades out for 3 sec If the ignition is turned on the room lamp goes off immediately The front room lamp and center room lamp are illuminated for 30 sec whe...

Page 906: ...enter room lamp 3 Glove box lamp The glove box lamp comes on when the glove box is opened after the tail lamp is illuminated The sun visor lamp comes on when the sun visor vanity mirror cover is opened Luggage lamp control by coupled operation switch when opening closing tailgate The luggage lamp comes on when the tailgate is open The luggage lamp goes off as soon as the tailgate is closed 1 2 4 S...

Page 907: ...07 40 Courtesy lamp The door courtesy lamp comes on when the driver s door or passenger s door is opened 5 Courtesy lamp ...

Page 908: ......

Page 909: ...07 42 Room lamp circuit diagram ...

Page 910: ...07 43 8310 00 ...

Page 911: ...wiper switch to the OFF position before any car wash to avoid unwanted operation of the wipers Wiper mist washer coupled wiper Auto washer coupled wiper Rain sensor coupled wiper operation LIN Speed sensitive intermittent wiper Wiper low high 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 ...

Page 912: ...e switch is turned ON and the wiper relay is turned ON for 4 cycles After that the washer motor is operated for about 2 seconds to spray the washer fluid again and the relay is turned ON for 3 cycles and then the relay is turned OFF 2 Rear Washer Fluid Supply System The front washer fluid reservoir supplies the rear washer fluid without additional washer fluid reservoir Operating part for rear wip...

Page 913: ...cordance with a seamless contact condition between the mounting surface of the nozzle and the curved surface of the engine hood The inside of the nozzle is designed in a fan shape to change the spray direction continuously based on the time the fluid is sprayed Refer to the figure below The spray direction is changed by means of the whirlwind and back flow generated while the washer fluid is passi...

Page 914: ...M according to the driver s choice This sensor emits infrared rays through LED and then detects the amount of rain drops by receiving the rays reflected off the sensing section rain sensor mounting section on the windshield with photodiode AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay auto speed control A position that can control the sensitivity for the amount of rains on ...

Page 915: ...ends the operating request signal to the BCM which drives the wiper directly At this moment the BCM also sends the information on whether the wiper is in operation mode or whether the multifunction wiper switch is in AUTO position to the rain sensor BCM Underhood Fuse Box ...

Page 916: ... 8 Rain sensor unit Wiper and washer switch 3 SYSTEM LAYOUT INCLUDING RAIN SENSOR Wiper Front wiper Rear wiper Rear washer hose and nozzle For vehicles with rear spoiler For vehicles without rear spoiler ...

Page 917: ...08 9 7810 00 BCM Front nozzle assembly Washer fluid reservoir assembly Washer motor Reservoir tank Washer motor ...

Page 918: ...ard when the windshield wiper switch is in AUTO position Fast Fast interval Slow Slow interval Wipers are not in operation Operates automatically according to the vehicle speed and amount of rainfall Continuous wipe fast operation Continuous wipe slow operation MIST OFF AUTO LO HI Front auto washer switch When you press this switch with the front wiper switch in OFF position washer fluid will be s...

Page 919: ...e with the IGN1 ON the wiper relay is turned on after 0 1 sec has passed When the wiper returns to the park position the wiper relay is turned off When the MIST switch signal is input the wiper is operated at high speed When the switch is release from the MIST position the wiper is operated at low speed 1 2 ...

Page 920: ...g wiper operation The wiper relay should stay ON in low high wiper operation mode even if the parking signal for the wiper motor is not received In INT AUTO wiper operation mode the wiper relay should be turned OFF after 5 seconds if there is no parking signal for the wiper for 3 seconds and informs the driver of parking position signal abnormality While the wiper operates at low high speed the fr...

Page 921: ...he wiper stops after three more wipes since that the washer switch is turned to OFF position 1 2 Windshield Washer Control Function 1 Windshield washer coupled wiper Wiper and Washer Coupled Operation Pull the switch briefly for less than 0 6 sec One wiping cycle Pull and hold the switch for more than 0 6 sec Three wiping cycles with washer fluid spray ...

Page 922: ...e wiper operation by the intermittent automatic wiper switch the wiper will operate only once When holding the washer switch for more than 0 6 seconds the wiper relay is activated 0 5 seconds after The wiper stops after three more wipes since that the washer switch is turned to OFF position 2 ...

Page 923: ...r operation When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent automatic wiping mode will be started The front and rear washer switch signal are overridden during the operation of auto washer The input from the switch during the AUTO washer coupled wiper operation also is ignored 1 2 3 4 5 2 AUTO washer couple...

Page 924: ...ontinue until you release the lever TYPE B 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 Rear wiper is not in operation TYPE A INT Rear wiper operation Intermittent ON Rear wiper operation Normal Speed Rear wiper operation When t...

Page 925: ...ch signal is received during the rear washer switch operation the washer motor stops and the front washer or automatic washer motor begins to operate 1 2 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 926: ...5 Rain Sensor Coupled Wiper Control Function AUTO Wiper operates automatically by rain sensor FAST Auto delay auto speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly ...

Page 927: ...08 19 7810 00 System layout 1 Rain sensor coupled wiper operation LIN ...

Page 928: ...on When the INT AUTO wiper switch is turned on from off with the ignition switch ON the wiper is operated at low speed for the 1st cycle regardless of the rain sensor signals After that if the INT AUTO wiper switch is turned on from off the wiper cycles one time at low speed only when the rain sensor detects the presence of rain 1 2 2 Power up reminder wiper ...

Page 929: ...egardless of the communication with the rain sensor However if the washer switch signal is received the washer relay is activated and wiper relay remains activated when the data coupled with rain sensor indicates continuous wiper operation 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 operation during rain sensor...

Page 930: ...ch in ON position and wiper motor stop parking position the wiper motor operates one cycle at low speed only when the rain sensor detects raindrops If the wiping speed control switch is changed more than 2 stages within 2 seconds the wiper motor operates only one cycle 1 4 Sensitivity control instant wiping ...

Page 931: ...urrent signal for parking status continuously The wiper motor is operated only when there is a request from the rain sensor 2 The wiper system sends continuously the signal for current status when the wiper parking terminal is shorted to ground with IGN2 ON and intermittent wiper switch in ON position The wiper motor is operated only when there is a request from the rain sensor 1 5 For abnormal wi...

Page 932: ... communication error signal from the rain sensor unit with IGN ON and the INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor cycles one time at low speed provided that the BCM receives a faulty sensor signal from the rain sensor unit with IGN ON and the INT AUTO switch ON 1 6 For faulty rain sensor ...

Page 933: ...sition the wipers do not operate When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position the wipers operate one cycle The wiper s operation cycle depends on the vehicle speed CAN communication with instrument cluster and wiping speed the side fascia panel Wiping cycle 3 0 5 sec FAST to 19 2 sec SLOW 1 2 3 7 Speed sensitive intermittent wiper ...

Page 934: ...08 26 Speed sensitive intermittent wiper interval ...

Page 935: ...ation if the foreign materials are removed the sensor operates normally Not defective but improperly working When the sensing portion is frozen operates normally after thawed When reversing on rough roads gravel roads hills or grass When receiving other ultrasonic signals metal sounds or air braking noises from heavy commercial vehicles When there is heavy rainfall or water drops When the sensor i...

Page 936: ...istance to any obstacle The PAS detects the returning signals reflected to the obstacles at regular intervals when the vehicle is parked to indicate the display and alarm for the distance between the obstacles by phase so as to allow the driver easy parking by securing safe distance 1 OVERVIEW Buzzer for PAS Buzzer sounds using instrument cluster buzzer Rearview camera ...

Page 937: ...09 5 8790 00 PAS sensor Parking aid unit 2 CONFIGURATION Installation of PAS sensor ...

Page 938: ...S 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 If there is no obstacle starts to detect the obstacles after self diagnosis again ...

Page 939: ...h long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously Sensor detection range Within 20 cm from the ground Objects may not be detected in this range Buzzer interval when measuring distance 2 Rear PAS Sensor ...

Page 940: ...09 8 Circuit diagram of ECU Internal circuit diagram of sensors ...

Page 941: ...09 9 8790 00 Sensor operating sequence The ultrasonic sensors transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it in the following order L C R ...

Page 942: ...d the PAS returns to undetected condition Process while re inputting After timeout the process is performed normally if the signal required for display is received from beginning to end not detectable if the signal is received in the midst of process 1 2 Exception error handling Self diagnosis is performed once when the ignition is switched on gear shift lever in R position If the system is defect...

Page 943: ...N ratio Signal noise ratio FM 45 db AM 40 db Stereo channel separation FM 20 db MP3 WMA USB Frequency response 20 Hz 20 kHz S N ratio Signal noise ratio 60 dB Channel response 54 dB MP3 WMA CD Frequency response 20 Hz 20 kHz 3 db S N ratio Signal noise ratio 50 dB Channel response 35 dB Bluetooth Frequency 2 402 2 480 MHz Specification Supports headset hands free A2DP and AVRCP profile formats Hea...

Page 944: ...4 Unit Item Specification Micro pole antenna Audio specification Operating current Max 150 mA Operating voltage DC 10 5 V to 16 V Operating temperature 30 60 Storage temperature 40 80 I O impedance 75 Ω FM ...

Page 945: ...accident fire or electric shock Do not use the system if it is malfunctioning sound or video output problem Doing so may lead to an accident or electric shock Please contact a Ssangyong service dealer immediately The system should be used only when the engine is started Using the system for an extended period of the with the engine off may discharge the battery Do not leave beverages or foreign ma...

Page 946: ...tal clock LCD display digital clock adopted center fascia switch audio LCD display LCD resolution LCD display resolution increased Audio head unit Audio head unit design changed 3 MAJOR CHANGES Audio head unit Digital clock ...

Page 947: ... USB insertion reverse direction normal direction iPod support function added to USB terminal USB AUX jack USB cable USB cable length changed due to new instrument panel Front rear feeder cables Front and rear feeder cables length changed due to new instrument panel ...

Page 948: ...11 8 Front tweeter speaker Design changed Front door speaker Design changed Front tweeter speaker Front door speaker ...

Page 949: ...11 9 8910 05 Rear door speaker Rear door speaker Design changed ...

Page 950: ...tenna and its own integrated amplifier to improve the radio frequency reception rate and to provide the high quality sound The iPod function also has been added to the USB terminal Front door speaker Audio remote control switch Audio head unit USB AUX jack assembly Bluetooth hands free microphone Front door tweeter speaker ...

Page 951: ...11 11 8910 05 Micro pole antenna Rear door speaker Bluetooth hands free microphone Audio remote control switch USB AUX jack assembly Audio head unit ...

Page 952: ...It has a built in high output amplifier allowing to provide the high quality sound Micro pole antenna Micro pole radio antenna is fitted to ensure the high sensitivity Bluetooth hands free Once the pairing is complete after searching for the Bluetooth phone you can use a various functions and contents in the phone via Bluetooth Audio remote control switch Outputs the signal when power mode volume ...

Page 953: ...11 13 8910 05 Door speaker FL Door speaker RL Door speaker FR Door speaker RR Tweeter speaker FL Tweeter speaker FR ...

Page 954: ... currently playing Press and hold Displaying data table of music currently playing 4 MEDIA button Playing connected external device such as USB iPod Bluetooth AUX 5 SET button Enter into setting mode 6 Adjustment button 7 Dial button Briefly press Receive a phone call Press and hold Connect to Bluetooth phone 8 End button Briefly press End a call Press and hold Disconnect Bluetooth phone Radio mod...

Page 955: ...ctivate mute Pause ON OFF Press and hold Switch the system off Turn dial adjust volume 14 ENTER button TUNE FILE dial Turn dial change frequency song or menu Press dial Change or select item or setting value Press and hold dial Turn off display window backlight comes on if any of buttons is pressed Radio mode Briefly press Select a stored station directly Press and hold Store the listening broadca...

Page 956: ...fied station number P1 P6 1 2 3 4 5 6 Disc insertion display Play mode display RDM Random Play folder in random orderRPT Repeat Play folder repeatedly INT Intro Play folder intro Current folder name Play disc Current playing song name Other information of current playing song Play time album artist genre 7 8 9 10 11 12 USB USB connection USB play 13 14 BT AUDIO Bluetooth connection 15 ...

Page 957: ...s the ENTER button Select one of the following Bass Middle Treble Balance Fader EQ sound effect Turn the TUNE dial or press the ENTER button to select the desired setting value Bass setting the bass level 7 7 Middle setting the middle level 7 7 Balance setting LH RH speaker balance LEFT 15 RIGHT 15 EQ Equalizer select EQ sound effect style EQ OFF POP ROCK COUNTRY VOICE JAZZ CLASSIC Default initial...

Page 958: ...select a desired setup item and press the ENTER button Select one of the followings Set Time Set Time Format Set Date Display Digital Clock On Off Turn the TUNE dial or press the ENTER button to select the desired setting value Repeat these steps if several items need to be set e g YY MMDD in date setting Set Time Set the current time Set Time Format Set the time format to 12 hour or 24 hour syste...

Page 959: ...ss the SCAN button briefly to keep listening it 4 Registering broadcasting frequency manually Select the broadcasting frequency to register When the 1BACK 6FLDR buttons to register is pressed for more than 2 seconds the beep sounds to indicate the registration is completed 1 2 Registering broadcasting frequency automatically Press the BAND button repeatedly to select the desired broadcasting band ...

Page 960: ...ect the song number or name to play the system begins playing the song 1 MP3 WMA song information view If you press the INF button briefly and repeatedly when a song is playing other information artist album genre play time for the song is displayed for 3 seconds If you press and hold the INF button when a song is playing the data table for the song is displayed for 5 seconds 1 2 To set scroll fun...

Page 961: ...registration is completed normally the audio system screen displays BT CONNECT and displays cellular phone model name or BT MOBILE together with the Bluetooth icon The Bluetooth device can be registered just once Although several devices can be registered you can select only 1 device to connect the system If the registered Bluetooth device is set to connect to other device disable the previous con...

Page 962: ...e MUTE button again to resume your conversation 1 Private mode When you press the Call button during hands free call PRIVATE is displayed and hands free call is changed to cellular phone call When you press the Call button during cellular phone call BT TEL is displayed and cellular phone call is changed to hands free call This function may not be available on some phone models 1 You can change to ...

Page 963: ...is stored to the USB terminal Press the MEDIA button repeatedly to select the USB or iPod function USB or I POD is displayed and the music files which has been played previously are played automatically 1 2 3 To use AUX jack Turn off the external device s power supply and connect its sound output to the AUX jack Press the MEDIA button repeatedly and select the AUX IN function Turn the VOL dial to ...

Page 964: ...ng playback it may be broken or operate incorrectly When you use the USB device for charging or heating by using the USB terminal on the audio system it may cause the system to deteriorate or fail iPod is a registered trademark of Apple Inc This audio system supports only the following iPod products iPod Nano iPod iPod Touch iPhone This audio system may not support some iPod iPhone products Always...

Page 965: ...1730 34100 PN 41730 34220 New 16 inch Silver 17 inch Silver 18 inch Diamond cutting PN 41730 34200 PN 41730 34300 PN 41730 34400 16 17 and 18 inch wheel assembly design changed For 17 inch existing 18 inch design used For 18 inch Hyper silver type Diamond cutting type Wheel offset and tire size same as before 1 MAJOR CHANGES ...

Page 966: ...g lamp Global warning lamp TPMS warning lamp Comes on if an error occurs in any component related to the TPMS regardless of tire inflation pressure Global warning lamp Comes on when the tire pressure is low DOT LCD display window supervision type Displays current tire pressure and abnormality ...

Page 967: ...e and temperature in tire rotating direction and wheel module ID code etc using the radio frequency to the TPMS ECU TPMS ECU The TPMS ECU is located to the rear bumper rail under the vehicle It outputs the tire pressure and each wheel s condition to the instrument cluster based on the wheel module information and CAN data ...

Page 968: ... power 3P Torque angle sensor 8P Battery 2P Connector to vehicle 8P Fuse for EPS Steering wheel angle sensor SWAS The steering wheel angle sensor is mounted between the steering column and the steering column shaft It is commonly used by the ESP Electronic Stability Program system And it receives signals of the steering wheel angle sensor from the ESP HECU Hydraulic Electronic Control Unit EPS uni...

Page 969: ...or during abrupt braking and acceleration 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 buses TGS Lever assembly The TGS communicates with TCU Transmission Control Unit ECU ESP HECU and instrument clus...

Page 970: ...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 and the slip joint E coupling control unit E Coupling ECU The E...

Page 971: ... 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 doesn t have PTU prop...

Page 972: ...f the HPS type steering gear box 4 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 box assembly Front sub fra...

Page 973: ...d 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 Body mounting Body mounti...

Page 974: ...this type of suspension the steering linkage tie rod is mounted on the knuckle The Macpherson Strut suspension is an independent suspension which has a spring on the strut with a built in shock absorber The lower arm is installed on sub frame and large strut damper is installed on the knuckle to support the tire Lower arm assembly The lower arm assembly connects the frame and knuckle It supports t...

Page 975: ...pe 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 976: ...sembly 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 is installed between knuck...

Page 977: ... 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 bar Bushing Clamp Lin...

Page 978: ... other D Front brake assembly The disc brake for 4WD vehicle is the same with the one for 2WD vehicle 7 BRAKE SYSTEM AND ESP SYSTEM LAYOUT 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 Caliper Disc Parking brake warning light ABS warning lamp ESP indicator ...

Page 979: ...brake for 4WD vehicle has the same structure with the one for 2WD vehicle but the appearance and knuckle shape is different from each other Caliper G Brake pedal Disc F 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 different sensor a...

Page 980: ... Hydraulic Power Steering The hydraulic pump is a vane type pump and consists of the flow control valve and pressure relief valve The oil reservoir sends the oil to the power steering pump and receives the oil from the power steering gear There is a shock absorber which is folded in the axial direction when the vehicle is crashed and a ignition switch assembly on the column shaft The lower shaft m...

Page 981: ... 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 ECU Tie rod end Tie rod end Gear box Steering cylinder Steering wheel assembly BLAC motor Lower shaft Column shaft Colum shaft assembly The column shaft a...

Page 982: ...his manual and follow the instructions carefully Signal words such as WARNING CAUTION and NOTE have special meanings indicates information to assist maintenance and instructions However above references and cautions cannot be inclusive measures so should have habits of paying attentions and cautions based on common senses indicates a potentially hazardous situation which if not avoided may result ...

Page 983: ...the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or mix the fasteners If necessary especially for inspection clean the removed parts completely Apply the oil or grease on the running and sliding surfeces before installation Use the specified sealant and gasket to prevent leakage if necessary Tighten the fasteners to the specified tightening t...

Page 984: ...exhaust system including catalytic converter Inspect all the components and body frame near the exhaust system 4 Tires Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads may indicates the uneven tire inflation pressure or poor wheel balance 5 Steering and suspension system Inspect the front and rear suspension and the steering system for damage...

Page 985: ...ts and installation status front side Jack up points for 2 post lift Stand jack up points and installation status rear side Stand jack up points and installation status front side Jack up points for 2 post lift Installation status Installation status ...

Page 986: ...uring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ...

Page 987: ...rake 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 is activated a...

Page 988: ...witches 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 moving this switch to f...

Page 989: ... 0 859 6th gear 0 676 Reverse gear 3 178 Oil Type Fuchs TITAN ATF 3292 Capacity approx 7 5 L Change interval EU Inspect every 20 000 km or 12 months But change every 60 000 km under severe condition General Inspect every 15 000 km or 12 months But change every 60 000 km under severe condition Resistance of oil temperature sensor 20 430 7 to 533 9 kΩ 0 146 8 to 175 7 kΩ 20 56 74 to 65 86 kΩ 100 3 2...

Page 990: ...02 6 2 Sectional Diagram Double planetary gear set Clutch pack Single planetary gear set Oil pump Torque converter Input shaft Intermediate shaft Differential assembly ...

Page 991: ...ew 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 mm X 2 3 9 to 7 8 ...

Page 992: ...rols the oil pressure for various internal clutches and bands to select the gear It also controls the electronic elements shift pressure and torque converter slip If the system is defective TCU provides FMEC Failure Mode Effect Control to maintain the functionality of transaxle This keeps the basic function of transaxle gear selection even when there are failure in controls and power supply There ...

Page 993: ...er 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 Converter Clutch Lock Up...

Page 994: ... 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 occur automatically whe...

Page 995: ...thly on an icy and slippery road 3 MODES AND FUNCTIONS 1 Mode Switch 2 M Mode Manual Mode This allows the driver to define the highest possible gear by selecting or on the gear selector when the lever is in the M position When the lever is first moved to the manual M position the transaxle will select the lowest possible gear W Winter mode pressed OUT Use the standard mode in normal driving condit...

Page 996: ...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 available 5th gear has engine bra...

Page 997: ...gislation 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 over temperature c...

Page 998: ...perates 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 connector The TCU processes inf...

Page 999: ...d 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 the instrument clus...

Page 1000: ...elected 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 Mode The hot mode is progr...

Page 1001: ...als 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 1002: ...ear 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 5th ON 0 1 1 0 1 6th O...

Page 1003: ... planetary gear Generates the gear ratio and transfers the power Engaged by hydraulic pressure and transfers the power to C1 clutch Transfers the power from torque converter to rear planetary gear Generates the gear ratio and transfers the power Engaged by hydraulic pressure and transfers the power to C1 clutch Transfers the power from input shaft to intermediate shaft Changes the rotating directi...

Page 1004: ...G 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 1005: ......

Page 1006: ...02 22 3 Hydraulic Circuit Diagram ...

Page 1007: ...02 23 3680 01 ...

Page 1008: ...02 24 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 1009: ...02 25 3680 01 3 Drive 2nd 2nd Auto 2 375 1 Power flow 4 Drive 3rd 3rd Auto 1 522 1 Power flow ...

Page 1010: ...02 26 5 Drive 4th 4th Auto 1 144 1 Power flow 6 Drive 5th 5th Auto 0 859 1 Power flow ...

Page 1011: ...02 27 3680 01 7 Drive 6th 6th Auto 0 676 1 Power flow 8 Reverse 3 178 1 Power flow ...

Page 1012: ...02 28 9 Neutral Park Power flow ...

Page 1013: ...ransmission control unit 3 ATF Automatic transmission fluid 4 DC Damper clutch 5 PCSV Pressure control solenoid valve 6 UD Under drive 7 OD Over drive 8 LR Low reverse 9 LP Line pressure 10 SOL Solenoid 11 VFS Variable force solenoid 12 PG A Input speed sensor 13 PG B Output speed sensor ...

Page 1014: ...tary gear set 3EA Clutches 2EA Brake 3EA O W C 1EA 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 receives and uses the s...

Page 1015: ...ine and depress the brake pedal before the attempt Shift 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 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 S...

Page 1016: ... 772 Reverse gear 3 385 Shift pattern Variable Shift range 4 Range P R N D Manual mode Shift range valve VFS 6EA Planetary gear 3EA Front Middle Rear Clutch 2EA Brake 3EA O W C 1EA Oil Type ATF SP IV M Capacity approx 7 1 L Change interval Maintenance free However under the severe conditions or commercially used change the oil at every 100 000 km EU 90 000 km Resistance of oil temperature sensor 2...

Page 1017: ...03 7 3660 01 4 COMPONENTS HPT 6A T 6F24 One way clutch Torque converter with slip lockup Oil pump Harness Valve body Side gear Driven gear ...

Page 1018: ...r 10 mm X 2 9 8 11 7Nm Bolt detent spring 12 mm X 1 12 0 16 0Nm Bolt valve body 10 mm X 8 9 8 11 7Nm Bolt V B solenoid bracket H5 mm X 9 9 8 11 7Nm Bolt torque converter housing 12 mm X 20 28 0 35 0Nm Bolt oil guide A 10 mm X 3 9 8 11 7Nm Bolt oil guide B 10 mm X 1 5 0 7 0Nm Bolt oil filter H5 mm X 2 9 8 11 7Nm 5 TIGHTENING TORQUE Descriptions Size x Numbers Tightening torque Nm TGS lever Nut 12 m...

Page 1019: ...omatic transaxle Bolt oil lubrication pipe 10 mm X 1 9 8 11 7Nm Bolt oil pump 12 mm X 7 20 0 26 0Nm Bolt parking rod guide 10 mm X 2 9 8 11 7Nm Bolt U D brake retainer T40 X 6 31 0 36 0Nm Bolt U D brake chamber T30 X 2 4 9 9 8Nm Bolt rear cover 12 mm X 13 28 0 35 0Nm ...

Page 1020: ...Name Tool How to use 00104 001 UD Remover Installer U D brake return sprin 00104 002 OD Remover Installer O D clutch return spring 00104 003 LR use with 00104 001 Remover Installer L R brake return spring Special service tool Supplier Tool Tech ...

Page 1021: ...If the system is defective TCU provides FMEC Failure Mode Effect Control to maintain the functionality of transaxle This keeps the basic function of transaxle gear selection even when there are failure in controls and power supply There are selector shaft position sensor inhibitor switch and oil temperature sensor in transaxle In manual mode TCU receives the information from TGS Transmission Gear ...

Page 1022: ...ted to enhance engine braking Drive and Reverse Engagement A soft engagement feature avoids harsh take up of drive when selecting Drive or Reverse This is achieved by limiting engine speed and engine torque which results in a rapid but progressive engagement of either Drive or Reverse when moving from the Park or Neutral positions Drive and Reverse engagements from either Park or Neutral are perfo...

Page 1023: ...tegy 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 occur automatically...

Page 1024: ...ver is in the M position When the lever is first moved to the manual M position the transaxle will select one lower gear than current gear When driving on a slippery road push the tip switch forward into the position in M position This causes the transaxle to shift into the 2nd gear which is better for smooth driving on a slippery road ...

Page 1025: ...g available 3rd Gear State The 3rd gear state will display on the instrument cluster 3rd gear has engine braking available 4th Gear State The 4th gear state will display on the instrument cluster 4th gear has engine braking available 5th Gear State The 5th gear state will display on the instrument cluster 5th gear has engine braking available 6th Gear State The 6th gear state will display on the i...

Page 1026: ...alid shifting to1st and 2nd gear is forbidden Limp home C The TCU communicates with other vehicle electronic control modules by the controller area network CAN If a major fault is developed the transaxle may not accomplish the intelligent shift control The TCU controls the transaxle with preset values The TCU also provides for transaxle diagnostics which meet the requirements of OBD II regulation ...

Page 1027: ...Unit The transaxle control unit TCU is mounted under the driver s seat and controls the operation of the transaxle Internal sensors and signals received across the CAN bus in analogue and digital forms such as Transaxle input speed Transaxle output speed Accelerator pedal position Gear selector position Engine torque Engine speed Transaxle fluid temperature Brake pedal status Engine oil temperatur...

Page 1028: ...ignals to be used by other vehicle systems via the CAN bus such as Selector lever position Selected gear state Manual mode activation Transaxle fluid temperature Engine torque reduction requests Schematic Diagram of Network Communication ...

Page 1029: ...Drive 6th gear 1 Overview Name Component C1 OVER DRIVE CLUTCH C2 35R CLUTCH B1 LOW REVERSE BRAKE B2 2 6 BRAKE B3 UNDER DRIVE BRAKE 1F 1 2 ONE WAY CLUTCH GEAR CLUTCH BRAKE OWC Gear Ratio OD 35R 26 LR UD 1ST O O 4 212 2ND O O 2 637 3RD O O 1 800 4TH O O 1 386 5TH O O 1 000 6TH O O 0 772 REV O O 3 385 N P O 1 Gear Selection and Engagement Element Operation when vehicle speed under 5kph ...

Page 1030: ...sun gear rotated Rear inner pinion reverse rotated Rear outer pinion rotated Rear annulus gear rotated Front annulus gear rotated Front pinion rotated Front sun gear reverse rotated Underdrive U D hub reverse rotated Input shaft rotated Overdrive clutch OD C retainer rotated Input shaft rotated 35R clutch rotated Power flow Description 35R C OD C 26 B UD B LR B O W C P N ...

Page 1031: ...e annulus gear front planetary gear rotates in reverse direction with decreased speed and the power flows through the front planetary gear The rear planetary gear set reduces the rotating speed of rear front annulus gears and the front planetary gear set rotates the front sun gear in reverse direction without load Power flow Description 35R C OD C 26 B UD B LR B O W C R ...

Page 1032: ...ed power is transferred to rear front annulus gear The power is secondarily reduced at front planetary gear locked with sun gear and flows to front planetary gear At this moment the middle sun gear rotates in reverse direction without load idling by the rotation of middle annulus gear integrated with front planetary gear Power flow Description 35R C OD C 26 B UD B LR B O W C 1ST Operated below 5 k...

Page 1033: ...erred to the rear front annulus gears and then the reaction power from the front planetary gear and middle annulus gear locked with sun gear is transferred to middle rear planetary gear to circulate the power Accordingly the power flows through the front planetary gear while keeping the balance Power flow Description 35R C OD C 26 B UD B LR B O W C 2nd ...

Page 1034: ...red to the rear front annulus gears and then the reaction power from the front planetary gear and middle annulus gear locked with sun gear is transferred to middle rear planetary gear to circulate the power Accordingly the power flows through the front planetary gear while keeping the balance Power flow Description 35R C OD C 26 B UD B LR B O W C 3rd ...

Page 1035: ...ar planetary gear set and the power with 1 1 ratio flows to the front planetary gear locked with sun gear after passing through the rear front annulus gears At this moment by operation of speed reduced annulus gears and carrier in 1 1 ratio the middle sun gear in middle planetary gear set increases its speed without load idling Power flow Description 35R C OD C 26 B UD B LR B O W C 4th ...

Page 1036: ...netary gear because the middle planetary gear and sun gear in middle planetary gear set rotate simultaneously At this moment the rear planetary gear set rotates in 1 1 ratio same in 4th gear However the front planetary gear set is not related to that and the front sun gear rotates without load idling in 1 1 ratio Power flow Description 35R C OD C 26 B UD B LR B O W C 5th ...

Page 1037: ...y gear rotates the middle annulus gear increases the speed and the power is transferred to front planetary gear The rear planetary gear set rotates in 1 1 ratio same in 4th 5th gears However the front planetary gear set is not related to that and the front sun gear increases its speed without load idling Power flow Description 35R C OD C 26 B UD B LR B O W C 6th ...

Page 1038: ... 957 3rd 1 179 1 033 1 207 4th 0 814 0 786 0 905 5th 0 734 0 730 0 842 6th 0 628 0 595 0 714 Reverse 3 910 3 747 3 747 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 Item Specification Remark D20DTF D...

Page 1039: ...iving 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 Replacement interval DSL EU GEN GSL Inspect and replenish every 60000 km or 4 years Normal driving condition Fill for Life Severe driving condition Change every 120000 km ...

Page 1040: ... 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 11 8 Nm 7 EA 13...

Page 1041: ...EW 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 1042: ...ch 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 breather Deten...

Page 1043: ...04 8 2 Internal Configuration ...

Page 1044: ...atio 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 One input gear is used for 1st forward driving and back up driving One input gear is used for 4th and 6th forward driving ...

Page 1045: ...04 10 2 POWER FLOWS 1st speed gear 2nd speed gear 3rd speed gear Sectional view of WM6F1 M T ...

Page 1046: ...04 11 3190 01 Reverse gear 4th speed gear 5th speed gear 6th speed gear ...

Page 1047: ...ctor 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 1048: ...sverse 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 mm Concentric slave cylind...

Page 1049: ...lt Hexagon 5 mm 10 to 16 Nm 3 Concentric slave cylinder oil pipe nut 24 5 to 28 4 Nm Remove the nut if it is necessary Once removed apply the Loctite on the thread before installation 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...

Page 1050: ...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 flywheel from the...

Page 1051: ...ctivates 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 1 Adjusting eq...

Page 1052: ... 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 with a splined ...

Page 1053: ...05 8 3 Layout Clutch disc Clutch cover assembly Concentric slave cylinder Dual mass flywheel DMF Clutch setting jig ...

Page 1054: ...mission The divided dual masses are connected to the coil spring and damping system internally The DMF has the following benefits Reducing fuel consumption by lowering engine speed Reducing rattling noise and vehicle vibration in all driving ranges Reducing synchronization wear Facilitating gear change Protecting power train parts by preventing excessive load from being delivered Primary flywheel ...

Page 1055: ...ngth 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 axle side 39 2 to 49 0 Nm Bolt n...

Page 1056: ...he 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 length change splines ...

Page 1057: ...haft 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 Do not remove the rubber coupling since the vibration balance could be improper once removed it ...

Page 1058: ...tside 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 Rear axle side Rubber coupling Sl...

Page 1059: ...For 2WD vehicle Front drive shaft LH Front drive shaft RH Intermediate shaft Power transfer unit PTU 4WD Propeller shaft 4WD 1 2 3 4 5 E coupling 4WD Rear differential carrier 4WD Rear drive shaft LH 4WD Rear drive shaft RH 4WD 6 7 8 9 ...

Page 1060: ...ent this the intermediate shaft called Intermediate shaft is employed on each side so that the bending angle and the length are kept constant A gyroscope is a device for measuring or maintaining orientation based on the principles of angular momentum In essence a mechanical gyroscope is a spinning wheel or disk whose axle is free to take any orientation Although this orientation does not remain fi...

Page 1061: ...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 1062: ...ameter 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 compressed 361 mm Coil spr...

Page 1063: ...e 433 mm Camber maintenance free 0 5 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 1064: ...08 5 0000 00 2 TIGHTENING TORQUE Front suspension assembly ...

Page 1065: ...08 6 Rear suspension assembly ...

Page 1066: ...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 1067: ...mper 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 easy installation Le...

Page 1068: ...endent 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 1069: ...ypoid gear 23 38 Oil IDEMITSU LW 80W 90 Oil capacity 0 58 L 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 1070: ...essing 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 Vehicle speed Drivi...

Page 1071: ...onic 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 coupling control ...

Page 1072: ...y 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 1073: ...d 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 1074: ... B Master cylinder and booster C HECU F Front rear wheel speed sensor Front rear 4WD Rear 2WD H Parking brake 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 1075: ... 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 Mechanically expanded rear lining Operating t...

Page 1076: ...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 through the brake...

Page 1077: ...Nm Air breather screw 8 8 10 8Nm Caliper mounting bolt 19mm x 2EA 83 3 102 9Nm Brake hose bolt 12 mm 19 6 29 4Nm Wheel disc Brake caliper Brake hub Brake disc Knuckle Drive shaft Brake hose Brake pad Shock absorber Brake disc Back plate Knuckle 2 SECTIONAL DIAGRAM Front disc brake ...

Page 1078: ...ake hub Brake disc Fastener Tightening torque Remark Brake pad guide bolt 25 5 30 4Nm 14 mm x 2EA Brake caliper mounting bolt 52 9 63 7Nm 17 mm x 2EA Brake hose bolt 19 6 29 4Nm 12mm Brake hose bracket mounting bolt 9 8 12 8Nm 12mm Air breather screw 8 8 10 8Nm 1 Tightening torque ...

Page 1079: ...10 10 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 1080: ......

Page 1081: ...10 12 4 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 1082: ...10 13 4850 00 ...

Page 1083: ...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 16 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 1084: ...11 4 ABS ESP CBS Circuit diagram of wheel speed sensor ...

Page 1085: ...t 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 coupled with anti lock br...

Page 1086: ...ppearance 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 EBD warning lamp ABS warning lamp Brake warning lamp 1 ABS hydraulic device and control unit Located under the power steering fluid reservoir and contains the pressure sensor 2 COMPONENT ...

Page 1087: ...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 sensor Wheel ...

Page 1088: ...ion 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 front wheels The longitudi...

Page 1089: ...nsing 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 1090: ... the system is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected 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 ...

Page 1091: ...s 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 the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected 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 6 Wh...

Page 1092: ...11 12 5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Page 1093: ...rawn 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 the brake force whi...

Page 1094: ...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 lock On these surfaces ...

Page 1095: ...in 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 zero if the wheel lo...

Page 1096: ...s the mean I e average speed of all wheel speeds determined by simple approximation Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previous...

Page 1097: ...omparing 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 1098: ... 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 utilizes the existing rea...

Page 1099: ...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 Close ...

Page 1100: ...rder 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 Valve Open Close Pump mot...

Page 1101: ... 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 1102: ...ydraulic pressure to the wheel increases the wheel speed will reduce This operation continues repetitively until there are no signs that the ABS HECU tends to lock the wheels Since the ABS hydraulic pressure control process takes place repeatedly for a short time there may be some vibration and noises at the brake pedal Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Op...

Page 1103: ...11 23 4890 00 7 CIRCUIT DIAGRAM ...

Page 1104: ...ure 40 150 Operating frequency 1 2 500 Hz Unit Description ABS ESP HECU Clock frequency 32 MHz Clock frequency 50 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 longitudinal G sensor 4WD Longit...

Page 1105: ...mperature 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 sensor 14 7m Sec ...

Page 1106: ... steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer understeer or cornering The ESP ECU controls against oversteer or understeer during cornering by controlling the vehicle stability using input values from these sensors and applying the braking force to the corresponding wheels independently The system also controls the engine power right be...

Page 1107: ...ted under the power steering fluid reservoir and contains the pressure sensor 2 COMPONENTS 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 1108: ...plied and when the brakes are not applied on a curve If the ESP system operates when the brake is applied the brake pressure will be increased on the corresponding wheel which already has braking pressure for the ESP controls ARP Operation During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle spee...

Page 1109: ...tem is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected 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 6 ABS ...

Page 1110: ...n ABS HECU is defective 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 7 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 t...

Page 1111: ...12 10 5 SYSTEM DESCRIPTION 1 Block Diagram of ESP HECU ...

Page 1112: ...corresponding wheels independently The system also controls the engine power right before the wheel spin synchronized with the ASR function to decelerate the vehicle automatically in order to maintain the vehicle stable during cornering 1 Under steering What is understeering Understeer is a term for a condition in which the steering wheel is steered to a certain angle during driving and the front ...

Page 1113: ...ering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction Compared to understeering vehicles it is hard to control the vehicle during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases ESP controls during oversteer The ESP system recognizes the directional angle with the steeri...

Page 1114: ...rake pedal is depressed or not depressed during cornering when the ABS is operating and when braking without the ABS It also includes the vehicle conditions when the TCS a part of the ESP system is operating Condition Understeer control Oversteer control Only ESP in operation No braking by driver ESP Normal braking no ABS operation ESP ABS brake ESP ASR ...

Page 1115: ...uring initial braking according to pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels 2 Operation The b...

Page 1116: ... when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns Lateral sensor In sensor cluster Vehicle speed Brake force Radius The vehicle driving condition is controlled by the internally programmed logic according to the input...

Page 1117: ...A 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 1118: ...o the vehicles behind 3 Operating process When receiving the emergency stop signal through PCAN communication it blinks with the interval of 4 Hz and when receiving the emergency stop OFF signal through PCAN communication it blinks with the interval of 1 25 Hz normal operating speed However the manual operation of the switch has a priority over this function Priority Manual operation Emergency sto...

Page 1119: ...hicle speed increases more than 10 km h above the speed when the signal is received during operation by emergency braking signal the emergency hazard flasher stops operation When turning emergency hazard flasher switch OFF during operation by emergency braking signal it stops operation It is deactivated automatically 10 seconds after if items 2 and 3 above are not met during operation by emergency...

Page 1120: ...12 19 0000 00 6 HYDRAULIC CIRCUIT OF ESP MCP Master Cylinder Primary MSP Master Cylinder Secondary ESV Electric Shuttle Valve NO Normal Open NC Normal Close LPA Low Pressure Accumulator ...

Page 1121: ...control the vehicle over the physical limit Do not solely rely on the system but be advised to drive the vehicle safely Drive feeling during ESP operation When the ESP system activates the driving feeling can be different depending on vehicle driving conditions For example it will feel different when the ESP system is activated while the ABS is operated by depressing the brake pedal and when the E...

Page 1122: ...n 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 1123: ...ls 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 1124: ...ill 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 1125: ...nd 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 1126: ...e pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the wheel starts to lock the...

Page 1127: ...12 26 7 CIRCUIT DIAGRAM Wheel speed sensor Stop lamp switch Self diagnostic connector Warning lamp ABS ESP ...

Page 1128: ...12 27 0000 00 ...

Page 1129: ... Outer 31 07 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 deg Down 3 0 deg Lower shaft Type Ball slip Steering oil Oil type S PSF 3 Oil reservoir capacity about 1 ℓ Change interval EU Diesel Check and add at every 20 000 km GEN Diesel Gasoline Che...

Page 1130: ...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 49 1 Nm 22 mm 10 Loos...

Page 1131: ... 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 No 1 idle pulley 9 No 2 idle pulley 10 Power steering pump HPS Hydraulic Power Steering EPS Electric Power Steering ...

Page 1132: ...re relief valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydraulic...

Page 1133: ...n 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 1134: ...o 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 50 7 mm rev Rack stroke 145 mm Maximum steering angle Inner...

Page 1135: ...14 4 2 TIGHTENING TORQUE ...

Page 1136: ... 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 No 1 idle pulley 9 No 2 idle pulley 10 Power steering pump HPS Hydraulic Power Steering EPS Electric Power Steering ...

Page 1137: ...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 communication function betw...

Page 1138: ...ystem 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 1139: ... 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 1140: ... 34100 PN 41730 34220 New 16 inch Silver 17 inch Silver 18 inch Diamond cutting PN 41730 34200 PN 41730 34300 PN 41730 34400 16 17 and 18 inch wheel assembly design changed For 17 inch existing 18 inch design used For 18 inch Hyper silver type Diamond cutting type Wheel offset and tire size same as before 2 MAJOR CHANGES ...

Page 1141: ...ansmit the signal of the pressure and temperature in tire rotating direction and wheel module ID code etc using the radio frequency to the TPMS ECU Repair kit Repair kit casing design changed open cover type integrated type Repair kit changed Newly added TPMS Tire Pressure Monitoring System ...

Page 1142: ...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 sidewall the sh...

Page 1143: ...es the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly resulting in increased life The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire is excessive so a lot of heat is generated and the tire is worn...

Page 1144: ...be blown out in a short period of time If the standing wave symptom occurs on the tire rubber on the tread comes off and eventually the tire can be blown out which is very dangerous When driving at high speed the inflation pressure should be increased to decrease heat generation due to extension and contraction motion to decrease hydroplaning and to prevent standing wave To prevent this symptom it...

Page 1145: ...t 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 1146: ...lance 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 figure 2 a if tw...

Page 1147: ...ting 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 BRKT ENG MTG RR BRKT ENG MTG FRT ...

Page 1148: ...ransaxle 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 1149: ...nting 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 1150: ...t 2 Rear Mounting bracket Mounting bolt 3 Transaxle mounting Front For manual transaxle For automatic transaxle diesel 4 Transaxle mounting Rear 1 Sectional Diagram and Bolts for Front Sub Frame Mounting nut 29 4 to 39 2 Nm Bolt 9 4 to 39 2 Nm ...

Page 1151: ...16 7 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 1152: ...de 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 of front sub frame 2WD Th...

Page 1153: ...ar 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 and for 2WD it con...

Page 1154: ...quency 433 92 Mhz Wheel module Pressure measuring range 0 6 375 bar 0 92 43 psi 1 bar about 14 5 psi Tolerance range of measured pressure 5 40 10 2 10 70 5 70 100 Tolerance range of measured temperature 5 40 10 2 10 70 5 70 100 Temperature measuring range 50 205 Battery life Lithium battery about 3 0 3 2 V 160 000 km or 10 years It can be shortened depending on use condition Tire Inflation pressur...

Page 1155: ...following torque wrench and connecting adapter should be prepared when installing the TPMS wheel module Torque wrench 0 1 5 0 Nm E socket T 10 Tire valve changer When fitting the wheel module tighten the mounting bolt to the specified tightening torque 1 4 Nm to prevent the wheel module from being damaged due to excessive tightening ...

Page 1156: ...module and the TPMS ECU for communication Therefore if the vehicle is equipped with the electronic equipment such as mobile camera monitor or the vehicle is passing through the area with a strong electromagnetic field the system may not operate normally For the vehicle equipped with the TPMS the TPMS warning lamp on the instrument cluster comes on and pressure values on the EL display is displayed...

Page 1157: ...the wheel rim depending on the mounting surface type of the rim Therefore always use the SYMC genuine wheel and wheel module for the vehicle Clean the wheel mounting surface and inner side of the wheel thoroughly when replacing the tires However never inject the commercial anti flat fluid or similar substance It may cause a critical error to the wheel module ...

Page 1158: ......

Page 1159: ...nformation and its status through the instrument cluster The wheel module fitted in the tire transmits the internal data for the tire to the TPMS ECU periodically through the wireless transmission The TPMS ECU can detect the positions of the wheel modules fitted to each wheel automatically and sends the signal on tire condition through the CAN line to the instrument cluster so that the driver can ...

Page 1160: ...15 9 4190 00 Wheel module The wheel modules are mounted to each wheel rim and hole TPMS ECU The TPMS ECU is mounted to the rear bumper beam ...

Page 1161: ...15 10 3 TPMS ECU I O DIAGRAM ...

Page 1162: ...ning to the driver it transmits the data once every about 1 second Since the battery consumption will be increased rapidly until the data transmission interval will be returned to normal after certain length of time adjust the tire pressure to the specified one after rectifying the cause The tire pressure is displayed through the following sequences which occur at the same time Wheel module detect...

Page 1163: ...inutes the 2nd warning is given At this time the Check tire message is displayed on the DOT LCD display and the global warning lamp comes on At room temperature of 20 C While the proper tire pressure in this vehicle is 32 psi at room temperature of 20 the TPMS ECU receives the ambient temperature signal from the instrument cluster through CAN communication and calculates the proper tire pressure t...

Page 1164: ...15 13 4190 00 At room temperature of 0 C At room temperature of 40 C ...

Page 1165: ...s lamp comes on when the engine is initially started or the ignition switch is pressed ON for about 4 0 seconds Then it goes off if the system is normal In the event of TPMS system including sensor failure it flashes for 70 seconds at interval of 0 4 seconds and comes on Comes on when the tire pressure is low It informs the driver of current tire pressure and abnormalities such as loss or over inf...

Page 1166: ...e inflation pressure This lamp comes on when the engine is initially started or the ignition switch is pressed ON for about 4 0 seconds Then it goes off if the system is normal In the event of TPMS system including sensor failure it flashes for 70 seconds at interval of 0 4 seconds and comes on Comes on when the tire pressure is low The tire pressure for front wheels is displayed on the LCD displa...

Page 1167: ... minimum tire pressure Corresponding status lamp comes on if tire pressure is 24 psi or less Sudden tire pressure loss Corresponding status lamp blinks with shading reverse at interval of 0 4 seconds if tire pressure changes more than 3 psi per 1 minute at speed of 0 km h or above Imbalance between left and right tire pressure Corresponding status lamps blink alternately at interval of 1 0 second ...

Page 1168: ...hows only tire pressure and Low tire pressure warning If the tire pressure is less than 13 of the proper value for more than 8 minutes the 1st low tire pressure warning is given And if the tire pressure is less than 20 for more than 4 minutes the 2nd warning is given The message Check tire is displayed on the instrument cluster DOT LCD display see LOW TIRE PRESSURE WARNING in this section Priority...

Page 1169: ...tom is occurred as the inflation pressure displayed on the instrument cluster becomes different by tires as different load is applied to each tire due to driving condition number of occupants irregular temperature change in tire and load condition If there is another vehicle equipped with the TPMS keep the distance from this vehicle for at least 5 mm to prevent interference of wheel module transmi...

Page 1170: ...ire inflation judgment B Fill the tire pressure air according to the tire inflation procedure Fill specified tire pressure 32 psi Drive vehicle at 20 km h or higher for less than 10 min If checking for the tire shows it is normal carry out the work again according to the tire inflation procedure Finish Not OK OK Supervision type Standard type ...

Page 1171: ... 20 Cautions for TPMS tire inflation If the tire pressure is 10 psi lower than the specification 32 psi replace the valve insert on the wheel module valve body with a new one and inject air into the tire ...

Page 1172: ...15 21 4190 00 8 CIRCUIT DIAGRAM ...

Page 1173: ...88 x 455 x 16 2 625 Capacity kcal h 12 000 Capacity of receiver drier 250 cc Compressor Volume 170 cc rev Diameter of pulley Ø120 Max continuous speed 8 000 rpm Voltage DC 12 V Current consumption 2 2 A Heater A C control assembly FATC Rated voltage DC 13 5 V Operating voltage DC 9 V to 16 V Operating temperature 30 80 Max current consumption 2 5 A Dark current 1 1 mA Button switch Type Push type ...

Page 1174: ...age DC 9 V to 16 V Operating temperature 30 80 Max current consumption 2 5 A Dark current 1 1 mA Button switch Type Push type self return Operating force 2 54 0 5N Temperature switch Type Dial type Rotation angle 220 Fan speed switch Type Dial type Rotation angle 180 Refrigerant Type R134a Volume 430 30 g ...

Page 1175: ...gital display LCD display with FATC used Push button type switch used self return type 2 MAJOR CHANGES Change of air conditioner pipe With MTC With FATC With MTC With FATC Changes in heater and control assembly Liquid and suction pipe Liquid and suction pipe route changed due to change of headlamp mounting bracket ...

Page 1176: ...trol device which receives signals from various sensors ambient temperature sensor water temperature sensor sun load sensor AMP sensor and control switches to control the blower motor and all kinds of actuator mode door actuator mix door actuator air source door actuator through MICOM in the FATC therefore the interior temperature of the vehicle is kept to the temperature which is set by a driver ...

Page 1177: ......

Page 1178: ... the refrigerant in the condenser Refrigerant pressure sensor It is mounted to the latter part of the right headlamp It converts the A C refrigerant pressure to voltage value and sends it to the engine ECU A C compressor It is installed to the left side of the engine assembly compresses the low temperature and low pressure coolant and converts it to the high temperature and high pressure coolant T...

Page 1179: ...e front section of the vehicle and detects the ambient temperature to send the voltage value according to the resistance change to the heater and A C control assembly Engine ECU It controls the A C compressor electric fan and PTC heater according to the signal from the A C control panel Expansion valve It is mounted to the inlet of the evaporator core and supplies the appropriate quantity of refri...

Page 1180: ...anel with FATC and detects the interior air temperature drawn through the senor inlet Air conditioner module It is mounted to inside of the instrument panel and has the evaporator core heater core PTC heater and corresponding actuator and different sensors Heater A C control assembly With FATC With MTC It falls in to two categories FATC Full Automatic Temperature Control and MTC Manual Temperature...

Page 1181: ...ening according to the control command from the heater and A C control assembly Evaporator core It cools the surrounding air by passing through the low temperature and low pressure refrigerant sprayed from the expansion valve Heater core It is mounted to the left hand of the air conditioner module and heats the indoor using the heat of the engine coolant Mode actuator It controls the air outlet da...

Page 1182: ...r to the air vent Intake actuator It changes the air source selection mode according to the control command from the heater and A C control assembly A C filter It is mounted to the top of the blower motor and filters the air before it is discharged through the duct MOS module It controls the rotation speed of the blower motor by receiving the fan speed control signal from the heater and A C contro...

Page 1183: ...inds of actuator mode door actuator mix door actuator air source door actuator through MICOM in the FATC therefore the interior temperature of the vehicle is kept to the temperature which is set by a driver The driver can check the status of A C through the LCD display of the A C control assembly The fan speed and the temperature are adjusted automatically by the input values from different sensor...

Page 1184: ...ssing this switch AUTO is shown on the display and the fan speed and air distribution mode are adjusted automatically to keep interior temperature to the set temperature ON OFF switch Pressing the switch turns the FATC on off When the FATC is turned on it memorizes the previous status before becoming off Defroster mode switch This is used to remove the condensation from the windshield When you pre...

Page 1185: ...de is switched to the recirculation mode at the same time When pressed again the indicator goes out and switched to the fresh air mode at the same time Fan speed dial Turn the dial to the left or right to adjust the fan speed in 8 steps and the fan speed can be checked through the LCD display A C switch When the switch is pressed the indicator comes on and the air conditioner starts at the same ti...

Page 1186: ...receives various signals such as the indoor temperature ambient temperature engine coolant temperature sunlight from different sensors to control the A C compressor mode actuator intake actuator temp actuator blower motors etc to keep indoor environments fresh Max cooling heating control AUTO mode If the temperature is set to the lowest level Lo or highest level Hi the system will go into the maxi...

Page 1187: ...es steplessly Sun load compensation control The system increases the fan speed by adding up 2 5 V of voltage in direct sunlight Blower step Blower motor voltage V 1 4 0 2 5 0 3 6 0 4 7 0 5 8 0 6 9 0 7 10 5 8 VIGN Control for defrosting 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 ce...

Page 1188: ... low or the wind temperature is not warmed up sufficiently the driver might feel uncomfortable by the air flow from the vent Therefore the fan speed is set to the 1st stage and the cool air is sent to the windshield until the coolant temperature increases to the proper level DEF mode As the engine coolant temperature goes up the mode is changed to Defrost Foot mode or AUTO mode to increase the spe...

Page 1189: ...ent temperature is high during cooling the air source is changed from fresh air to recirculation to lower the temperature Control by vehicle speed heating The air source selection is controlled in accordance with the vehicle speed while driving Operating conditions and control process are as follows AUTO mode When the vehicle speed is 45 km h or lower in fresh air mode the air source door is open ...

Page 1190: ...01 20 ...

Page 1191: ...his switch is pressed the defroster mode A C ON fresh air mode fan speed of 1 level or above is activated Pressing the switch again returns the unit to the previous status Air distribution switch The mode is switched in the following order each time the switch is pressed Vent mode Bi level mode Foot mode Defroster Foot mode Air distribution switch switches in order Defroster switch LCD display air...

Page 1192: ...uto control The air flow mode is controlled automatically in accordance with the vehicle indoor conditions But it is controlled as described below during initial driving after overnight parking in cold weather ...

Page 1193: ...lay and the indicator of the A C switch 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 indoor temperature and ambient temperature If the intake sensor detects the freezing of the evaporator or the ambient temperature is low 2 or below in winter the compressor is turned off to protect the A C compressor A C...

Page 1194: ...ent be sure to check the default code by using self diagnosis function The diagnostic trouble code DTC flashes twice and is displayed repeatedly in order as long as a separate operation is not performed Code Defective part 00 Normal 21 Ambient temperature sensor 22 Incar sensor 23 Water temperature sensor 24 Intake sensor 26 Temp door control 31 Mode door vent 32 Mode door bi level 33 Temp door co...

Page 1195: ...01 25 6810 00 How to enter self diagnosis ...

Page 1196: ... on for 3 seconds 1 The LCD display shows 2 and starts to check the sensor and actuator in the air conditioning system automatically 2 After about 20 seconds the LCD display shows whether there is fault 00 for normal 3 The self diagnosis ends when turning the ignition key from the OFF position to the ON position or pressing the AUTO mode switch 4 Press for more than 5 sec Segments comes on for 3 s...

Page 1197: ...s 51 1 The values for each sensor are shown in sequence on the LCD display each time the defroster switch is pressed 2 When the temperature control dial is turned anti clockwise the menu returns to status when entering self diagnosis mode 3 Sensor data check The value of the sun load sensor is displayed after being converted to one tenth Defroster switch Temperature control dial ...

Page 1198: ...s The MTC Manual Temperature Control system controls all the actuator and blower motor by the driver The heater and A C control assembly with MTC has the dials and switches with the indicators so that the driver can know the air conditioning system s operation ...

Page 1199: ...cator comes on and the air conditioner starts at the same time and vent and recirculation modes are selected automatically Defroster mode switch This is used to remove the condensation from the windshield When you press the switch the indicator comes on and the air distribution is changed to the windshield at the same time then the air conditioner starts to operate Defroster foot mode switch If th...

Page 1200: ...erature control dial operation by the driver The driver can select one of the 17 levels Blower step Blower motor voltage V 1 4 0 2 5 0 3 6 0 4 7 5 5 9 0 6 10 5 7 VIGN 3 Blower control The fan speed increments by 1 level per revolution of the fan speed dial allowance 0 5 V Temperature control dial Fan speed dial ...

Page 1201: ...or comes on at recirculation mode Control by vehicle speed The air source selection is controlled in accordance with the vehicle speed while driving Operating conditions and control process are as follows When the PTC heater operates at fresh air mode in winter When the vehicle speed is 45 km h or lower in fresh air mode the air source door is open 30 of its maximum opening If the vehicle speed is...

Page 1202: ...ing on Vent mode If the vent mode switch is pressed the indicator comes on while the air flows to the upper part of the body Bi level mode Foot mode If the bi level mode switch is pressed the indicator comes on while the air flows to the footwell and upper part of the body If the foot mode switch is pressed the indicator comes on while the air flows to the footwell Defroster mode switch Bi level m...

Page 1203: ...es on while the air flows to the footwell and the windshield Defroster mode This is used to remove the condensation from the windshield When you press the switch the indicator comes on and the air distribution is changed to the windshield at the same time then the air conditioner starts to operate ...

Page 1204: ...been activated when an indicator lamps at the A C switch and MAX A C switch comes on If the intake sensor detects the freezing of the evaporator core it stops the air conditioner by turning off the compressor MAX A C control This is designed for increasing driver comfort When the switch is pressed the air conditioner is operated and vent and recirculation modes are selected automatically The disch...

Page 1205: ...cal power the electric load and alternator capacity is greater than the conventional one The PTC is not operated when a the engine is cranking b the battery voltage is below 11 V c the glow plug is being preheated The ceramic PTC features that the resistance rises quickly in a certain temperature range The PTC heater has 3 circuits with power of 330 W While only 1 circuit in the PTC heater is conn...

Page 1206: ...s for deactivating Air conditioner blower switch OFF When the ambient temperature sensor is faulty short or open circuit in the wiring Engine is cranking Battery voltage is 11 V or less Glow plug is being preheated Glow indicator comes on Coolant temperature 15 Coolant temperature 15 65 and intake temperature 10 Coolant temperature 15 65 60 and intake temperature 10 0 Coolant temperature 15 65 and...

Page 1207: ......

Page 1208: ...01 38 6 CIRCUIT DIAGRAM ...

Page 1209: ...01 39 6810 00 ...

Page 1210: ...Air bag module and seat belt pretensioner Resistance at 30 to 85 C 2 0 0 3 Ω Non ignition current at 85 C 0 4 A for 10 seconds All ignition current at 35 C 1 2 A for 2 ms Front and side impact sensors Operating temperature 40 C to 125 C Power voltage 5 0 to 11 0 V Measurement range 5 0 to 11 0 V Contact Coil Rated voltage 12 0 V Voltage range 9 0 V to 16 0 V Air bag circuit resistance 0 23 to 1 0 ...

Page 1211: ...ce and connector 1 EA 2 EA of SDM have been changed The logic for the air bag warning lamp operation has been changed Event data recorder EDR function has been added Passenger air bag module Passenger air bag module The air bag module type has been changed to Invisible ...

Page 1212: ...02 5 8810 00 Impact sensor Front impact sensor The appearance of the front impact sensor has been changed Side impact sensor The appearance of the side impact sensor has been changed ...

Page 1213: ...infant or a child could be severely injured by the air bag deployment A child restraint system must not be installed on the front seat An infant or a child could be severely injured by the air bag deployment when it is fitted to the passenger seat Do not place any objects on the air bag inflation location You may get injured by those objects during deployment Never put your arms around the front s...

Page 1214: ... on the accident conditions The air bag components will be very hot after deployment Do not touch them The deployed air bag seat belt pretensioner cannot deploy again It will work when an additional impact is applied Once the air bag system is triggered the triggered air bag assembly should be removed from the vehicle and replaced with a new one The air bag warning lamp is illuminated for 3 to 7 s...

Page 1215: ......

Page 1216: ...door unlock function and various lamps including hazard warning lamp and room lamps when the crash signal from the SDM is received to notify others of emergency situation and let the occupant escape easily The SDM is equipped with self diagnosis function and it performs the diagnosis on the internal external devices of the air bag system for a certain period of time after IGN ON And it monitors th...

Page 1217: ...put signals that activates the front air bag system Air bag warning lamp This lamp notifies the driver about the result of the diagnosis and faults Passenger air bag This air bag is installed in the upper side of the instrument panel on the passenger side It activates in the same way of the driver air bag 2 AIR BAG SYSTEM LAYOUT Passenger Air Bag ON OFF Switch The front passenger air bag is disabl...

Page 1218: ...otection for the front and rear outboard occupants in a side collision Side impact sensor The side impact sensors are fitted at the bottom of both LH and RH B pillars and output signals that activates the side air bag system BCM Crash signal The BCM activates the auto door UNLOCK hazard warning lamp and room lamps when a crash signal of the air bag unit SDM is input Seat belt pretensioner The seat...

Page 1219: ...o door unlock function and various lamps including hazard warning lamp and room lamps when the crash signal from the SDM is received to notify others of emergency situation and let the occupant escape easily Major functions Detects frontal and side collision Rear end collision only with EDR trigger Activates the front air bag side air bag curtain air bag and belt pretensioners Indicates system rea...

Page 1220: ...02 13 8810 00 The front air bags and side air bags are activated independently according to the area and amount of an impact ...

Page 1221: ... for the seat belt to protect the occupant properly The air bag will be hardly deployed when 2 Front Air Bag System Operating Process 1 Front air bag system deployment conditions there is underbody impact from the road surface impact against the curb at a very high speed or dropping impact onto the road surface with a large angle The air bag will not be deployed when 2 Front air bag system deploym...

Page 1222: ... is on the vehicle is stationary or a frontal collision occurs at low speed a rear collision occurs the impact of the collision is low enough for the seat belt to protect the occupant properly The air bag will be hardly deployed when 3 Side Air bag System Operating Process 1 Side air bag system deployment conditions the vehicle rolls over or tips over sideward with a severe impact the vehicle is s...

Page 1223: ...sition left side right side Item Impact to side LH RH Side air bag Driver side Ignite Not ignite Side air bag Passenger side Not ignite Ignite Curtain air bag Driver side Ignite Not ignite Curtain air bag Passenger side Not ignite Ignite Seat belt pretensioner Driver side Not ignite Not ignite Seat belt pretensioner Passenger side Not ignite Not ignite 3 Component change after deployment Side air ...

Page 1224: ...n device of the corresponding air bag inflator when a collision signal from the impact sensor is sent to the air bag unit When the ignition device of the inflator is ignited the gas generator generates nitrogen gas by being burned and this gas inflates the air bag cushion through the filter The nitrogen gas used to inflate the air bag exhausts through the vent hole immediately Cross section of dri...

Page 1225: ...the seat belt pretensioner gas is generated from the inflator and this pushes up the piston When the piston gear engages with the pinion gear the clutch is integrated and winds the seat belt When the load on the seat belt increases and the inner device stars being deformed the pinion rotates in reverse direction and the piston moves downward The residual pressure is released through the vent hole ...

Page 1226: ...y others of emergency situation and is used as a signal that turns on the room lamps and activates auto door unlock function for the occupants The air bag unit of a vehicle without side air bag system can also send the crash signal to the BCM according to the value of the acceleration sensor to activate the auto door unlock and various lamps including hazard warning lamp and room lamps ...

Page 1227: ...he deployment signal is sent the second crash out will be 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 msec and decreasing for 10 msec before crash At the time of crash the air bag deployment signal is output to the BCM for 200 ms immediately 1 Air bag deployment signal output crash out ...

Page 1228: ... bag deployment signal is input Resetting the auto door unlock function turns off the battery cutting off BCM power 2 BCM control when air bag deployment signal is input The UNLOCK by the air bag deployment signal takes priority over the LOCK UNLOCK control from other functions The LOCK UNLOCK requests from other functions during or after the UNLOCK output by the air bag signal are ignored However...

Page 1229: ...learing the errors is as follows Monitoring system Diagnosis cycle Time for detecting Time for clearing Clearing fault Inflator circuit 400 ms 4 seconds 8 seconds with a diagnostic device warning lamp circuit 100 ms 4 seconds 8 seconds with a diagnostic device Battery voltage 10 ms 4 seconds 4 seconds with a diagnostic device Impact sensor IGN ON 1 seconds 2 to 4 seconds next Ign with a diagnostic...

Page 1230: ... the unit monitors the system regularly and notifies the driver by turning on the air bag warning lamp when a fault is found in the system System normal Comes on for 6 seconds after IGN ON and then goes out The air bag warning lamp comes on when diagnosis is performed for the inside external devices of the system when the ignition is turned on the air bag system is malfunctioning the air bag unit ...

Page 1231: ...after IGN ON and goes out for 1 second and then remains on 2 Air bag warning lamp operation during driving The air bag warning lamp comes on when the air bag unit SDM detects a system malfunction The warning lamp goes out when the malfunction disappears ...

Page 1232: ...t too high too low is determined to be fault only when the signal is detected for continuous 4 seconds Emergency power function The SDM has an emergency power function that ensures the internal operation of the central unit and buffering firing circuits for a minimum of 150 ms after loss of battery power Full emergency power capability is available after the minimum specified operating voltage has...

Page 1233: ...al errors Air bag operation Front air bag system Side air bag system X axis acceleration sensor error Disabled Disabled Y axis acceleration sensor error Disabled Z axis acceleration sensor error available ROM checksum error Disabled RAM checksum error Disabled NVM checksum error Disabled Internal acceleration sensor test The air bag unit checks internal acceleration sensor when the ignition is tur...

Page 1234: ...el of test current and monitors the resistance of the inflator circuit within a specified range to deploy the air bag It limits certain functions of the air bag sets a DTC and turns on the air bag warning lamp according to the conditions Inflator circuit resistance monitoring ...

Page 1235: ...D after IGN ON Communication error Communication data error Approx 2 seconds Open Short circuit B Short Circuit to Ground Short Circuit to Ground approx 2 to 4 seconds 6 DTC and Air Bag Deployment Data Storing DTC storing Airbag deployment data storing The DTCs realated to low battery voltage are not accumulated The air bag deployment data due to a collision cannot be cleared The air bag unit shou...

Page 1236: ...ving information data and updates the data with new one periodically If a collision is detected by front and side impact sensors the acceleration sensor in the SDM detects the change in acceleration The air bag unit stores the information on internal acceleration sensor driving status and air bag deployment at this time The EDR stores the driving information also when the acceleration sensor in th...

Page 1237: ...02 30 6 CIRCUIT DIAGRAM ...

Page 1238: ...02 31 8810 00 ...

Page 1239: ......

Page 1240: ...03 3 7410 00 1 SPECIFICATION 1 Specifications ...

Page 1241: ...iver passenger seats DC 12 V 5 A 10 Ventilation driver seat DC 12 V max 0 9 A Cut off over current Heated wire driver passenger seats DC 12 V 0 75 A 10 Ventilation driver seat DC 12 V 8 5 A 10 Ventilation motor Operating current Level 1 DC 12 V 0 5 A 10 Level 2 DC 12 V 0 6 A 10 Ventilation motor revolutions rpm Seat cushion Level 1 2 400 RPM 10 Level 2 2 750 RPM 10 Seat back Level 1 3 160 RPM 10 L...

Page 1242: ...insulates against the heat such as a blanket or cushion Make sure that the head restraints are in place and secured properly Never drive the vehicle with the head restraint removed To minimize the injuries in a collision or an abrupt stop make sure the seatback is in the upright position before driving If the seatback is reclined too much the occupant could slide under the seat belt in a collision...

Page 1243: ...tion passenger seat heated wire The heated wire and ventilation unit is not applied to a vehicle with heated wire only Mounting location for ventilation motor 4 MAJOR CHANGES Front seat heated wire and ventilation unit Heated wire and ventilation unit mounting location Seatback Seat cushion Seat heated wire and ventilation unit switch application ...

Page 1244: ...03 7 7410 00 Head restraint warning label Rear seat head restraint Rear seat head restraint Head restraint warning label has been attached to the side of rear seat head restraint ...

Page 1245: ...enger and rear seat The front seat has the heated wire in the seat cushion and seatback and the rear seat has it in the seat cushion The ventilation function is only applied to the driver seat The seat belts of all seats are 3 point type 2 SEAT SEAT BELT LAYOUT Driver seat heated wire switch Passenger seat heated wire switch Driver seat heated wire switch Driver seat ventilation switch Passenger s...

Page 1246: ...410 00 Rear seat belt 3 point type Rear LH center Rear RH Rear seat Rear seat heated wire switch LH RH Rear seat belt LH Rear center seat belt Rear seat belt RH Rear double buckle 1st row Rear buckle 1st row ...

Page 1247: ... has to operate the lever manually to adjust the seat However the head restraint and driver seat lumber support should be adjusted manually for both types of seats Heated wire is installed in the seatback and seat cushion and ventilation function may be added to driver seat depending on vehicle specifications The switch for the front seat heated wire and ventilation is located on the TGS lever sid...

Page 1248: ...eatback lock released Then release the recliner knob at the desired angle to lock the seatback Power seat Manual seat Moving the slide knob forward backward moves the seat forward backward by activating the slide motor To move the seat forward or backward pull up and hold the seat slide lever and move the seat to the desired position 1 Driver seat operation Seat slide adjustment forward rearward S...

Page 1249: ... lever moves the lumbar support to the forward position and raising the lever moves the lumbar support to the backward position Power seat Manual seat Moving the slide switch upward downward moves the seat cushion upward downward as the front rear up down motors rotate the rail Pulling the recliner knob upward downward moves the seat upward downward Seat adjustment height Driver seat lumbar suppor...

Page 1250: ...t heated wire Driver seat heated wire switch vehicle with heated wire function only Driver seat heated wire and ventilation switch vehicle with heated wire and ventilation functions Seat back board 2 Driver seat heated wire and ventilation functions ...

Page 1251: ...e to lock the seatback Seat slide adjustment forward rearward To move the seat forward or backward pull up and hold the seat slide lever and move the seat to the desired position Passenger seat heated wire switch Heated wire and ventilation Heated wire Passenger seat heated wire 3 Passenger seat operation Passenger seat 4 Passenger seat heated wire and functions Seat back board ...

Page 1252: ...nt s neck in the event of a rear end collision The active head restraints may be installed to both driver and passenger seats depending on the vehicle specifications 1 System configuration Active head restraint sensor Active head restraint passenger seat Active head restraint driver seat 2 Active Head Restraint ...

Page 1253: ...03 16 2 Active head restraint deployment No in operation In operation ...

Page 1254: ...lled and its G sensor is operated in the event of a rear end collision As the G sensor in the active head restraint sensor is operated the power is supplied to the driver s or passenger s active head restraint Then the lock in the head restraint is disengaged and the front part of the head restraint is separated and moved toward the neck of an occupant ...

Page 1255: ...ed And the heated wires in the rear seat cushion and seatback can be operated with rear seat heated wire switches located on the LH RH rear door trim The head restraint can be raised without pressing the head restraint sleeve A or lowered with the sleeve A pressed Seatback reclining adjustment To adjust the seatback angle pull the lock release lever on the upper part of the seat to release the loc...

Page 1256: ...03 19 7410 00 Seatback folding Rear seat heated wire Rear seat heated wire switch 2 Rear seat heated wire functions Rear armrest LH RH ...

Page 1257: ...s pressed the temperature level goes down by one level Pressing the switch a third time will turn off the operation Pressing the desired side of the switch heats the seat cushion and seatback or activates the seat ventilation function The temperature of the seat is kept uniform by cutting off or connecting power through thermistor fitted in the seat The seat heated wire and ventilation unit contro...

Page 1258: ...be adjusted in 3 levels Level 2 Level 1 OFF with the front seat heated wire and ventilation switch Every time the switch is pressed the temperature level goes down by one level Pressing the switch a third time will turn off the operation The front seat heated wire and ventilation functions cannot be operated at the same time ...

Page 1259: ...switch 5 Heater switch LH 6 Heater switch RH 7 Heater level 1 LH 8 Heater level 1 RH 9 Ventilation level 1 LH 10 Heater back LH NTC 11 Heater back RH NTC 12 Cushion ventilation power 13 Heater back LH HTR 14 ALT 15 16 17 18 19 20 Heater level 2 LH 21 Heater level 2 RH 22 Ventilation level 2 LH 23 Heater back LH NTC 24 Heater back RH NTC 25 Heater back RH HTR 26 Ground ...

Page 1260: ...nd ventilation switch Every time the switch is pressed the temperature level goes down by one level Pressing the switch a third time will turn off the operation Operating process When the front seat heated wire and ventilation switch is pressed the front seat heated wire and ventilation unit supplies the power to the corresponding seat for heated wire and ventilation operation through the switch T...

Page 1261: ...fter the ignition is turned on pressing a rear seat heated wire switch activates the heated wire of the corresponding seat and pressing the switch again turns off the heated wire operation Operating process When the front or rear seat heated wire switch is pressed the power is supplied to the corresponding front or rear seat heated wire through the switch The seat heated wire and ventilation unit ...

Page 1262: ... seat belt immediately to protect the occupant s face and chest when a strong frontal collision occurs Front 3 point type seat belt Driver Passenger seats Rear 3 point type seat belt RH Front seat belt Height adjuster Rear seat belt RH Rear seat belt LH Rear double buckle 1st row Rear center seat belt Rear buckle 1st row 6 Seat Heated Wire and Ventilation 1 Seat belt configuration 3 point type sea...

Page 1263: ... 26 Rear seat belt LH RH 3 point type Rear center seat belt 3 point type 2 Mounting location for seat belt Driver seat Belt 3 point type Passenger seat Belt 3 point type LH Rear seat belt Front seat belt ...

Page 1264: ...ward and keeping occupants in a stable posture The load limiter is also installed to reduce the chest impact to a front seat occupant by loosening the seat belt while maintaining the force applied by the seat belt uniformly when the pretensioner retracts the seat belt instantly The seat belt pretensioner is operated first and then the load limiter is activated Height adjuster This feature improves...

Page 1265: ...g 6 to 9 months Seat belt U SU X 13kg 12 to 15 months Seat belt U SU X Front face seat 9 18kg 9 to 48 months Seat belt ISOFIX seat U UF SU X Booster seat 15 25kg 4 to 6 years Seat belt U X Booster cushion 22 36kg 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 be f...

Page 1266: ...e seat belt is not needed No lower anchor is installed to the rear center seat The approved ISOFIX child restraint system can be mounted to the vehicle with ISOFIX system 2 lower latches and one rear seatback anchor When installing ISOFIX child restraint system to the vehicle all the seat belts in the rear seat should be buckled The mounting latches and anchors for the ISOFIX system are only for t...

Page 1267: ...ng child restraint system on the back side of the rear seatback as shown in the figure Route the belt of the child restraint system over the seatback of the rear seat Attach the hook of the child restraint system belt to the anchor firmly and securely tighten the child restraint to the seat ...

Page 1268: ......

Page 1269: ...03 32 5 CIRCUIT DIAGRAM 1 Front Power Seat Heated wire Ventilation ...

Page 1270: ...03 33 7410 00 ...

Page 1271: ...03 34 2 Front Manual Seat Heated Wire ...

Page 1272: ...03 35 7410 00 ...

Page 1273: ...03 36 3 Front Power Seat Heated Wire ...

Page 1274: ...03 37 7410 00 ...

Page 1275: ...03 38 4 Rear Seat Heated Wire ...

Page 1276: ...03 39 7410 00 ...

Page 1277: ...r and torque load for 7 5 Nm or above 2 step opening amount 1st step sliding open 370 5 mm 2nd step sliding open 450 5 mm Vertical horizontal tolerance for sunroof glass panel 2mm Cautions during work Wear a clean work clothes and gloves Any unauthorized modification or operational test is not allowed since the sunroof motor and control unit are preset at the factory Take care not to drop or stack...

Page 1278: ...04 4 OPEN Sunroof switch 1 SYSTEM LAYOUT Sunroof assembly TILT Sunroof motor control unit ...

Page 1279: ... glass can be open in two steps and can be tilted by the switch operation The sunroof switches are included in the overhead console switches and consists of the TILT CLOSE and OPEN switches TILT CLOSE OPEN Sun shade panel Sunroof glass Sunroof switch Opens only rear section of the sunroof Closes the sunroof Opens the sunroof Sunroof glass Sun shade panel ...

Page 1280: ...sed as long as pulling down the switch Pull down the switch Push up the switch Push up the switch briefly 2 step auto sliding open When pushing up the switch briefly the sunroof is automatically opened Opening is carried out in 2 steps In first step the area 5 cm behind the sunroof is not opened Push up the switch once again in order to open the sunroof completely The sunroof operation stops if yo...

Page 1281: ... the sunroof is completely closed The sunroof may look closed but it might be tilted up Tilt Down The rear side of the sunroof is tilted up when 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 ...

Page 1282: ...ns adjust by opening the window or sunroof The anti pinch function is deactivated just before the sunroof closes The sunroof safety function is just a safety supplementary system which cannot replace driver s care and caution Moreover it may not be able to operate due to electric part or other conditions To prevent any body parts from being trapped by the sliding sunroof an Anti Pinch Function aut...

Page 1283: ... in malfunction Especially in winter never operate the sunroof if operation areas are iced Wait until melted Make sure that the sunroof is completely closed when leaving the vehicle Leaving the vehicle with the sunroof open result in a theft In addition rain or snow can get into the vehicle through the open sunroof When the sunroof is fully open wind buffeting symptom can be worse In this case try...

Page 1284: ...04 10 4 CIRCUIT DIAGRAM ...

Page 1285: ...trument panel The design and material of IP have been changed An invisible type passenger air bag module has been applied LH side fascia panel molding The design of LH side fascia panel molding has been changed 1 MAJOR CHANGES Instrument Panel Cluster fascia molding RH cluster fascia panel ...

Page 1286: ...been changed RH center fascia panel has been newly applied RH glove box housing extension RH glove box housing extension panel has been newly added on the right side of glove box housing Center fascia panel RH side fascia panel Center fascia molding RH side fascia molding LH and RH center fascia panels RH side fascia panel Center fascia molding RH side fascia molding Crash pad upper cover The name...

Page 1287: ... the front console cup holder housing has been changed Front Console Front door trim The design of front door trim has been changed Door Trim Rear door trim The design of rear door trim has been changed 2 Mounting points 3 Mounting points ...

Page 1288: ...f the radiator grille has been changed The emblem on the radiator grille has been changed 1 MAJOR CHANGES Hood panel The appearance of the hood panel has been changed Hood latch The appearance of the hood latch safety hook has been changed ...

Page 1289: ...f the front bumper has been changed The front end upper panel has been newly applied Front end upper member The front bumper bracket has been newly applied Headlamp member Aiming hole has been added because of the changed headlamp The install location of front impact sensor has been changed The appearances of the front bumper bracket and headlamp bracket have been changed ...

Page 1290: ...06 4 Rear quarter panel The outline of the rear combination lamp mounting has been changed ...

Page 1291: ...07 3 5110 01 Top view Side view Front side Rear view 1 MAJOR DIMENSION ...

Page 1292: ...07 4 2 JACK POINTS 1 2WD ...

Page 1293: ...07 5 5110 01 2 4WD ...

Page 1294: ...07 6 3 SEALING APPLICATION POINTS 1 Dash Panel Engine Tunnel Floor Etc ...

Page 1295: ...07 7 5110 01 2 White Body ...

Page 1296: ...07 8 3 Front Rear Door Panel ...

Page 1297: ...07 9 5110 01 4 Engine Hood Panel ...

Page 1298: ...07 10 4 DEADENER APPLICATION POINTS Asphalt 4 7t ...

Page 1299: ...07 11 5110 01 5 UNDER COATING ...

Page 1300: ...07 12 6 MAJOR WELDING POINTS 1 Cross Sectional View of Major Panels ...

Page 1301: ...07 13 5110 01 2 Side Panel ...

Page 1302: ...07 14 3 Front Panel Welding point ...

Page 1303: ...07 15 5110 01 4 Apron Panel ...

Page 1304: ...07 16 5 Dash Cowl Panels ...

Page 1305: ...07 17 5110 01 6 Front H Frame Panel ...

Page 1306: ...07 18 7 Front Floor Panel ...

Page 1307: ...07 19 5110 01 8 Rear Floor Panel ...

Page 1308: ...07 20 9 Rear End Panel ...

Page 1309: ...07 21 5110 01 10 Roof Panel ...

Page 1310: ...07 22 7 MAJOR BODY DIMENSIONS 1 Under Body Unit mm ...

Page 1311: ...07 23 5110 01 2 Vehicle Structure Unit mm ...

Page 1312: ...07 24 3 Side Structure Unit mm ...

Page 1313: ...07 25 5110 01 4 Windshield Glass Area Unit mm ...

Page 1314: ...07 26 5 Tail Gate Area Unit mm ...

Page 1315: ...07 27 5110 01 6 Front End Unit mm ...

Page 1316: ...07 28 7 Engine Room Unit mm ...

Page 1317: ...07 29 5110 01 8 Back Panel Unit mm ...

Page 1318: ...07 30 8 GAP CHART 1 Side Body Unit mm ...

Page 1319: ...07 31 5110 01 2 Front Unit mm ...

Page 1320: ...07 32 3 Rear Unit mm ...

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