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SSANGYONG KYRON 2005.10, Manual

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SSANGYONG KYRON 2005.10 Manual Download Page 255

01-31

ENGINE D20DT

KYRON 2005.10

0000-00

6. Follow the job procedures. If you find a defective component, replace it with new one.

Disconnect the negative battery cable.

For safety reasons: check pressure is low before opening the HP systems (pipes)

Use special tools and torque wrench to perform the correct works.

Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel 
rail and each injector should be replaced with new ones. The pipes should be 
tightened to specified tightening torques during installation. Over or under torques 
out of specified range may cause damages and leaks at connections. Once 
installed, the pipes have been deformed according to the force during installtion, 
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 disconnected parts with sealing caps, and remove the caps immediately 

before replacing the components.

Summary of Contents for KYRON 2005.10

Page 1: ...GENERAL INFORMATION 0000 00 GENERAL INFORMATION GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 2 LAYOUT OF ELECTRICAL SYSTEM 3 6 ...

Page 2: ......

Page 3: ...l No1 Refer to Major Connector Position Section 2 D S201 Splice pack S201 S207 Refer to Major Splice Pack Position Section2 E Wiring Harness Color Refer to Wiring Harness Color Abbreviation F Internal circuit of component Relay Component Name and Terminal Number G Internal circuit of component Switch Component Name Terminal Number and Connecting Wiring Circuit H Lower horizontal line Ground line G...

Page 4: ...B Black Lg Light Green 6 HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on Female Terminal Male Connector ex Terminal Number 4 of C901 connection Power supply No Power supply condition 15 Battery Voltage B supply in Ignition Switch ON and ST IGN 1 15A Battery Voltage B supply in Ignition Switch ON IGN 2 15C Battery Voltage B supply in Ignition Switch ON and ACC 30 Battery...

Page 5: ... Joint connector that connects various wiring harness 1 Part location number Part number according to locating section Part Numbe Location 1 Engine compartment 2 Instrument panel 3 Passenger compartment 4 Tailgate 5 Underbody In the locating section the assignment for part number startsfrom left bottom and proceeds clockwise In the fuse and relay box or the instrument panel the partnumber is assig...

Page 6: ... PAS Unit Driver Seat Memory SW TCCU TCU Under the I P Driver Seat SSPS Sensor D27DT Immobilizer 1 POSITION OF INTERIOR UNIT SENSOR SSPS Sensor Immobilizer Curtain Air Bag Module TV ANT AMP Sun Sensor Curtain Air Bag Module DVD Changer Sub Woofer TV ANT AMP DSP AMP TV Tuner TCCU TCU SSPS Unit Under the ENG ECU DR Lock Relay Chime PAS Buzzer STICS 2 LAYOUT OF ELECTRICAL SYSTEM ...

Page 7: ...IT SENSOR FFH Ass y Receiver Dryer Tripple Pressure SW Horn RH AQS Sensor Ambient Temp Sensor FFH ESP Pressure Sensor 1 2 ABS ESP HECU IWE Solenoid Valve 4WD Fuse Relay Box Burglar Horn Under the BATT Horn LH AQS AmbientSensor Ambient Temp Sensor FFH Under the BATT TRAY ...

Page 8: ... Bezel Ass y Center Fascia SW Passenger P Window SW 4WD SW Driver Seat Warmer SW Passenger Seat Warmer SW HDC SW TRIP SW Hazard SW Deicer SW RR DEF SW O S Mirror DEF SW ESP OFF SW O S Mirror Fold g SW Audio Remocon SW Audio Remocon SW Room Lamp Main SW S Roof SW RR Fog Lamp SW O S Mirror SW 3 INTERIOR SWITCH O S Mirror SW Bezel Ass y Steering S Roof SW ...

Page 9: ...000 00 4 AV SYSTEM DVD Tape Woofer Position Upper the G Box panel Etc Audio Head Unit 6pcs INDASH CD TAPE RADIO CD RAIDIO 6pcs Indash Tape CD Insert AV SYSTEM DSP AMP Tuner TV ANT AMP RH Radio ANT AMP Audio Remocon Center Speaker DVD Changer ...

Page 10: ...C Sun Sensor Upper the IP LH AQS Mode SW Compressor AQS Ambient Temp Sensor Condensor Coolant Temp Sensor ENG ECU Receiver Dryer LH Mode Actuator W H A Con Control Unit W H Main Intake Sensor Power TR Coolant Temp Sensor Air Mix Actuator Intake Actuator A C Filter AQS Sensor Ambient Temp Sensor Heater Unit Blower Unit ...

Page 11: ...2005 10 0000 00 AIR DUCT LAY OUT W H A CON MODULE Coolant Temp Sensor Intake Actuator Power TR Blower Motor Intake Air Temp Sensor Air Mix Actuator W H Main Connector Incar Sensor A Con Control Unit Mode Actuator A Con Wiring Setting ...

Page 12: ......

Page 13: ...10 08 CONNECTOR GROUND WIRING 8201 00 WIRING HARNESS COMPONENTS LOCATION CONNECTOR GROUND 8210 00 W H ENGINE ROOM 8210 02 W H MAIN 8210 03 W H FLOOR 8210 09 W H ROOF 8210 10 W H TAIL GATE 8210 06 W H DRIVER DOOR 8210 07 W H PASSENGER DOOR 8210 08 W H RR DOOR 3 19 20 21 23 23 24 24 25 ...

Page 14: ......

Page 15: ...0 3 CONNECTOR GROUND KYRON 2005 10 8201 00 WIRING HARNESS 8201 00 WIRING HARNESS COMPONENTS LOCATION 1 WIRING HARNESS 2 COMPONENTS LOCATION ...

Page 16: ...0 4 KYRON 2005 10 8201 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 17: ...0 5 CONNECTOR GROUND KYRON 2005 10 8201 00 GROUND SPLICE PACK ...

Page 18: ...0 6 KYRON 2005 10 8201 00 CONNECTOR GROUND 4 SPLICE PACK CIRCUIT S101 S201 S202 CAN S203 GND S204 ILL S205 GND ...

Page 19: ...0 7 CONNECTOR GROUND KYRON 2005 10 8201 00 S206 S301 CAN S302 S303 ...

Page 20: ...0 8 KYRON 2005 10 8201 00 CONNECTOR GROUND 5 CONNECTOR C104 C105 C106 C101 C102 C103 ...

Page 21: ...0 9 CONNECTOR GROUND KYRON 2005 10 8201 00 C107 C108 C110 C111 C112 C114 C113 D20DT D27DT GSL ...

Page 22: ...0 10 KYRON 2005 10 8201 00 CONNECTOR GROUND C115 DSL C115 GSL C116 ...

Page 23: ...0 11 CONNECTOR GROUND KYRON 2005 10 8201 00 C201 C203 C202 C204 ...

Page 24: ...0 12 KYRON 2005 10 8201 00 CONNECTOR GROUND C205 Curtain A Bag C207 C206 ...

Page 25: ...0 13 CONNECTOR GROUND KYRON 2005 10 8201 00 C208 C209 C210 C211 Curtain A Bag C212 DSL GSL ...

Page 26: ...0 14 KYRON 2005 10 8201 00 CONNECTOR GROUND C213 C214 C301 Power Seat W Memory Manual Seat W O Memory ...

Page 27: ...0 15 CONNECTOR GROUND KYRON 2005 10 8201 00 C302 C351 C361 C371 ...

Page 28: ...0 16 KYRON 2005 10 8201 00 CONNECTOR GROUND C381 C401 C402 C901 Auto T M Manual T M C902 DSL GSL C904 ...

Page 29: ...0 17 CONNECTOR GROUND KYRON 2005 10 8201 00 WIRNING CONNECTOR MODE CONNECTOR UNIT CONNECTOR ...

Page 30: ...0 18 KYRON 2005 10 8201 00 CONNECTOR GROUND SWITCH CONNECTOR LAMP CONNECTOR SENSOR CONNECTOR ETC ...

Page 31: ...0 19 CONNECTOR GROUND KYRON 2005 10 8210 00 CONNECTOR 8210 00 W H ENGINE ROOM ...

Page 32: ...0 20 KYRON 2005 10 8210 02 CONNECTOR GROUND 8210 02 W H MAIN ...

Page 33: ...0 21 CONNECTOR GROUND KYRON 2005 10 8210 03 8210 03 W H FLOOR ...

Page 34: ...0 22 KYRON 2005 10 8210 10 CONNECTOR GROUND ...

Page 35: ...0 23 CONNECTOR GROUND KYRON 2005 10 8210 09 8210 09 W H ROOF 8210 10 W H TAIL GATE ...

Page 36: ...0 24 KYRON 2005 10 8210 07 CONNECTOR GROUND 8210 06 W H DRIVER DOOR 8210 07 W H PASSENGER DOOR ...

Page 37: ...0 25 CONNECTOR GROUND KYRON 2005 10 8210 08 8210 08 W H RR DOOR ...

Page 38: ......

Page 39: ...ON FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 8410 04 I P LH FUSE RELAY BOX 8401 06 I P RH FUSE RELAY BOX ELECTRICITY DIVIDE 8210 02 ENGINE ROOM FUSE RELAY BOX CIRCUIT 8410 04 I P LH FUSE RELAY BOX CIRCUIT 8410 06 I P RH FUSE RELAY BOX CIRCUIT 3 5 6 7 10 15 ...

Page 40: ......

Page 41: ...0 3 POWER DISTRIBUTION KYRON 2005 10 8410 02 FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 1 UPPER 2 LOW 3 ENGINE ROOM FUSE RELAY BOX ...

Page 42: ...0 4 KYRON 2005 10 8410 02 POWER DISTRIBUTION 4 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 5 ENGINE ROOM FUSE BOX CONNECTOR NUMBER ...

Page 43: ...0 5 POWER DISTRIBUTION KYRON 2005 10 8410 04 8410 04 I P LH FUSE RELAY BOX 1 I P LH FUSE RELAY BOX 2 POWER SUPPLY ...

Page 44: ...0 6 KYRON 2005 10 8410 06 POWER DISTRIBUTION 8410 06 I P RH FUSE RELAY BOX 1 I P RH FUSE RELAY BOX ...

Page 45: ...0 7 POWER DISTRIBUTION KYRON 2005 10 8210 02 ELECTRICITY DIVIDE 8210 02 ENGINE ROOM FUSE RELAY BOX CIRCUIT 1 SB5 SB6 Ef4 Ef5 Ef11 HORN RELAY HEAD LAMP RELAY HI LO 2 SB2 SB4 SB7 SB9 Ef3 P WINDOW RELAY ...

Page 46: ...0 8 KYRON 2005 10 8410 02 POWER DISTRIBUTION 3 SB10 SB11 CONDENSOR FAN RELAY HI LO 4 SB12 SB16 START RELAY PTC RELAY ...

Page 47: ...0 9 POWER DISTRIBUTION KYRON 2005 10 8410 02 5 Ef1 Ef2 Ef6 Ef7 6 Ef8 Ef10 TAIL LAMP RELAY FRT FOG LAMP RELAY ...

Page 48: ...0 10 KYRON 2005 10 8410 02 POWER DISTRIBUTION 7 Ef12 Ef15 Ef18 Ef23 COMPRESSOR RELAY 8 WIPER MOTOR RELAY HI LO WASHER RELAY FRT RR ...

Page 49: ...0 11 POWER DISTRIBUTION KYRON 2005 10 8410 04 8410 04 I P LH FUSE RELAY BOX CIRCUIT 1 F24 F28 2 F29 F34 ...

Page 50: ...0 12 KYRON 2005 10 8410 04 POWER DISTRIBUTION 3 F35 F40 RR WIPER RELAY 4 F41 F48 ...

Page 51: ...0 13 POWER DISTRIBUTION KYRON 2005 10 8410 04 5 F49 F51 DRL RELAY RR FOG LAMP RELAY 6 F52 F55 BURGLAR HORN RELAY ...

Page 52: ...0 14 KYRON 2005 10 8410 04 POWER DISTRIBUTION 7 F56 F57 HDC RELAY FLASHER UNIT ...

Page 53: ...0 15 POWER DISTRIBUTION KYRON 2005 10 8410 06 8410 06 I P RH FUSE RELAY BOX CIRCUIT 1 F58 F64 ENG MAIN RELAY 2 F65 F71 HAZARD RELAY ...

Page 54: ...0 16 KYRON 2005 10 8410 06 POWER DISTRIBUTION 3 BLOWER RELAY P OUTLET RELAY INJECTOR RELAY SNR RELAY ...

Page 55: ...R OUTLET CIRCUIT 7340 03 SUN ROOF CIRCUIT 8310 01 HEAD LAMP DRL DAY TIME RUNNING LIGHT UNIT CIRCUIT 8510 00 HLLD HEAD LAMP LEVEL G DEVICE CIRCUIT 8320 01 TAIL LAMP CIRCUIT 8410 01 TURN SIGNAL HAZARD LAMP CIRCUIT 8210 01 TRAILER LAMP CIRCUIT 8310 10 FOG LAMP CIRCUIT 4810 01 STOP BACK UP LAMP CIRCUIT 7770 02 INTERIOR LAMP CIRCUIT 7770 10 AUTO DIMMING ROOM MIRROR CIRCUIT 8910 01 AUDIO CLOCK CIRCUIT 8...

Page 56: ......

Page 57: ...0 3 CIRCUIT KYRON 2005 10 1461 01 1461 01 STARTING CHARGING 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 58: ...0 4 KYRON 2005 10 2820 01 CIRCUIT 2820 01 PREHEATING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 59: ...ontrol after monitoring the engine preheating post heating and glow plug diagnosis function the fault contents will be delivered to ECU Engine preheating post heating functions Preheating relay activation by ECU controls Senses engine temperature and controls the preheating post heating time Preheating warning light K LINE for information exchanges between preheating unit and ECU Transmits preheat...

Page 60: ...YRON 2005 10 1491 01 CIRCUIT 1491 01 ECU ENGINE CONTROL UNIT DSL ENG MAIN RELAY PEDAL MODULE HFM SENSOR VALVE CRUISE CONTROL SW 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 61: ...10 1491 01 2 FUEL FILTER WARNING LAMP IMMOBILIZER SENSOR CIRCUIT FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT KNOCK COOLANT TEMP FUEL TEMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 62: ...0 8 KYRON 2005 10 1491 01 CIRCUIT 3 INJECTOR CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 63: ... speed Driving mode control If the vehicle runs normally fuel injection volume will be calculated by accelerator pedal travel and engine rpmand the drive map will be used to match the drivers inputs with optimum engine power C ECU INPUTS OUTPUTS D STRUCTURE AND FUNCTION OF ECU ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and...

Page 64: ...0 10 KYRON 2005 10 1491 01 CIRCUIT 1491 01 ECU ENGINE CONTROL UNIT GSL G32 1 IGN COIL INJECTOR PEDAL MODULE THROTTLE SENSOR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 65: ...0 11 CIRCUIT KYRON 2005 10 1491 01 2 O SENSOR CPS KNOCKSENSOR HFM SENSOR CANISTER PURGE VALVE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 66: ...0 12 KYRON 2005 10 1491 01 CIRCUIT 3 S AIR PUMP STOP LAMP CRUISE CONTROL SW FUEL PUMP IMMOBILIZER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 67: ...0 13 CIRCUIT KYRON 2005 10 8210 01 8210 01 DIAGNOSIS CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 68: ...0 14 KYRON 2005 10 3110 01 CIRCUIT 3110 01 TCU DC5 A T 1 START MOTOR TGS LEVER CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 69: ...0 15 CIRCUIT KYRON 2005 10 3110 01 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 70: ... habits downhill gripping approx 11 13 5 When W mode is selected the Winter mode indicator in meter cluster comes on and the vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road In winter mode the up shift becomes faster and the down shift becomes slower for improving fuel consumption The W mode is automatically changed to S mode in full throttle or kick down ope...

Page 71: ...ront planetary carrier If the speed sensor is defective the transmission is operated in emergency driving mode Below table shows the detection of speed sensor H LOCKUP SOLENOID VALVE This valve activates and releases the lockup clutch by adjusting the current to solenoid valve according to engine throttle opening value and output shaft speed The lockup clutch operates in 3rd 4th and 5th gear with ...

Page 72: ...0 18 KYRON 2005 10 3110 01 CIRCUIT K DTC DIAGNOSIS TROUBLE CODE OF DC5AT ...

Page 73: ...0 19 CIRCUIT KYRON 2005 10 3110 01 ...

Page 74: ...0 20 KYRON 2005 10 3110 01 CIRCUIT ...

Page 75: ...0 21 CIRCUIT KYRON 2005 10 3110 01 ...

Page 76: ...0 22 KYRON 2005 10 3410 01 CIRCUIT 3410 01 TCCU 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 77: ...vehicle Note through the CAN communication Delete the pin related to the speed sensor from TCCU pins Change the transfer case wiring connector from No 4 pin to No 1 pin Power and ground related to the speed sensor The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU Instrument panel In non ABS vehicle the vehicle speed sensor is installed on the rear d...

Page 78: ...ECTOR When selecting a position in the 4WD switch 2H 4H 4L TOD control unit exactly changes the motor position to 2H 4H and 4L by detecting the electric signals from position encoder that monitors motor position 6 MAGNETIC CLUTCH COIL POWER SUPPLY CONNECTOR The transfer case integrated in KYRON doesn t have an internal speed sensor and receives the speed signal from ABS ESP HECU or the instrument ...

Page 79: ...0 25 CIRCUIT KYRON 2005 10 3410 01 8 DIAGNOSTIC TROUBLE CODE ...

Page 80: ...0 26 KYRON 2005 10 4892 01 CIRCUIT 4892 01 ABS ESP W SPEED SENSOR STOP LAMP SW DIAGNOSIS WARNING LAMP ABS ESP HDC 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 81: ...0 27 CIRCUIT KYRON 2005 10 4892 01 PRESSURE SENSOR S W A SENSOR SENSOR CLUSTER ESP OFF SW 2 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 82: ...perienced elderly or physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver D SWAS STEERING WHEEL ANGLE SENSOR The steering wheel angle sensor is located between clock spring and multifunction switc...

Page 83: ...f return type switch when you press it once it starts to operate and when you press it again it stops the operation H ESP ELECTRONIC STABILITY PROGRAM ESP Electronic Stability Program recognizes critical driving conditions such as panic reactions in dangerous situations and stabilizes the vehicle by wheel individual braking and engine control intervention with no need for actuating the brake This ...

Page 84: ...m of 4 times every 175 milliseconds and the buzzer sounds for at least 1 4 seconds with 100 ms interval L ESP SYSTEM CANCELLATION USING THE ESP OFF SWITCH When the ESP switch at the center switch panel is pushed for over approximately 150 ms the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on th...

Page 85: ...0 31 CIRCUIT KYRON 2005 10 4892 01 N ABS ESP TROUBLE DIAGNOSIS ...

Page 86: ...0 32 KYRON 2005 10 4892 01 CIRCUIT ...

Page 87: ...0 33 CIRCUIT KYRON 2005 10 4892 01 ...

Page 88: ...0 34 KYRON 2005 10 4620 12 CIRCUIT 4620 12 S S P S SPEED SENSITIVE POWER STEERING 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 89: ...ty effect by binding the input shaft with supplied hydraulic pressure from PCV C Solenoid valve The SSPS control unit controls the amount of electric current to the solenoid valve according to the vehicle speed In other words the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve spool position that is linked with solenoid valve according to the amount...

Page 90: ...ICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE SCHEDULE 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 STANDARD BOLTS SPECIFICATIONS GENERAL 3 4 6 7 9 10 12 13 15 ...

Page 91: ...01 2 KYRON 2005 10 0000 00 GENERAL ...

Page 92: ...01 3 GENERAL KYRON 2005 10 0000 00 0000 00 GENERAL GENERAL 1 DIMENSIONS Unit mm Optional ...

Page 93: ...01 4 KYRON 2005 10 0000 00 GENERAL 2 SPECIFICATIONS Optional ...

Page 94: ...01 5 GENERAL KYRON 2005 10 0000 00 Optional ...

Page 95: ... Number The engine number is stamped on the lower area of cylinder block behind the Intake manifold 2 Chassis Number The chassis number is stamped on the frame behind the front right tire 3 Certification Label The certification label is located on the driver s door sill ...

Page 96: ...rrain sandy or dusty area High load driving such as trailer towing Severe Conditions in Automatic Transmission and Axle Towing a trailer or off road driving Taxi patrol service or delivery service extended idling and excessive driving with low speed Severe Conditions in Air Conditioner Filter Pollutant area or off road driving extended air conditioner or heater operation Severe Conditions in Air C...

Page 97: ...ving in hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Severe Conditions in Automatic Transmission and Axle Towing a trailer or off road driving Taxi patrol service or delivery service extended idling and excessive driving with low speed Severe Conditions in Air Conditioner Filter Pollutant area or off road driving extended air conditioner or heater opera...

Page 98: ...0 5 RECOMMENDED 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 99: ...01 10 KYRON 2005 10 0000 00 GENERAL 6 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 100: ...01 11 GENERAL KYRON 2005 10 0000 00 2 5 Link System Lifting Point Dotted Circles ...

Page 101: ...01 12 KYRON 2005 10 0000 00 GENERAL 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 102: ...01 13 GENERAL KYRON 2005 10 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 103: ...01 14 KYRON 2005 10 0000 00 GENERAL 2 Components Locator ...

Page 104: ...01 15 GENERAL KYRON 2005 10 0000 00 9 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 105: ...ng 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 abo...

Page 106: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

Page 107: ......

Page 108: ...01 3 ENGINE GENERAL KYRON 2005 10 0000 00 0000 00 ENGINE GENERAL GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 109: ...01 4 KYRON 2005 10 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 110: ... FFH L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 111: ...01 6 KYRON 2005 10 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 112: ...01 7 ENGINE GENERAL KYRON 2005 10 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 113: ...00 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 114: ...ilter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 115: ...YRON 2005 10 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 116: ...NCTION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 117: ...TAKE SYSTEM Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 118: ... 2005 10 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 119: ...4 KYRON 2005 10 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM LAYOUT DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 120: ...n will happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the ...

Page 121: ...01 16 KYRON 2005 10 0000 00 ENGINE GENERAL 6 LUBRICATION SYSTEM LAYOUT Cylinder Head Cover Oil Pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 122: ...appen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake s...

Page 123: ...YOUT Coolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 124: ...01 19 ENGINE GENERAL KYRON 2005 10 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 125: ...M LAYOUT Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 126: ...01 21 ENGINE GENERAL KYRON 2005 10 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 127: ...n sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decre...

Page 128: ... 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 right side figure shows the clearance between internal operating elements The core elements of fuel system has very...

Page 129: ...e on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing c...

Page 130: ...es The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to ...

Page 131: ...e by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history faults 10...

Page 132: ...n heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due t...

Page 133: ...aintenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity en...

Page 134: ... Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the ...

Page 135: ...d by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works How...

Page 136: ...f contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of pola...

Page 137: ... foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly...

Page 138: ...etween 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 Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance ...

Page 139: ...hicle and then support with chassis stand before service work Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work ...

Page 140: ...rease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line b...

Page 141: ...ce Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting Positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front ...

Page 142: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 143: ...he cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Insp...

Page 144: ...le Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system includ...

Page 145: ...the glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the co...

Page 146: ...01 41 ENGINE GENERAL KYRON 2005 10 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 147: ...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 148: ...ically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque Coolant reservoir FFH Engine oil dipstick Oil separator PCV valve Vacuum pump Air cleaner assembly HFM sensor VGT Turbo charger Engine Engine oil filler cap ...

Page 149: ...E ASSEMBLY KYRON 2005 10 1212 01 EGR valve Vacuum modulator Brake fluid reservoir ABS ESP modulator Fuel filter priming pump Power steering oil reservoir PWM electric fan fan shroud Washer fluid reservoir Battery ...

Page 150: ... 4 VGT Turbo charger 5 EGR pipe 6 Water pump pulley 7 Alternator 8 Crankshaft pulley 9 Oil pan 10 Auto tensioner 11 Air conditioner compressor 12 Auto tensioner pulley 13 Power steering pump pulley 14 Power steering pump 15 EGR valve 16 Idle pulley 17 Viscos clutch pulley 1 Engine Structure Front View 12 1 7 Nm ...

Page 151: ... cover 10 1 0 Nm 180 20 3 Oil pipe 4 Fuel pressure sensor 5 Water outlet port 6 EGR valve 7 Oil filler 8 Booster pressure sensor 9 Common rail 10 Vacuum pump 11 Glow plug 12 Cylinder head cover 13 VGT Turbo charger Top View 10 1 0 Nm 40 4 0 Nm 25 2 5 Nm 10 1 0 Nm 15 3 Nm ...

Page 152: ...5 HP pump assembly 6 Air conditioner compressor 7 Engine mounting bracket 8 Vacuum modulator for VGT turbocharger actuator 9 Flywheel 10 Crank position sensor 11 Vacuum modulator for EGR valve 12 Oil filter oil cooler 13 Vacuum pump 14 Booster pressure sensor 15 Intake manifold 0 8 0 4 Nm Gap 0 7 1 5 mm Right Side View 20 2 6 Nm ...

Page 153: ...10 1212 01 1 Cylinder head jack valve screw 2 VGT Turbo charger assembly 3 Cylinder block assembly 4 Engine mounting bracket 5 Oil pan 6 Alternator 7 Water pump 8 EGR pipe 9 Oil dipstick gauge 10 Oil separator with PCV Left Side View ...

Page 154: ...02 8 KYRON 2005 10 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 155: ...02 9 ENGINE ASSEMBLY KYRON 2005 10 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 156: ...02 10 KYRON 2005 10 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 157: ...02 11 ENGINE ASSEMBLY KYRON 2005 10 1212 01 ...

Page 158: ...02 12 KYRON 2005 10 1212 01 ENGINE ASSEMBLY ...

Page 159: ... rpm and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining...

Page 160: ...ter drain plug water separating operation every 10 000km 3 Priming pump When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 161: ...uel gets out from the port then turn the drain plug to B direction to tighten it 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to...

Page 162: ...ion driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from co...

Page 163: ...mpletely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure pump t...

Page 164: ...03 8 KYRON 2005 10 1881 01 ENGINE FUEL SYSTEM 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE High pressure supply line Transfer pressure supply line Return line ...

Page 165: ...vent excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the c...

Page 166: ...aterials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel Filter ...

Page 167: ...reases system pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High Pressure Pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value ...

Page 168: ...njector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line 6 Fuel Filter Replacement Fuel filter ...

Page 169: ...03 13 ENGINE FUEL SYSTEM KYRON 2005 10 1881 01 6 CIRCUIT DIAGRAM ...

Page 170: ...03 14 KYRON 2005 10 1881 01 ENGINE FUEL SYSTEM ...

Page 171: ...03 15 ENGINE FUEL SYSTEM KYRON 2005 10 1881 01 ...

Page 172: ......

Page 173: ...ry Element Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2321 01 ENGINE INTAKE SYSTEM ...

Page 174: ...on chamber and the air temperature Major Functions It controls the EGR feedback It controls the pressure control valve for the turbocharger booster 1 Plug in sensor 2 Cylinder housing 3 Protection grid 4 Hybrid cover 5 Measuring duct cover 6 Housing 7 Hybrid 8 Sensor 9 Mounting plate 10 O ring 11 Temperature sensor Turbocharger actuator Intake air cleaner Com pressed air intercooler Exhaust gas Ex...

Page 175: ...wered or the knocking may happen as the intake air is heated and the density of air is lowered The intercooler is the device which cools the supercharged air Intake manifold Intake air Exhaust gas Exhaust gas Intake manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum pump EGR valve IP interior fuse RH No 63 7 5A Engine ECU No 96 Intake Manifold Intake air ...

Page 176: ...04 6 KYRON 2005 10 2321 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 177: ...tial and helical port which increases the swirl ratio in mid low operating range improves acceleration fuel consumption and decreases particle materials However there are some differences in the form of the EGR valve and 4 cylinder engine The inlet port and coolant outlet port is integrated together Therefore be careful not to let the residual coolant in the manifold enter the inlet port when remo...

Page 178: ...GR valve 4 Intake air intercooler Intake Manifold Incoming of intake air and exhaust gas Operation of EGR valve Incoming of intake air No operation of EGR valve Coolant emission port Coolant emission port The SUS Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect Intake air Intake air Exhaust gas ...

Page 179: ...ession process in the turbocharger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine from high temperature 100 110 C to maintain the turbocharging efficiency Thus more air is entered the cylinder than the engine only with the turbocharger to give more power Intercooler For removal and installation procedures refer to the Cooling sys...

Page 180: ...04 10 KYRON 2005 10 2321 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 181: ...r s complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to...

Page 182: ...ce the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing input signal from the related sensors such as acceleration pedal sensor and engine RPM r...

Page 183: ...Valve and Installation Location 1 EXHAUST SYSTEM LAYOUT OVERVIEW AND OPERATION PROCESS Intake manifold Intake manifold EGR pipe Intake manifold Intake air intercooler EGR pipe LH To turbo charger To EGR valve Exhaust manifold Diesel catalytic converter Muffler EGR pipe RH ...

Page 184: ...05 6 KYRON 2005 10 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 185: ...ess than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature 40 140 C Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH GENERAL 1533 01 LUBRICATION SYSTEM ...

Page 186: ...n oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Inlet port Blow by gas air duct ...

Page 187: ...06 5 LUBRICATION SYSTEM KYRON 2005 10 1533 01 Cylinder Head Cover Oil pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil Filter Oil Cooler Oil cooler Oil filter ...

Page 188: ...LUBRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 ...

Page 189: ...ON 2005 10 1533 01 2 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 190: ...07 3 COOLING SYSTEM KYRON 2005 10 2112 01 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 191: ... 4 KYRON 2005 10 2112 01 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING OVERVIEW AND OPERATION PROCESS ...

Page 192: ...1 PTC Engine Coolant Flows FFH Engine Coolant Flows 2 COOLING SYSTEM FLOW Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 193: ...er in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley Cylinder head Intake manifold Coolant outlet port Improved shape and gasket material to prevent coolant from leaking It prevents ...

Page 194: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2005 10 1461 01 1461 01 ENGINE ELECTRICAL SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 195: ... Fuel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF ELECTRIC IN ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 196: ...INE ELECTRIC DEVICES KYRON 2005 10 1461 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 197: ...08 6 KYRON 2005 10 1461 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 198: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2005 10 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 199: ...NTS GENERAL Water Pump and Pipe Coolant Port Engine Oil Filter and Cooler Cylinder block Reservior coolant inlet hose Radiator Thermostat inside Coolant outlet port Oil cooler Oil filter Oil cooler Oil Filter cap Oil pressure switch Radiator Coolant outlet hose Return hose Coolant reservoir Coolant inlet hose ...

Page 200: ...09 4 KYRON 2005 10 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 201: ...09 5 ENGINE CONTROL SYSTEM KYRON 2005 10 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 202: ...Knock sensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Pr...

Page 203: ... range of ECU is normally 40 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 circuit divides current applying time...

Page 204: ...complete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined ac...

Page 205: ...ming 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 liabl...

Page 206: ...is made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a function...

Page 207: ...ot flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order...

Page 208: ...sure As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel a...

Page 209: ...nes the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and cho...

Page 210: ...moke emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of t...

Page 211: ...re the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The ...

Page 212: ...nnot 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 The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection a...

Page 213: ...st be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled and...

Page 214: ...ersion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors...

Page 215: ...st optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number 1...

Page 216: ...d mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 217: ... when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerat...

Page 218: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 219: ...10 5 CRUISE CONTROL SYSTEM KYRON 2005 10 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 220: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 221: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 222: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 223: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 224: ...s an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may r...

Page 225: ...M LAYOUT 6 EXHAUST SYSTEM LAYOUT 7 LUBRICATION SYSTEM LAYOUT 8 COOLING SYSTEM LAYOUT 9 FUEL SYSTEM LAYOUT 10 FUEL SUPPLY SYSTEM 11 CLEANNESS 12 MAINTENANCE AND REPAIR 13 GUIDELINES FOR SERVICE WORK SAFETY 14 DURING SERVICE WORK FOR INSPECTION 15 DURING SERVICE WORK FOR ELECTRIC DEVICES 16 OWNER INSPECTIONS AND SERVICES 17 STANDARD BOLTS SPECIFICATIONS 3 7 11 15 17 19 21 23 25 27 29 35 37 41 43 44 ...

Page 226: ......

Page 227: ...01 3 ENGINE D20DT KYRON 2005 10 0000 00 GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH Side View D20DT D27DT 0000 00 ENGINE GENERAL ...

Page 228: ...01 4 KYRON 2005 10 0000 00 ENGINE D20DT 2 RH side view D20DT D27DT ...

Page 229: ...01 5 ENGINE D20DT KYRON 2005 10 0000 00 3 Front view D20DT D27DT ...

Page 230: ...01 6 KYRON 2005 10 0000 00 ENGINE D20DT 4 Fan belt D20DT D27DT ...

Page 231: ...01 7 ENGINE D20DT KYRON 2005 10 0000 00 2 COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ...

Page 232: ...01 8 KYRON 2005 10 0000 00 ENGINE D20DT ...

Page 233: ...01 9 ENGINE D20DT KYRON 2005 10 0000 00 ...

Page 234: ...01 10 KYRON 2005 10 0000 00 ENGINE D20DT ...

Page 235: ...01 11 ENGINE D20DT KYRON 2005 10 0000 00 3 ENGINE CONTROLS LAYOUT 1 Ecu related componets 1 D20DT Engine ...

Page 236: ...01 12 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 237: ...01 13 ENGINE D20DT KYRON 2005 10 0000 00 2 ENGINE AND SENSORS 1 D20DT Engine ...

Page 238: ...01 14 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 239: ...01 15 ENGINE D20DT KYRON 2005 10 0000 00 4 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1 D20DT Engine ...

Page 240: ...01 16 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 241: ...01 17 ENGINE D20DT KYRON 2005 10 0000 00 5 INTAKE SYSTEM LAYOUT 1 D20DT Engine ...

Page 242: ...01 18 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 243: ...01 19 ENGINE D20DT KYRON 2005 10 0000 00 6 EXHAUST SYSTEM LAYOUT 1 D20DT Engine ...

Page 244: ...01 20 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 245: ...01 21 ENGINE D20DT KYRON 2005 10 0000 00 7 LUBRICATION SYSTEM LAYOUT 1 D20DT Engine ...

Page 246: ...01 22 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 247: ...01 23 ENGINE D20DT KYRON 2005 10 0000 00 8 COOLING SYSTEM LAYOUT 1 D20DT Engine ...

Page 248: ...01 24 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 249: ...01 25 ENGINE D20DT KYRON 2005 10 0000 00 9 FUEL SYSTEM LAYOUT 1 D20DT Engine ...

Page 250: ...01 26 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 251: ...ines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissio...

Page 252: ...01 28 KYRON 2005 10 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 253: ... is stucked due to foreign materials injector remains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operati...

Page 254: ...z dust and foreign materials from getting into fuel system Wash your hands and do not wear working gloves Follow the below procedures before starting service works for fuel system 1 2 3 4 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 DIAGNOSIS section in this manual At this point th...

Page 255: ...s The pipes should be tightened to specified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to ...

Page 256: ...t value by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history fau...

Page 257: ...TEM 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 pump c...

Page 258: ......

Page 259: ...intenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity eng...

Page 260: ...Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the b...

Page 261: ... by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Howe...

Page 262: ... contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of polar...

Page 263: ...foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly ...

Page 264: ...tween 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 Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance d...

Page 265: ...icle and then support with chassis stand before service work Before service work be sure to isconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 ...

Page 266: ...ease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line be...

Page 267: ...e Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front o...

Page 268: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 269: ...a true oil level reading Engine Coolant Level and Condition Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Windshield Washer Fluid Level Check the washer fluid level in the reservoir Add fluid if necessary 3 At least twice a month Tire And Wheel Inspection and Pressure Check Check the tire for abnormal wear or d...

Page 270: ...e Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Exhaust System Inspection Inspect t...

Page 271: ... hinges and the latches the glove box and the console doors and any folding seat hardware Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the coo...

Page 272: ...01 48 KYRON 2005 10 0000 00 ENGINE D20DT 17 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 273: ...ring 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 a...

Page 274: ......

Page 275: ...l 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 1114 01 ENGINE ASSEMBLY 1 MA4JOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT 1 D20DT ENGINE GENERAL The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque ...

Page 276: ...Coolant reservoir 8 Fuel filter 2 FFH device 9 ABS ESP unit 3 Brake fluid reservoir 10 Priming pump 4 Washer fluid reservoir 11 EGR valve 5 Common rail 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 2 D27DT ENGINE ...

Page 277: ...10 Poly grooved belt 11 Cam position sensor 12 EGR valve 13 Power steering pump 14 EGR center pipe 1 TVD Torsional Vibration Damper 2 Air conditioner compressor 3 Power steering pump pulley 4 Idle pulley 5 Water pump pulley 6 Alternator 7 Viscos clutch pulley 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 EGR valve 13 Power steering pump 14 EGR center pipe ...

Page 278: ...ler cap 24 Glow plug 25 Booster pressure sensor 26 PCV valve and oil separator 27 Oil dipstick 28 EGR LH pipe 15 Cylinder head cover 16 Intake manifold 17 Water outlet port 18 Common rail 19 Fuel pressure sensor 20 Fuel pipe 21 Injector 22 Fuel return line 23 Oil filler cap 24 Glow plug 25 Booster pressure sensor 26 PCV valve and oil separator 27 Oil dipstick 28 EGR LH pipe 2 Top View D27DT D20DT ...

Page 279: ...n plug 33 Turbo charger 34 EGR RH pipe 35 PCV valve and oil separator 36 Oil dipstick 37 Exhaust manifold 29 Cylinder head 30 Cylinder block 31 Oil pan 32 Drain plug 33 Turbo charger 34 EGR RH pipe 35 PCV valve and oil separator 36 Oil dipstick 37 Exhaust manifold 3 Right Side View D27DT D20DT ...

Page 280: ...ssure pump 39 Turbo charger booster vacuum modulator Gray 40 EGR valve vacuum modulator 41 EGR valve Black 38 High pressure pump 39 Turbo charger booster vacuum modulator Gray 40 EGR valve vacuum modulator 41 EGR valve Black 4 Left Side View D27DT D20DT ...

Page 281: ...02 9 ENGINE D20DT KYRON 2005 10 1114 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 282: ...02 10 KYRON 2005 10 1114 01 ENGINE D20DT 2 Engine Performance Curve 1 Vehicle with A T Output and Torque D20DT engine D27DT engine ...

Page 283: ...02 11 ENGINE D20DT KYRON 2005 10 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 284: ...02 12 KYRON 2005 10 1114 01 ENGINE D20DT Output and Torque 2 Vehicle with M T D20DT engine D27DT engine ...

Page 285: ...02 13 ENGINE D20DT KYRON 2005 10 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 286: ...02 14 KYRON 2005 10 1114 01 ENGINE D20DT 4 TIGHTENING TORQUE ...

Page 287: ...02 15 ENGINE D20DT KYRON 2005 10 1114 01 ...

Page 288: ...02 16 KYRON 2005 10 1114 01 ENGINE D20DT ...

Page 289: ...m and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining pr...

Page 290: ...in plug water separating operation every 10 000 km 1 2 Priming pump 3 When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 291: ...gets out from the port then turn the drain plug to B direction to tighten it 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to per...

Page 292: ...river s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant...

Page 293: ...mpletely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure pump t...

Page 294: ...03 8 KYRON 2005 10 1881 01 ENGINE D20DT 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Page 295: ...t excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the cond...

Page 296: ...rials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel filter ...

Page 297: ...stem pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value It is bec...

Page 298: ...rs The fuel injection device is composed of electrical solenoid valve needle and nozzle and controlled by engine ECU The injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel u...

Page 299: ... D20DT KYRON 2005 10 1881 01 6 Fuel filter replacement Fuel filter change interval every 30 000 km Water separation interval every 10 000 km same with engine oil change interval Never reuse the removed fuel filter ...

Page 300: ...03 14 KYRON 2005 10 1881 01 ENGINE D20DT 7 Circuit Diagram ...

Page 301: ...03 15 ENGINE D20DT KYRON 2005 10 1881 01 ...

Page 302: ...03 16 KYRON 2005 10 1881 01 ENGINE D20DT ...

Page 303: ...ange every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2 Special Tools and Equipment Special Tools and Equipment Application Y99220112B Intake manifold guide pin Installation of intake manifold 2321 01 INTAKE SYSTEM ...

Page 304: ...04 4 KYRON 2005 10 2321 01 ENGINE D20DT OVERVIEW AND OPERATION PROCESS 1 ENGINE INTAKE COMPONENTS LOCATOR 1 D20DT Engine Air Cleaner Cover Elemen t Housing Intake Manifold HFM Sensor Intercooler ...

Page 305: ...04 5 ENGINE D20DT KYRON 2005 10 2321 01 2 D27DT Engine Air Cleaner Intake Manifold HFM Sensor Intercooler Cover Element Housing ...

Page 306: ...04 6 KYRON 2005 10 2321 01 ENGINE D20DT 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 307: ... s complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to ...

Page 308: ...05 4 KYRON 2005 10 1913 01 ENGINE D20DT D20DT D27DT HUBER EGR System for IDI Engine Including the EGR Valve Potentiometer EGR System for DI Engine ...

Page 309: ... D20DT KYRON 2005 10 1913 01 1 COMPONENTS LOCATOR OF EXHAUST SYSTEM Muffler Exhaust Manifold EGR Valve Turbo Charger Catalytic Converter DOC EGR Pipe Vacuum Modulator OVERVIEW AND OPERATION PROCESS 1 D20DT ENGINE ...

Page 310: ...05 6 KYRON 2005 10 1913 01 ENGINE D20DT Turbo Charger EGR Valve Muffler Exhaust Manifold Catalytic Converter DOC EGR Pipe Vacuum Modulator ...

Page 311: ...05 7 ENGINE D20DT KYRON 2005 10 1913 01 2 EXHAUST GAS FLOWS ...

Page 312: ...ps are less than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km 3 When operating in dusty sandy and salty areas 4 In hilly or moutainous terrain 5 When doing frequent trailer towing Oil Pressure Switch 1 Operating temperature 40 140 2 Operating pressure 0 3 0 55 bar 3 Permissible pressure 10 bar 1533 01 ENGINE LUBRICATION SYSTEM GENERAL 1 ...

Page 313: ...005 10 1533 01 ENGINE D20DT 1 COMPONENTS OF LUBRICATION SYSTEM 1 D20DT ENGINE Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover OVERVIEW AND OPERATION PROCESS ...

Page 314: ...06 5 ENGINE D20DT KYRON 2005 10 1533 01 Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover 2 D27DT Engine ...

Page 315: ...01 ENGINE D20DT Cylinder Head Cylinder Block Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 2 LUBRICATION SYSTEM LAYOUT ...

Page 316: ...05 10 1533 01 1 Opening pressure of by pass valve in oil filter 3 0 4 bar 2 To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head 3 LUBRICATION DIAGRAM ...

Page 317: ...07 3 ENGINE D20DT KYRON 2005 10 9210 05 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 318: ...ON 2005 10 9210 05 ENGINE D20DT Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING OVERVIEW AND OPERATION PROCESS 1 D20DT Engine ...

Page 319: ...07 5 ENGINE D20DT KYRON 2005 10 9210 05 Coolant Reservoir FFH Coolant Temperature Sensor Radiator Water Pump Cooling Fan 2 D27DT Engine ...

Page 320: ... 2 COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 321: ...ws from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley D20DT D27DT Cylinder head Intake manifold Coolant outlet port Cylinder head Coolant outlet port Intake manifold Improved shape and gasket material to prevent coo...

Page 322: ...08 3 ENGINE D20DT KYRON 2005 10 1461 01 1461 01 ENGINE ELECTRIC SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 323: ...e Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF ELECTRIC IN ENGINE 1 D20DT ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 324: ...YRON 2005 10 1461 01 Coolant Temperature Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 2 EA 2 D27DT ENGINE Booster Pressure Sensor Camshaft Position Sensor Fuel Pressure Sensor Fuel Temperature Sensor ...

Page 325: ... 2005 10 1461 01 ENGINE D20DT 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN 1 D20DT ENGINE Glow Plug Alternator Air Conditioner Compressor Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 326: ...08 7 ENGINE D20DT KYRON 2005 10 1461 01 1 D27DT ENGINE Air Conditioner Compressor Alternator Glow Plug Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 327: ...08 8 KYRON 2005 10 1461 01 ENGINE D20DT 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 328: ...08 9 ENGINE D20DT KYRON 2005 10 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 329: ...01 EGINE CONTROL SYSTEM 1 ENGINE ECU AND OTHER COMPONENTS 1 D20DT Engine GENERAL ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay ...

Page 330: ...N 2005 10 1491 01 ENGINE D20DT ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay 2 D20DT Engine ...

Page 331: ...09 5 ENGINE D20DT KYRON 2005 10 1491 01 3 TOP VIEW 1 D20DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 332: ...09 6 KYRON 2005 10 1491 01 ENGINE D20DT Fuel Pressure Sensor 2 D27DT Engine Booster Pressure Sensor Injectors 5 EA Glow Plugs 5 ...

Page 333: ...09 7 ENGINE D20DT KYRON 2005 10 1491 01 1 D20DT Engine 4 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 334: ...09 8 KYRON 2005 10 1491 01 ENGINE D20DT 2 D27DT Engine Coolant Temperature Sensor Knock Sensors 2 EA Fuel Temperature Sensor Fuel Pressure Regulating Valve Crankshaft Position Sensor ...

Page 335: ... sensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheat...

Page 336: ...ge of ECU is normally 40 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 circuit divides current applying time inj...

Page 337: ...lete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined accord...

Page 338: ... 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 to...

Page 339: ...ade according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a function of ...

Page 340: ...ow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order to m...

Page 341: ... As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel accor...

Page 342: ...the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and chooses...

Page 343: ... emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the f...

Page 344: ...e altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The diffe...

Page 345: ... 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 The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection and t...

Page 346: ...e extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled and the...

Page 347: ...n the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors It i...

Page 348: ...ptimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number 16 di...

Page 349: ...ninum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 350: ......

Page 351: ...POSITION WITH MEMORY OVERVIEW Functions of SPWM Adjusting the power seat s position with the seat adjusting switch Adjusting the angle of the outside rearview mirrors OSRVM Seat memory positions for 3 persons Folding Unfolding the outside rearview mirrors SPWM Location Bottom of diver s seat ...

Page 352: ...irror Outside rearview mirror folding switch Seat memory switch RH outside rearviewmirror 1 SEAT POSITION WITH MEMORY COMPONENTS OVERVIEW AND OPERATION PROCESS Front cushion motor sensor Seat adjusting switch Sliding motor sensor 1 2 3 Rear cushion motor sensor Reclining motor sensor SPWM Unit 4 5 6 ...

Page 353: ... the outside rearview mirrors press theswitch To unfold the mirrors press again 2 SEAT POSITION WITH MEMORY OPERATIONS 1 Outside Rearview Mirror Control Aiming Switch Select the driver side mirror L or pas senger side mirror R with the mirrorselection switch And then adjust theselected mirror up down left or rightby pressing the corresponding edgesof the switch to get the direct rearview 2 Seat Po...

Page 354: ...can be recalled automatically by pressing the position button SET button Positionbuttons 1 2 3 Storing Memory Settings Position the transmission shift lever to P with the ignition switch ON for your safety do not start the engine Apply the parking brake if the vehicle is equipped with M T Adjust the driver s seat and outside rearview mirrors to the desired positions Press the SET button The indica...

Page 355: ...failed the buzzer sounds threetimes The position memory recall is canceled if operating the seat or the outside rearview mirrors during itsoperation In the vehicle equipped with automatic transmission the position memory recall is not available if the parkingbrake is released and the gear shift lever is not in P position In the vehicle equipped with manual transmission the position memory recall i...

Page 356: ...04 8 KYRON 2005 10 7410 13 SPWM 3 SEAT POSITION MEMORY INPUT OUTPUT OF SPWM UNIT ...

Page 357: ...le when the vehicle speed is over 3 km h or the gear shift lever is not in P position with the parking brake released The memory set can be unlimitedly renewed The stored positions are erased when disconnecting the battery cables The buzzer sounds once if the memory set mode is activated The buzzer sounds twice if the memory setting recalling is completed The buzzer sounds three times if an error ...

Page 358: ...a position switch is pressed If any of the following conditions is met the memory recall function is deactivated When turning off the ignition switch When the gear shift lever is not in P position with the parking brake released When the parking brake is released only for the vehicle equipped with manual transmission When the vehicle speed is over 3 km h When pressing the STOP button during the me...

Page 359: ...ec to prevent the irruptive current frombeing overlapped The priorities are as follows Seat sliding Seatback reclining Seat cushion height adjusting front Seat cushion height adjusting rear Continuous motor driving timeSeat sliding 16 seconds Seatback reclining 50 seconds Cushion height adjusting 6 seconds Reverse controlWhen reversing the control motor the motor starts to rotate in the opposite d...

Page 360: ... operation stops However the seat can be adjusted by manual switches The memory recall operation can be activated after the failure is corrected This is determined when the systemdetects the value changes from the position sensor This is called the Release of automatic control stop Relay Protection Once the relay is turned on it will not be turned off within 60 ms Specifications Rated voltage DC 1...

Page 361: ...racteristics LOCK detection Timer monitors the motor driving time to detect LOCK condition Monitoring the memory recall time If the memory recall operation cannot be finished within 40 seconds after activating it the system stop themotor output and terminate the control Error Detection Even though the motor runs if the drive input change for 5 seconds from the position sensor doesn t change it isd...

Page 362: ...iew mirrors are folded Normal operation modeMode changes between Folding and Unfolding The outside rearview mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignitionswitch To prevent the outside rearview mirrors from stopping during its operation the mirror operating time is extended13 seconds when pressing the switch again Timing Chart ...

Page 363: ... 8010 01 GENERAL 8010 01 CLUSTER 1 DESCRIPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the data through CAN communication The HDC warning light and the engine hood open warning light are newly introduced ...

Page 364: ...05 4 KYRON 2005 10 8010 01 CLUSTER 2 WARNING INDICATOR PANE ...

Page 365: ...05 5 CLUSTER KYRON 2005 10 8010 01 ...

Page 366: ...05 6 KYRON 2005 10 8010 01 CLUSTER Main Connector Sub Connector 1 CLUSTER CONFIGURATION Front View Rear View OVERVIEW AND OPERATION PROCESS ...

Page 367: ...ator 11 A T P Parking output 12 Air bag 13 Seat blet driver 14 High beam 15 RH indicator lamp 16 High beam 17 LH indicator lamp 18 Oil pressure 19 Parking brake signal input STICS 20 PIN NO Function 1 2 3 4P output 4 Buzzer output 5 Light 6 PGND signal 7 Engine check 8 Door open 9 10 Battery 11 Troubleshooting 12 Fuel input signal 13 RESET MODE switch 14 M T N Neutral input 15 M T P Parking input ...

Page 368: ...anger rpmrange starts from 4 500 rpm Connect the tachometer for tune up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds abnormal noise there could be defectivesin tachometer If there is a differe...

Page 369: ...ointer vibrates stands at a certain range or sounds abnormal noise there could be defectives in speedometer However these symptoms also could be appeared when the tire has uneven wear different tire inflation pressures or different tire specifications Perform the speedometer test regarding the tolerance as described However it is not similar simple work in fielddue to lack of measuring conditions ...

Page 370: ...only when the fuel tank is removed The powersupply and resistance value should be measured at the connector in front of the fuel sender refer to wiring diagram When the power supply and output resistance are normal the float operation by fuel level may be defective if so replace the fuel sender Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value c...

Page 371: ... resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is outof specified range Resistance value by coolant temperature 20 C 2449W 5 50 C 826W 5 80 C 321W 5 100 C 12W 5 When the resistance value by coolant temperature is within the specified range check thermostat waterpump radiator related coolant circuit for normal operation Also che...

Page 372: ... 01 CLUSTER 5 TRIP ODOmeter TRIP A TRIP B and ODOmeter Odometer Trip Odometer When pressing the TRIP RESET switch on the cen ter panel the odometer trip odometer is convertedand the meter resets to 0 0 km in Trip A and Trip B ...

Page 373: ...el has two modes green function lamp and red warning lamp The HDCswitch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Initial ignition ON HDC system error occurs Brake system overheat Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above th...

Page 374: ...or over approximately 150 ms the ESP system will be cancelled and thevehicle will be driven regardless of the output values from the corresponding sensors Then the ESPwarning lamp on the instrument panel comes on The detailed operation procedures are as follows The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms The switch returns to normal position when the OFF switch...

Page 375: ...en the ESP OFF switch is pushed within 350 ms of being turned off the ESP warning lamp and ESP systemwill not be turned on 3 Resuming the ESP System by Using the ESP OFF Switch The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switchat the center switch panel is pushed for over approximately 150 ms while the ESP system is not operating The detail...

Page 376: ...erminesit as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms andthen goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESPunit resets the ESP OFF switch for approx 3 5 seconds ...

Page 377: ...Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compen sate the vehicle stability posture during ESP operation ...

Page 378: ...e or switch that detects the 1stgear position It detects only the forward reverse direction through the rear light switch and the neutral switch and cannot solely detect the 1st gear position The reason for noting the 1st gear above although the HDC alsooperates at over the 2nd gear is because the engine may be turned off during the HDC operation The HDC operates on the very steep road Thus it sho...

Page 379: ... of the ABS ESP installation This sensor is to signal the vehicle speed to the engine ECU TCCU transmission and instrument panel There isno separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication ...

Page 380: ...05 20 KYRON 2005 10 8010 01 CLUSTER 5 CLUSTER ELECTRICAL WIRING DIAGRAMS Gauge speed RPM fuel temp Warning Lamp fuel fuel filter ABS ESP brake HDC 4WD ...

Page 381: ...05 21 CLUSTER KYRON 2005 10 8010 01 Warning Lamp batt charge oil hood door eng check air bag ssps seat belt Turn Signal Fog Lamp Hazard ...

Page 382: ...ch side 12V 55W High Beam one at each side 12V 55W Position Lamp EU one at each side 12V W5W Position lamp and Turn Signal Lamp General one at each side 12V 28W 8W EU one at each side 12V P21W 8310 01 LAMP GENERAL 1 LOCATIONS OF LAMPS AND SPECIFICATIONS 1 Exterior Lamps ...

Page 383: ...N 2005 10 8310 01 Fog Lamp Assembly Fog lamp angle adjustment Fog Lamp General one at each side 12V 27W EU one at each side 12V H27W Side Repeater Assembly General one at each side 12V 5W EU one at each side 12V W5W ...

Page 384: ...Lamp Assembly T Stop Lamp General LH 1 12V 27W 8W EU LH 1 12V P21W 5W Turn Signal Lamp General one at each side 12V 27W EU one at each side 12V PY21W License Plate Reflector Assembly General one at each side 12V 5W EU one at each side 12V W5W Lamp Assembly ...

Page 385: ...Reversing Lamp Rear Fog Lamp Assembly Tail Lamp General one at each side 12V 27W 8W EU one at each side 12V P21W 5W Reversing Lamp General one at each side 12V 16W Rear Fog Lamp General one at each side 12V P21W High Mounted Stop Lamp Assembly ...

Page 386: ... on and stays for 30 seconds When the door is closed the lamp will go off When this switch is pushed towards the tailgate the lamp comes on when the tailgate is open If the switch is pushed to the opposite direction the lamp will go off and will not come on even if the tailgate is open 2 INTERIOR LAMPS Toward tailgate Toward dirver side Center room lamp coupled operation with door Luggage room lam...

Page 387: ...e separately turned on when pressing the switch 1 2 However the front lamps are turned on when opening a door and turned off when closing it The front room lamps and center are turned on when pressing the room lamp main switch 3 Glove Box Door Courtesy Lamp 12V 5W One at glove box 12V 5W one at each door ...

Page 388: ...oors Lock Unlock with this switch unit The position memory is available for up to three drivers Each driver can set his her own driver s seat and outside rearview mirrors positions and it will be separately stored in the integrated computer If somebody has moved the seat the memory positions can be recalled automatically by pressing the position button When this button is pressed once HDC is ready...

Page 389: ...ore than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer fluid will be sprayed onto the rear window glass once during rear wiper operation Auto Washer Switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid ...

Page 390: ...or unit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity To control the system the sensed values of rain sensor and auto light sensor are sent to pin no 63 in STICS unit Rain sensor emitter lens Light receiving area of auto light sensor The wiper and washer system are controlled by STICS according to driver s wiper switch operation And ...

Page 391: ...d reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone 3 Rear washer fluid supply system Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 392: ...s a shape of the inside of nozzle It is designed to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time Whirlwind Washer fluid outlet Passage Counter current Spray passage Washer fluid inlet It is designed to be changed spraying direction using the whirlwind and backflow generate...

Page 393: ...ER AND WASHER Overview and Operation Process WITH RAIN SENSOR Rain Sensor Unit Multifunction Wiper and Washer Switch Front Nozzle Assembly Washer Reservoir Tank Assemblyt Rear Washer Nozzle and Check Valve Rear nozzle assembly Rear nozzle Check valve 1 2 3 ...

Page 394: ...prove the spraying performance Front Nozzle Assembly There is no separate washer reservoir tank for the rear washer fluid The rear washer system uses the front washer fluid reservoir Washer Reservoir Tank Assemblyt Rear Washer Nozzle and Check Valve STICS STICS receives the rain sensing datafrom the rain sensor and controls the wiper and washer systems Rear Washer Hose Mounting There is no separat...

Page 395: ...08 8 KYRON 2005 10 7810 01 WIPER 2 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 396: ...on 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch ...

Page 397: ...econds the operation in step 1 is performed 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced...

Page 398: ...d on with the ignition switch ON and the INT switch OFF the washer motor output is activated for 1 second If the system recognizes this output the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second Then the wiper relay output is deactivated after 3 cycles ...

Page 399: ...uring the auto washer operation the auto washer operation stops and the auto INT operation is activated 5 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer sw...

Page 400: ...08 13 WIPER KYRON 2005 10 7810 01 3 WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS ...

Page 401: ...untofraindropsbyreceiving reflectedraysagainstsensingsection rainsensor mountingsectiononthewindshield with photodiode TheautolightsensorisIntegratedinto therainsensor refertothebelowpicture Multifunction wiper switch AUTO and sensitivity control AUTO Wiperoperatesautomaticallybyrainsensor FAST SLOW Autodelay Autospeedcontrol Apositionthatcancontrolsensitivityagainstrains onthewindshieldandtransmi...

Page 402: ...n sensor STICS Wiper relay LO Wiper relay HI Rear washer relay Front washer relay 1 Auto Light Sensor And Rain Sensor Coupled Control Rain detected headlamp Night detected wiping If it rains heavy which requires the highest INT speed the headlamps are turned on automatically When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatical...

Page 403: ...gh LOW relay regardless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions while the ignition key is in ON position When the wiper switch is turned to ON position again from other positions the system Drives the wiper motor through LOW relay one cycle only when the rain senso...

Page 404: ...ng the washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation ...

Page 405: ...is in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position control the tail lamp and headlamp by communicating with ...

Page 406: ... is in ON position and the INT switch is in ON position The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN HIGH the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position The wiper mo...

Page 407: ...eceiving the malfunction signal 1 from the rain sensor while the ignition key is in ON position and the INT switch is in ON position The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal 2 from the rain sensor while the ignition key is in ON position and the INT switch is in ON position ...

Page 408: ...h requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level ...

Page 409: ...09 11 RAIN SENSOR KYRON 2005 10 8610 09 3 ELECTRICAL WIRING DIAGRAM ...

Page 410: ...R position The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit 2 Parking Aid Sensor Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle Type Piezo ceramic element Frequency 40 KHz 2 KHz Detecting range 13 ...

Page 411: ...and it uses three Piezoelectric elements to measure vertical and horizontal distance to obstacles When placing the gear selector lever to R position the designated unit PAS unit activates the parking aid sensors to measure the distance to obstacles Gear Selector Lever R Position PAS buzzer STICS PAS piezoelectric buzzer ...

Page 412: ...10 5 PAS KYRON 2005 10 8790 03 Parking Aid Unit Left Right Center Sensor Location Center sensor Right sensor Connector Left sensor Center sensor ...

Page 413: ...er height is changed due to the heavy load When the sensing portion is frozen When the sensing portion is covered by rain water drops snow or mud When receiving other ultrasonic signals metal sound or air braking noises from heavy commercial vehicles When a high power radio is turned on When some accessories are attached in detecting ranges The parking aid system is just a supplemental device to h...

Page 414: ...ning beeps Alarm interval and display changes according to the distance as below While reversing if obstacles are within stage 1 the warning beep sounds with long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously When the power is applied gear selector lever is in R position the sensor will be diagnosed once If found...

Page 415: ...10 8 KYRON 2005 10 8790 03 PAS 3 PAS CIRCUIT DIAGRAM ...

Page 416: ... HEAD UNIT OVERVIEW DVD Cassette player 10 speakers center speaker woofer speakers tweeter speakers AV head unit DVD Cassette Radio Cassette tape slot DVD title insert slot MUTE button Tuner DVD 6 DISC changer DSP amplifier Subwoofer 8930 14 AV ...

Page 417: ...11 4 KYRON 2005 10 8930 14 AV OVERVIEW AND OPERATION PROCESS 1 AV SYSTEM CONFIGURATION AV System DVD Head Unit DVD Changer Audio System 6 Speakers ...

Page 418: ...11 5 AV KYRON 2005 10 8930 14 6 DISC changer TAPE RADIO CD RADIO DISC changer CD slot Tape ...

Page 419: ...er TV antenna AMP LH and RH The glass antennas at both rear quarter glasses are to receive TV and AM radio quarter RH glass signals and transmits each 2 channel video and audio signals to tuner Each AMP amplifies receives TV signals and then transmits to tuner It is installed in the center console Audio signal of DVD changer outputs to corresponding speakers through the cable Video signal is trans...

Page 420: ...11 7 AV KYRON 2005 10 8930 14 ...

Page 421: ...5 10 8930 14 AV 3 AV SYSTEM FUNCTIONS AV system head unit operates Radio TV Audio CD DVD and Video CD The touch screen type 6 5 TFT LCD monitor is installed on the system DVD slot Display when turning on the monitor ...

Page 422: ...11 9 AV KYRON 2005 10 8930 14 4 AV SYSTEM SPECIFICATIONS AND CONTROL ...

Page 423: ...11 10 KYRON 2005 10 8930 14 AV Function Settings on Touch Panel Example ...

Page 424: ...n Adjusting the sound according to the music genre Press EQ SETTING button in SET ADJ screen and adjust the sound To adjust the tone press TONE button The tone can be adjusted by BAS MID TRE bars on the screen BALANCE function and POSITION function cannot be used simultaneously DSP control EQ control BALANCE POSITION control Adjusting the sound according to the seated position Press BAL POS button...

Page 425: ... with a step up ratio of 0 83 as an overdrive The selector lever is controlled by electronically and mechanically The gears are shifted by the corresponding combination of three hydraulically actuated multiple disc brakes three hydraulically actuated multiple disc clutches and two mechanical one way clutches This electronically controlled automatic transmission adjusts the operating pressure to pr...

Page 426: ...e the lock up function as shown in figure S mode is used in normal driving When W mode is selected the vehicle starts from 2nd gear forward and reverse to achieve smooth starting on the slippery road Selector Lever Downshift Manual Mode 1 2 3 4 D The shiftable gear is down by one step as the lever is moved to left direction Upshift Manual Mode 1 2 3 4 D The shiftable gear is up by one step as the ...

Page 427: ...01 6 KYRON 2005 10 3650 01 DC 5 SPEED 2 AUTOMATIC TRANSMISSION DC 5 SPEED APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View ...

Page 428: ... 1 Torque converter 2 Oil pump 3 Input shaft 4 Disc brake B1 5 Disc clutch C1 6 Disc clutch C2 7 Disc brake B3 8 Disc clutch C3 9 Disc brake B2 10 Output shaft 11 Parking lock gear 12 Intermediate shaft 13 Freewheel F2 14 Center planetary gear set 15 Electric control unit valve body 16 Freewheel F1 Front planetary gear set 17 Stator shaft 18 Converter lockup clutch ...

Page 429: ...01 8 KYRON 2005 10 3650 01 DC 5 SPEED Specifications ...

Page 430: ...01 9 DC 5 SPEED KYRON 2005 10 3650 01 ...

Page 431: ... when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Upshift Downshift Lockup slipping Unlock open FAST OFF Dynamic shift zone 4th gear 1 000 5th gear 0 833 Rev 1st gear 3 147 Rev 2nd gear 1 93 Dynamic shift zone When operating the accelerator pedal B the 4 3 shift is completed by kick down signal after completion of 4 3 shift 100 of pedal position When promptly ope...

Page 432: ... by kick down signal after completion of 4 3 shift 100 of pedal position When promptly operating the accelerator pedal C the 4 3 shift is done in shaded area 93 of pedal position FAST OFF When abruptly releasing the accelerator pedal the transmission remains at 4th gear other than 4 5 shift when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Upshift Downshift Lockup...

Page 433: ...01 12 KYRON 2005 10 3650 01 DC 5 SPEED General Characteristics ...

Page 434: ...SPEED KYRON 2005 10 3650 01 Brake B1 disk assembly Brake B3 disk assembly Brake B2 disk assembly C1 Disk clutch assembly C2 Disk clutch assembly C3 Disk clutch assembly OVERVIEW AND OPERATION PROCESS 1 POWER FLOW ...

Page 435: ...01 14 KYRON 2005 10 3650 01 DC 5 SPEED Shifting Elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 436: ...lanetary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front sun gear Locked by F1 and B1 Planetary gear carrier Rotation with reduced speed Rear ring gear clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Clockwise rotation with reduced speed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with red...

Page 437: ...tary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Sun gear and planetary gear carrier Clockwise rotation by C1 activation Rear ring gear Clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Rotation with reduced speed Center ring gear Clockwise rotation Sun gear Locked by B2 Planetary gear carrier Rotation with reduced speed O...

Page 438: ...Rear planetary gear set L Stator M Center planetary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Center ring gear Clockwise rotation by clutch 2 activation direct connection Center sun gear Locked by B2 Planetary gear carrier Clockwise rotation with reduced speed Output shaft Clockwise rotation 1 2 3 4 5 ...

Page 439: ...wise rotation Center ring gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center sun gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring ge...

Page 440: ...t sun gear Locked by B1 Planetary gear carrier Rotation with reduced speed Rear planetary gear ring gear Clockwise rotation with reduced speed Center ring gear and rear planetary gear carrier Clockwise rotation by clutch C2 activation Rear sun gear Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear increased speed Center sun gear Clockwise rotation with incre...

Page 441: ...l V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locked by B3 Cent...

Page 442: ...r T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Front planetary gear carrier Clockwise rotation by clutch C1 activation direct connection Rear ring gear Clockwise rotation Rear planetary gear carrier and center ring gear Locked by brake B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center planetary gear...

Page 443: ...ft mechanism is used to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 3 4 The clutch release system is available to use CSC Concentric Slave Cylinder or Fork type according to the vehicle model 5 T...

Page 444: ...02 4 KYRON 2005 10 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications 2 Tightening Torque ...

Page 445: ...02 5 M T KYRON 2005 10 3170 01 Inside N Switch OVERVIEW AND OPERATION PROCESS 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch ...

Page 446: ...ion The gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm increase When the...

Page 447: ...iver must operate the HDC only in the 1st gear when driving a vehicle with the manual transmission When not depressing the accelerator pedal or brake pedal The vehicle speed is above 7 km h based on the automatic transmission 4H drive mode The ESP s vehicle position control function and HBA function are not in operation and and and The HDC is added to aid drivers when driving down the hill but whe...

Page 448: ...te sensor for the input signal and detects the inclination of hills by using the G sensor acceleration sensor in the sensor cluster HDC Switch When you see a steep downhill ahead press the HDC switch and the green HDC indicator comes on When the G sensor within the sensor cluster detects a inclination exceeding 10 the ESP s HDC function operates When this occurs the green HDC indicator goes off al...

Page 449: ... operates the green HDC indictor blinks with 0 5 seconds of interval Red Letters HDC Green Letters HDC The G sensor within the sensor cluster measures the actual road inclination However it may recognize a sharp turn or rough road as a downhill with a inclination exceeding 10 and the HDC may operate For the specific information please refer to the ABS ESP section ...

Page 450: ... to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Variant Coding Options ...

Page 451: ......

Page 452: ...03 3 CLUTCH KYRON 2005 10 3010 01 GENERAL 1 CLUTCH SPECIFICATIONS 2 TIGHTTENING TORQUE ...

Page 453: ...d into a clutch steel cover which is bolted to the flywheel The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consi...

Page 454: ...03 5 CLUTCH KYRON 2005 10 3010 01 3 Functions Components of Clutch Assembly Adapter Pipe Assembly Clutch Assembly Concentric Slave Cylinder ...

Page 455: ...03 6 KYRON 2005 10 3010 01 CLUTCH Cross Sectional View of Clutch Assembly 1 Transmission housing 2 Clutch disc assembly 3 Clutch disc cover assembly 4 Bolt 5 Washer 6 Bolt ...

Page 456: ...04 3 AXLE KYRON 2005 10 4120 01 GENERAL 1 AXLE SPECIFICATIONS Specification Torque Gear ratio Type Size Offset Housing Specification Capacity Length Width Weight ...

Page 457: ...s models in addition to existing 5 link suspension the IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle The below figures for rear axle show the rear axle with the independent type suspension 4WD A T Front Axle Rear Axle IRDA Independent Rear Drive Axle ...

Page 458: ...conventional part time transfer case but the changes in comparison to the conventional transfer case are as follows No additional coding is required when replacing TCCU Delete the devices tone wheel speed sensor wiring etc related to the speed sensor in the transfer case This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 through the CAN communic...

Page 459: ...KYRON 2005 10 3240 01 T C OVERVIEW AND OPERATION PROCESS 1 STRUCTURE Rear propeller shaft Part time transfer case Rear axle IRS type Transmission Front propeller shaft Front locking hub system IWE Front axle ...

Page 460: ...fer case main connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper Shift motor connector ...

Page 461: ...CTIONS 1 System Layout Indicators T C control indicator lamp T C control switch HECU Wheelspeedsignal TCCU CAN Communication Vacuum line Front output shaft Transfer case Magnetic clutch Motor Output Solenoid valve Atmo sphere FL Locking hub FR Locking hub ...

Page 462: ... and its components also have changed The vacuum locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Operating Process Vacuum gen...

Page 463: ...end hub gear In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released from the hub...

Page 464: ...40 01 4 POWER FLOW 1 POWER FLOW Switch Transfer 2H 4H 4L TCCU Locking Hub Solenoid Locking Hub Operation Internal vacuum released Front Propeller Shaft Transfer Rear Propeller Shaft Front Axle Front Wheel Rear Wheel Front Axle ...

Page 465: ...05 10 KYRON 2005 10 3240 01 T C 2 2H MODE 2WD Power Flow Transmission Output Shaft Transfer Case Input Shaft Output Shaft Rear Propeller Shaft Rear Wheel Rear Axle Rear Wheel ...

Page 466: ...E 4WD HIGH SPEED Power Flow Transmission Input Shaft TCCU Motor Shift Cam Rail Fork Magnetic Clutch T C Output Shaft Rear Propeller Shaft Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive 4WD HI ...

Page 467: ... LOW SPEED Power Flow Transmission Input Shaft TCCU Motor Shift Cam Rail Fork Planetary Gear Output Shaft Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive 4WD LO Rear Propeller Shaft Magnetic Clutch ...

Page 468: ... 3310 06 PROPELLER SHAFT GENERAL 1 SPECIFICATION OVERVIEW AND OPERATION PROCESS 1 OVERVIEW 2 COMPONENT LOCATOR 3310 01 FRONT PROPELLER SHAFT 3310 06 REAR PROPELLER SHAFT 3310 00 DISASSEMBLY AND REASSEMBLY PROPELLER SHAFT 3 4 5 7 9 11 ...

Page 469: ......

Page 470: ...06 3 PROPELLER SHAFT KYRON 2005 10 3310 00 3310 00 PROPELLER SHAFT GENERAL 1 SPECIFICATION ...

Page 471: ...duction gear It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and ...

Page 472: ...1 Cross Sectional View 1 Flange yoke 2 Journal bearing cap 3 Spider journal 4 Slip yoke assembly 5 Grease nipple 6 Dust cap 7 Oil seal 8 Split washer 9 Slip tube shaft 10 Tube 11 Tube yoke 12 Flange yoke 13 Center bearing Front propeller shaft Rear Propeller Shaft ...

Page 473: ...06 6 KYRON 2005 10 3310 00 PROPELLER SHAFT 2 Propeller Shaft Assemble 1 Propeller shaft 2 Joint propeller front 3 Joint propeller rear 4 Yoke front 5 Yoke rear ...

Page 474: ...ROPELLER SHAFT Manual Transmission Automatic Transmission For Gasoline Engine Remove the flange yoke mounting bolt on the transfer case side of the front propeller shaft 1 Put installation marks on the yoke to the propeller and the flange to the transfer case ...

Page 475: ...ELLER SHAFT Remove the flange yoke mounting bolt and nut on the front axle side of the front propeller shaft 2 Put installation marks on the yoke to the propeller and the flange to the transfer case Remove the front propeller shaft 3 ...

Page 476: ... 10 3310 06 3310 06 REAR PROPELLER SHAFT Remove the yoke mounting bolt and nut on the transfer case side of the rear propeller shaft 1 Put installation marks on the yoke of the rear propeller shaft and the flange of the transfer case ...

Page 477: ...05 10 3310 06 PROPELLER SHAFT Remove the intermediate bearing center bolts 2 Remove the yoke and flage mounting bolts and nuts on the rear axle side of the rear propeller shaft Then remove the rear propeller shaft 3 ...

Page 478: ...er shaft Place an alignment on the spiders before removing 1 2 Remove the snap ring with snap ring pliers 3 Tap the yoke shoulder on shaft with copper hammer to remove the roller bearing Remove the other bearings with same manner 4 If it cannot be removed hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer 5 ...

Page 479: ...0 PROPELLER SHAFT Disassemble the universal joint The universal joint compensates the angle changes due to vertical movement of the axle shaft 6 Remove the intermediate bearing bracket and remove the bearing with special tool 7 ...

Page 480: ...of the specified range correct it with press or replace it with new one 4 Starting torque of universal joint 5 Specified value 17 893 mm Limit 17 910 mm Specified value 0 03 0 098 mm Limit 0 25 mm Limit 0 4 mm Specified value 3 8 kg cm Major causes of vibration 6 Balance weights missing Excessive run out of propeller shaf When using the general bolts Excessive wear of universal joint Stuck in slee...

Page 481: ...ssemble the needle roller 2 Install the yoke bearing shaft on the shaft and insert the spider Place the cap on the opposite side and tap it with plastic hammer to seat it Adjust the clearance of spider below 0 1 mm and install the snap ring 3 Install the intermediate bearing to the rear propeller shaft Apply the grease on the propeller shaft and install it 4 5 Clean the components and replace if d...

Page 482: ...07 3 SUSPENSION KYRON 2005 10 4411 01 GENERAL 1 FRONT SUSPENSION SPECIFICATIONS 2 REAR SUSPENSION SPECIFICATIONS 4411 01 SUSPENSION ...

Page 483: ... internal Cylinders ABS ESP 5Link Suspension solid type disc ABS ESP Independent suspension ventilated disc 2 REAR BRAKE Rear Disc and Caliper 1 Internal Cylinder For the rear brake system specifications differ between ABS ESP system equipped vehicles and non ABS ESP system equipped vehicles The drum type brake is installed on non ABS equipped vehicles When ABS ESP is installed on the 5 link type ...

Page 484: ...e parking brake is installed on vehicles with the manual transmission and the foot operated type parking brake is installed on vehicles with the automatic transmission Hand Operated Type Vehicle with Manual Transmission Foot Operated Type Vehicle with Automatic Transmission ...

Page 485: ...08 5 ESP KYRON 2005 10 4890 01 3 SECTIONAL DRAWING Front Disc Brake Rear Disc Brake ...

Page 486: ... the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication Location of the wheel speed sensor rear right wheel Location of the Sensor Connector Connector Appearance Invehicl...

Page 487: ...08 7 ESP KYRON 2005 10 4890 01 2 BRAKE SYSTEM SPECIFICATIONS ...

Page 488: ...t imply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disk and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is in com...

Page 489: ...ive on rough roads the HDC may suddenly operate for these sudden shocks influence the G sensor values When such occurs the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle 3 During the HDC operation a loud noise and the vehicle vibration may occur from the HECU and the brake system but this is a normal condition during th...

Page 490: ... in HDC operation The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the ...

Page 491: ...ehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 about 5 71 degree ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Br...

Page 492: ...rance of wheel speed sensor Location Layout of relevant components ESP HECU ActiveWheelSpeedSensor HDC Switch The transfer case T C installed on this vehicle doesn t have the internal speed sensing device and receives the speed signal for T C control from ESP HECU via CAN bus With speed sensor Conventional T C ...

Page 493: ...08 13 ESP KYRON 2005 10 4890 01 New T C Without speed sensor ...

Page 494: ...ding on the vacuum condition within the actuator Thus the wheel speed sensor is installed on the front wheel end area It is installed inside the backing plate to be protected from heat and foreign materials Therefore the front wheel end system including disc should be removed before removing the front wheel speed sensor Front Wheel Speed Sensor 4WD Rear Wheel Speed Sensor IRS Type Backing plate Wh...

Page 495: ... and foreign materials from entering the IWE system In addition when installing the hub actuator of the IWE system you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed Please refer to the part time transfer case section for more specific information Rubber O ring Rubber seal ring Internal steel spring included ...

Page 496: ...c Control Unit and wheel speed sensor used in the ABS system The devices are as follows 2 pressure sensors installed on the master cylinder Sensor cluster integrated yaw rate sensor and lateral sensor and longitudinal sensor installed in IP SWAS Steering Wheel Angle Sensor installed in the steering column 1 2 3 Comparison with ABS System ...

Page 497: ......

Page 498: ...steering during cornering The yaw rate sensor lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the spin present at any wheels during over steering under steering or cornering The ESP ECU controls against over steering or under steering during cornering by controlling the vehicle stability using the input values from t...

Page 499: ...due to rear wheel moment when the rear tires lose traction and the vehicle speed increases ESP controls during under steering ESP controls during oversteering The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeering with the yaw rate sensor and the lateral se...

Page 500: ...perate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 degree seconds the ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function When various systems operate simultaneously under a certain situation there may be vehicle control problems due to internal mal...

Page 501: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 502: ...g is required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the ...

Page 503: ... that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions 1 Pressure over 20 bar 2 Pressure changes ...

Page 504: ...software is added to the existing ESP system and no additional device or switch is needed One must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s ...

Page 505: ...ut signals from wheel speed sensor steering angle sensor and lateral sensor During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane ...

Page 506: ...1G on steep roads slope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation The G sensor in sensor cluster measures the actual road steepness However it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10 and the HDC may op...

Page 507: ......

Page 508: ...eutral switch and cannot solely detect the 1st gear position The reason for noting the 1st gear above though the HDC also operates in 2nd gear position is because the engine may turn off during the HDC operation process You may face a very dangerous situation if the engine turns off at a steep hill The HDC is the device to improve the engine brake effect during downhill driving on a steep hill For...

Page 509: ...et speed in 4L mode Forward and reverse driving 3 km h 5 Vehicle position control function in ESP and HBA function are not in operation and The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden 6 Slope level exceeds 10 When the slope level exceeds 10 the HDC operates until the vehicle reaches...

Page 510: ...d on the operating numbers and conditions of HDC The red HDC warning lamp blinks when the internal temperature goes over 350 C When it reaches 450 C the HDC warning lamp comes on The HDC can be operated in the range even where the HDC warning lamp blinks 6 When the slope level is below 10 When the slope level exceeds 10 the HDC operates until the vehicle reaches the speed condition given in step 4...

Page 511: ...08 31 ESP KYRON 2005 10 4890 01 4 Input Output Signals for HDC Operation ...

Page 512: ...has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON HDC system erro...

Page 513: ......

Page 514: ...890 01 ESP 6 ESP COMPONENTS AND LOCATIONS Master cylinder pressure sensor Steering wheel angle sensor Sensor cluster Yaw rate lateral sensor longitudinal sensor HECU Valve body and ECU integrated type Valve body Motor pump ...

Page 515: ...08 35 ESP KYRON 2005 10 4890 01 Comparison with ABS System ABS ESP Indicator ESP OFF Switch HDC Indicator HDC Switch ActiveWheelSpeedSensor ...

Page 516: ...08 36 KYRON 2005 10 4890 01 ESP 7 INPUT OUTPUT SIGNALS FOR HDC OPERATION Input Output of ESP System ...

Page 517: ...08 37 ESP KYRON 2005 10 4890 01 8 ESP HYDRAULIC CIRCUIT DIAGRAM ...

Page 518: ...stem is operating the normally open separation valve will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve Then the inlet and outlet valves will be closed or open depending on the braking pressure increase decrease or unchanged conditions For details refer to Hydraulic Pressure for each ESP Operating Range ESP Hydraulic unit in idling and...

Page 519: ...eels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel ge...

Page 520: ...ing depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the w...

Page 521: ...earance of wheel speed sensor Location Layout of relevant components ABS HECU Active Wheel Speed Sensor for 4WD The transfer case T C installed on this vehicle doesn t have the internal speed sensing device and receives the speed signal for T C control from ABS HECU Conventional Transfer Case With Speed Sensor ...

Page 522: ...08 42 KYRON 2005 10 4890 01 ESP New Transfer Case Without Speed Sensor ...

Page 523: ...ks the 4WD depending on the vacuum condition within the actuator Thus the wheel speed sensor is installed on the front wheel end area It is installed inside the backing plate to be protected from heat and foreign materials Therefore the front wheel end system including disc should be removed before removing the front wheel speed sensor Front Wheel Speed Sensor Rear Wheel Speed Sensor Backing Plate...

Page 524: ... and foreign materials from entering the IWE system In addition when installing the hub actuator of the IWE system you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed Please refer to the part time transfer case section for more specific information Rubber O ring Rubber seal ring Internal steel spring included ...

Page 525: ...0 4890 01 12 CONFIGURATION OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor ...

Page 526: ...08 46 KYRON 2005 10 4890 01 ESP 13 INPUT AND OUTPUT DIAGRAM OF ABS Input Output of ABS without TPMS ...

Page 527: ...ront wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 528: ...tlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually No Hydraulic Pressure Circuit when ABS is Operating As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increas...

Page 529: ...es again The ABS ECU 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 Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber ...

Page 530: ...ief 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 press...

Page 531: ... Power steering return pipe 5 Power steering gear box pipe 3 Power steering high pressure hose and pipe 6 Power steering gear box assembly OVERVIEW AND OPERATION PROCESS 1 POWER STEERING SYSTEM LAYOUT 40 50 Nm Feed pipe nut Steering gear box mounting bracket bolts 14 mm 2EA 30 40 Nm ...

Page 532: ...09 5 STEERING KYRON 2005 10 4610 00 With SSPS 1 Power steering gear box 3 Power steering high pressure hose and pipe 2 Gear box pipe 4 Return hose and pipe SSPS Solenoid Valve cannot be replaced ...

Page 533: ...09 6 KYRON 2005 10 4610 00 STEERING Installation Drawing of SSPS Pipe bracket bolt 10 mm Pipe mounting nut Pipe bracket bolt 10 mm 9 14 Nm 9 14 Nm 20 26 Nm Gear box mounting bolt ...

Page 534: ...09 STEERING KYRON 2005 10 4610 00 Components 20 25 Nm 40 60 Nm 7 11 Nm 18 25 Nm 35 45 Nm 45 50 Nm 70 90 Nm 20 25 Nm 30 40 Nm Tie rod end Steering gear box Lower shaft Steering wheel Column shaft ...

Page 535: ...09 8 KYRON 2005 10 4610 00 STEERING Steering wheel Column shaft Lower shaft Steering gear box ...

Page 536: ...he vehicle speed which is called Speed Sensitive Power Steering SSPS SSPS by providing appropriate steerability to a driver according to the changes of vehicle speed gives steering stability The power steering control unit adjusts the hydraulic pressure to reaction plunger by controlling the pressure solenoid valve located in the gear box to optimize the steerability In other words the steering wh...

Page 537: ...pressure supplied to reaction device by moving the spool valve according to the changes of solenoid valve Reaction device This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from SSPS control unit ...

Page 538: ...d In other words the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve spool position that is linked with solenoid valve according to the amount of electric current The changes of hydraulic pressure applied to input shaft according to the pressure changes applied to the reaction plunger provide proper steerability based on the amount of electric curre...

Page 539: ...cut off and the manipulation of steering wheel becomes lighter 1 2 3 4 In medium and high speed driving The shaft operating force of solenoid rod is reduced due to the reduction of output current from the SSPS control unit The coil spring pulls the PCV spool toward solenoid valve to open it The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to...

Page 540: ...icle speed and the throttle position data via CAN communication The SSPS control unit controls the working current for the solenoid valve with PWM type duty ratio of 333 Hz frequency and sets the target current to 1A during 1 second after the ignition is ON When a trouble occurs in the system the SSPS control unit generates a trouble code using fail safe function 1 2 3 SSPS unit ...

Page 541: ...09 14 KYRON 2005 10 4610 00 STEERING 3 CIRCUIT DIAGRAM ...

Page 542: ...ovides heavy steerability with low current as the vehicle speed increases Also it provides light steerability with high current as the vehicle speed decreases During parking and low speed driving During parking and driving in low speed the control unit supplies approx 1 A of electric current to solenoid valve Then the spool located in PCV compresses the upper spring and elevates upward and the wor...

Page 543: ...s weak electric current to solenoid valve Then the spool located PCV moves from top to bottom and the working pressure A port from oil pump is applied to reaction plunger C port through B port As a result the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier ...

Page 544: ...TEM 1 SYSTEM LAYOUT AND COMPONENTS Type Air Conditioner Controller FATC Manual air conditioner AQS Switch Compressor AQS Sensor and Ambient Temperature Sensor A function that turns on off the air source selection and air quality system This sensor is installed at the front bottom of engine compartment This changes the air source mode by detecting the air pollution AQS sensor Ambient temperature se...

Page 545: ...t Side Bloor Unit Side Condenser Installed in front of vehicle and condenses vapor refrigerant into low temperature and high pressure liquid refrigerant Receiver Drier LH Engine ECU Passenger Footstep Coolant Temperature Sensor On Engine Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condi...

Page 546: ...01 4 KYRON 2005 10 6810 15 AIR CONDITIONER 1 VENTILATION SYSTEM COMPONENTS Locations of Vents Air Duct ...

Page 547: ...ONT AIR CONDITIONER MODULE WIRING LAYOUT Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Active incar sensor interior temperature sensor and humidity sensor Main wire connector Intake sensor Mode door actuator Air mix door actuator ...

Page 548: ...OCATIONS Coolant Temperature Sensor Air Source Door Actuator Air Conditioner Filter Mode Door Actuator Intake Sensor Power Transistor Blower Motor A C Controller Unit Interior Temperature Sensor Interior Humidity Sensor Power transistor Blower motor Interior temperature and humidity sensor ...

Page 549: ...01 7 AIR CONDITIONER KYRON 2005 10 6810 15 2 Components ...

Page 550: ...01 8 KYRON 2005 10 6810 15 AIR CONDITIONER 4 PTC HEATER AND FFH HEATER LAYOUT 1 PTC HEATER ASSEMBLY LAYOUT 2 FFH HEATER ASSEMBLY LAYOUT ...

Page 551: ... AQS OPERATION Air Quality System AQS changes the air source selection to recirculation mode when polluted air is detected through AQS sensor The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears 1 AQS sensor Ambient temperature sensor Connector Press the AUTO switch ...

Page 552: ...iagnosis and preheating mode of AQS is performed for 35 seconds 2 When pressing DEF switch during in this process the AQS indicator goes out and the air source selection is changed to fresh air mode from recirculation mode When pressing the AQS switch again the self diagnosis and preheating mode of AQS operates only for the remaining time AQS indicator comes on Changed to recirculation mode from f...

Page 553: ...ource selection to fresh air mode Although turning off the air conditioner while the AQS is in operation the AQS stays ON indicator on However if the air conditioner is turned on by turning the ignition switch ON from OFF the AQS stops its operation and the indicator goes out and the display window shows the initial screen 3 4 If the AQS switch is pressed in the AQS function works regardless of ai...

Page 554: ...ion mode A C switch operation At this mode the AQS system operates according to the AQS switch operation If the ignition switch is turned off with AQS ON the AQS is turned on when turning the ignition switch on again 6 The AQS is turned off When pressing the defroster switch When pressing the recirculation mode switch ...

Page 555: ... and changes it into current and then sends the signal to FATC controller Inspection Remove the sun sensor and measure the current between terminals under sunlight Measure the current again under shade It is in normal conditions if the measured value is less than the measured value under sunlight Turn the ignition switch to ON position Measure the voltage to the sun sensor from FATC connector appr...

Page 556: ...ture sensor This sensor is a negative temperature coefficient NTC thermistor and detects the interior temperature with air coming from senor hole and then sends the voltage value according to the changed resistance to FATC controller Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller Hum...

Page 557: ...ng to refrigerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below 20 C Coolant temperature over 115 C For approx 4 seconds after starting the engine When engine speed is below 650 rpm When e...

Page 558: ...on if the resistance is extremely high or low replace the sensor If the measured value is out of the specified range replace the water temperature sensor If the measured value is within the specified range check as below Turn the ignition switch to ON position and measure the voltage to water temperature sensor from the FATC controller connector standard approx 2 V at 25 C If the voltage value can...

Page 559: ... fan control signal from FATC Air conditioner power transistor 1 Inspection If the power transistor defect code DTC 6 appears check as below Turn the ignition switch to ON position Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6 The specified voltage value in each stage If the voltage is out of specified value check the circuit for open If the circuit is ...

Page 560: ...d adjusts the mode door for VENT FOOT and DEF mode to change the air flow directions according to FATC controller Under the FATC controller AUTO mode it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed Mode door actuator ...

Page 561: ...een terminal No 1 and 2 on the connector Check whether the output voltages ON approx 12 V off 0 V If the voltage value is out of the specified value replace the Intake Sensor If the circuit is in normal condition check as below Turn the ignition switch to ON position and turn on the air conditioner by pressing the A C button And measure the voltage between terminal A12 and A11 on the FATC controll...

Page 562: ...temperature and ambient temperature while PTC is operated by the coolant temperature intake air temperature FFH system consists of independent fuel lines and fuel pump coolant circuit and coolant circulation pump electrical glow plug and exhaust system It also provides the diagnostic function FFH system cannot be operated or stopped by driver s intention The FFH system is automatically operated by...

Page 563: ...racket assembly 8 Ambient temperature switch 14 Tube clip mounting 3 FFH bracket assembly 9 FFH fuel pump 15 Tube clip mounting 4 FFH water pump bracket 10 Fuel pump bracket 16 Intake hose 5 FFH NO 3 inlet hose 11 Fuel pipe NO 1 17 Clamp 6 FFH NO 2 inlet hose 12 Fuel pipe NO 2 18 FFH NO 1 inlet hose 2 FFH LAYOUT 1 Components ...

Page 564: ...01 22 KYRON 2005 10 6810 15 AIR CONDITIONER 2 Exploded View ...

Page 565: ...01 23 AIR CONDITIONER KYRON 2005 10 6810 15 ...

Page 566: ...ipe 14 Flame sensor 15 Bush for flame sensor graphite 16 Control and overheating sensor with cable 17 O ring 18 Surface sensor with cable 19 Controller connector 14 pin connector waterproof 20 Pressure spring for surface sensor 21 Pressure spring for control and overheating sensor 22 O ring 23 Coolant hose inlet 24 Coolant hose outlet 25 Tooth ring 2x 26 Cable harness cover 27 Rubber seal 28 O rin...

Page 567: ...01 25 AIR CONDITIONER KYRON 2005 10 6810 15 3 SPECIFICATIONS ...

Page 568: ...rature difference when operating FFH FFH is operated again For example if the initial operating temperature was 4 C the ambient temperature at repeat operation should be below 1 C and the coolant temperature should be below 75 C 2 FFH Operations According To the Changes of Coolant Temperature Above graph shows the FFH control process while the FFH is operating The control element is coolant temper...

Page 569: ...ature from radiation and direct contact Before working on the coolant circuit disconnect the negative battery cable and wait until all components have cooled down completely When installing the heater and the water pump note the direction of flow of the coolant circuit Fill the heater and water hoses with coolant before connecting to the coolant circuit When routing the coolant pipes observe a suf...

Page 570: ...01 28 KYRON 2005 10 6810 15 AIR CONDITIONER 4 Circuit Diagram ...

Page 571: ...erheated lack of water poorly vented cooling circuit the overheating sensor triggers the fuel supply is interrupted and the heater is switched off The heater is switched off if the lower or upper voltage limit is reached The fuel pump does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted The fan motor speed is monitored continuously If the fan motor does ...

Page 572: ...01 30 KYRON 2005 10 6810 15 AIR CONDITIONER 6 Specification Water Pump 7 Characteristic Curve of Water Pump 12 V ...

Page 573: ...01 31 AIR CONDITIONER KYRON 2005 10 6810 15 8 Function Diagram 9 Switching Diagram According to Temperature Changes ...

Page 574: ...gs and seat belt pretensioners included the air bag unit must be replaced Please do not attempt to delete the failure code with scan 100 because some data about the deployment situation are stored in the unit The air bag related components especially the air bag unit must be stored in a sealed case to prevent any damage Please do not connect a tester to any air bag connector or single item to meas...

Page 575: ...rts when the front air bags deploy the air bag units and their connection wires connectors included the seat belt pretensioners and their connection wires connectors included the entire front air bags and the instrument panel IP Replacement parts when a curtain air bag deploys the new curtain air bag for the deployed side the air bag unit and its connection wires connectors included the collision ...

Page 576: ...ongitudinal collisions and determine whether or not the air bags are deployed The roles of each collision sensor are as below Front G sensors inside the air bag unit Curtain air bag G sensors These are located inside the left and right B pillar panel bottoms When a collision occurs the air bag at the side of collision deploys accordingly Please pay attention to that in the case of the curtain air ...

Page 577: ...e air bag unit and its connection wires connectors included the collision G sensor assembly for the curtain air bag and the trims and roof headlining for the broken parts When an air bag deploys curtain air bags and seat belt pretensioners included the air bag unit must be replaced Please do not attempt to delete the failure code with SCAN 100 because some data about the deployment situation are s...

Page 578: ......

Page 579: ...2 8 KYRON 2005 10 8810 03 AIR BAG 2 LOCATIONS AND RELATED COMPONENTS LH RH When the curtain air bag LH deploys When the curtain air bag RH deploys BPT Belt Pretensioner Curtain air bag collision G sensor ...

Page 580: ... SDM The collision G sensor is installed nside this And it sends out signals to deploy the front air bags driver s and passenger s air bags and or the driver s and passenger s seat belt pretensioners or the driver s and passenger s curtain air bag When the front collision G sensor sends out only the air bag deployment signal the signal deploys the two front air bags and activates their seat belt p...

Page 581: ...ION PROCESS The overall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyoung Motors Air Bag System Block Diagram Functions and Roles Included ...

Page 582: ...02 11 AIR BAG KYRON 2005 10 8810 03 ...

Page 583: ...leration sensor inside the air bag unit is activated by the deceleration from vehicle collision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver 1 Components Air bag cover Air bag hou...

Page 584: ...s the driver s one The driver s air bag the passenger s air bag and the seat belt pretensioners on both seats are made to operate together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and i...

Page 585: ...nerator A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B pillar The signal is transmitted to the air bag unit The air bag unit instantly inflates the necessary air bag necessary by sending a high current When the Curtain Air Bag is Installed Terms of the Curtain Air Bag When the Curtain Air Bag Deploys Curtain air bag mounting point N...

Page 586: ...02 15 AIR BAG KYRON 2005 10 8810 03 Tightening torque 8 10 Nm Tightening torque 8 10 Nm Sectimal view a a Sectimal view b b 1 Components a a b b ...

Page 587: ... BPT Belt Pre Tensioner The belt pretensioner retracts the seat belt to tighten or take up slack in the wearer s belt When a collision occurs or when brakes are applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat Curtain air bag G sensor ...

Page 588: ... reel assembly Reel bracket Ring upper stay D ring Bending tongue Tongue stopper Mini anchor D bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D bolt Label D bolt Spacer Bush Mini anchor cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 589: ...02 18 KYRON 2005 10 8810 03 AIR BAG Location of Air Bag 5 Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 590: ...nsor is installed inside each B pillar of the driver s and passenger s seats that is around the pretensioner reel The body panel has guiding holes to ensure its correct installation But incorrect tightening torque may break the sensor or make it insecure As a result the sensor may have inaccurate judgment and have the air bag deployed inaccurately ...

Page 591: ...ires the detonator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for a firing Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag rela...

Page 592: ...when colliding When the ignition key is the ON position the air bag signal is not accepted for the first 7 seconds When the ignition key is the ON position and the vehicle speed is 3 km h or higher 40 ms after receiving the air bag deployment signal the sticks sends out the door UNLOCK signal for 5 seconds Even though the ignition switch is turned off in the middle of the unlock signal being sent ...

Page 593: ...unlock request by other functions is ignored unless the ignition key switch is turned off When another lock or unlock output is requested while the door is being either locked or unlock the new request will be ignored But if an unlock request is made by the air bag signal or the remote control key the request will be accepted When the lock and unlock functions are simultaneously requested the lock...

Page 594: ...bag unit flashes the air bag warning lamp six times by supplying an intermittent ground to the warning lamp circuit After flashing six times the air bag warning lamp will turn off if no more malfunctions have been detected 2 When Turning the Ignition Switch to the ON Position When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for a...

Page 595: ...e Air Bag Unit Receives Any Malfunction Signals from the Other Systems When due to an error from outside the system the intermittent failure signal is received 5 times or less the air bag warning lamp comes on for about 6 seconds and then goes off ...

Page 596: ...02 25 AIR BAG KYRON 2005 10 8810 03 8 AIR BAG ELECTRICAL WIRING DIAGRAM ...

Page 597: ...03 3 SEAT KYRON 2005 10 7410 01 7410 01 SEAT AND SEAT BELT 1 SEAT OVERVIEW 1 FRONT SEAT DRIVER S SEAT Reclining Motor Lumbar support lever ...

Page 598: ...AT SPWM Seat Position With Memory Unit Seat cushion up down bar front Sliding rail Sliding rail Seat cushion up down bar rear Sliding motor 1 SEAT OVERVIEW 1 Front Seat Driver s Seat Seat Cushion Motor Front Seat Cushion Motor Rear ...

Page 599: ...03 5 SEAT KYRON 2005 10 7410 01 Seat cushion angle adjusting lever rear Seat height control switch Seat cushion angle adjusting lever front Reclining lever Sliding lever ...

Page 600: ...03 6 KYRON 2005 10 7410 01 SEAT Location of Seat Position With Memory Unit Bottom of Driver Seat SPWM unit ...

Page 601: ...03 7 SEAT KYRON 2005 10 7410 01 2 Front Seat Passenger Seat Reclining Motor Sliding rail Sliding rail Sliding motor Reclining lever Sliding lever No seat height control function ...

Page 602: ...senger s seat window side seats of second row seat third row seat 2 Point type seat belt center seat of second row seat Pretensioner Installed at front seats The seat belt pretensioner rewinds the seat belt immediately to protect occupant s face and chest when a strong frontal collision occurs ...

Page 603: ...rd Row Seat Seat Melt in Front Seats Bracket Seat belt Seat belt anchor Seat belt Seat belt Oring Seat belt O ring Seat belt anchor Pre tensioner Buckle of 3 point type seat belt Buckle of 2 point type seat belt 2 Seat Belt 2 Point Type point type seat belt is installed only in the center seat of second row seat 2 ...

Page 604: ...5 10 7340 01 1 HAZARD MANUAL OPERATION The sunroof can be operated by rotating the motor operating hole on the sunroof motor with a proper tool 1 Circuit Diagram SCU Main Connector Motor Connector SCU 7340 01 SUNROOF SYSTEM ...

Page 605: ... operate properly when operating the sunroof switch 1 2 3 4 0 point reset of sunroof 3 Close the sunroof with the sunroof switch and keep the position for approx 10 seconds If the 0 point setting is successfully completed the sunroof should be properly opened from this position Check if the sunroof is fully closed Tilt the sunroof with the sunroof switch and keep it at the position for 10 seconds ...

Page 606: ...04 5 SUNROOF KYRON 2005 10 7340 01 3 TROUBLE DIAGNOSIS ...

Page 607: ...04 6 KYRON 2005 10 7340 01 SUNROOF 1 SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Sunroof Switch ...

Page 608: ... switch clockwise OPEN direction with the sunroof closed To partially open the sunroof rotate and hold the sunroof switch until it reaches at the desired position Close To fully close the sunroof briefly rotate the sunroof switch counterclockwise CLOSE direction with the sunroof open To partially close the sunroof rotate and hold the sunroof switch until it reaches at the desired position Tilt up ...

Page 609: ...04 8 KYRON 2005 10 7340 01 SUNROOF 3 SUNROOF CIRCUIT DIAGRAM ...

Page 610: ...NO DATA ...

Page 611: ...NO DATA ...

Page 612: ...07 3 BODY REPAIR KYRON 2005 10 4110 01 4110 01 BODY REPAIR 1 DIMENSIONS ...

Page 613: ...07 4 KYRON 2005 10 4110 01 BODY REPAIR 2 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 614: ...07 5 BODY REPAIR KYRON 2005 10 4110 01 2 5 Link System Lifting Point Dotted Circles ...

Page 615: ...Dash Panel and Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision Dash panel Dash reinforcement Deadening sheet ...

Page 616: ... Body Panel Reinforcement Sealer to the Door Outer Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise BPR sealer to reinforce the body panel and reduce the noise Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 617: ...l Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise The foaming pads are applied to the symmetry surface of the vehicle Thus totally 6 foaming pad are applied to the vehicle body ...

Page 618: ...07 9 BODY REPAIR KYRON 2005 10 4110 01 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 619: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 DIAGNOSIS ...

Page 620: ......

Page 621: ...0 3 ECU GASOLINE KYRON 2005 10 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 622: ...0 4 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 623: ...0 5 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 624: ...0 6 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 625: ...0 7 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 626: ...0 8 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 627: ...0 9 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 628: ...0 10 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 629: ...0 11 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 630: ...0 12 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 631: ...0 13 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 632: ...0 14 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 633: ...0 15 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 634: ...0 16 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 635: ...0 17 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 636: ...0 18 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 637: ...0 19 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 638: ...0 20 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 639: ...0 21 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 640: ...0 22 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 641: ...0 23 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 642: ...0 24 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 643: ...0 25 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 644: ...0 26 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 645: ...0 27 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 646: ...0 28 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 647: ...0 29 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 648: ...0 30 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 649: ...0 31 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 650: ...0 32 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 651: ...0 33 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 652: ...0 34 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 653: ...0 35 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 654: ...0 36 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 655: ...0 37 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 656: ...0 38 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 657: ...0 39 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 658: ...0 40 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 659: ...0 41 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 660: ...0 42 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 661: ...0 43 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 662: ...0 44 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 663: ...0 45 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 664: ...0 46 KYRON 2005 10 0000 00 ECU GASOLINE ...

Page 665: ...0 47 ECU GASOLINE KYRON 2005 10 0000 00 ...

Page 666: ......

Page 667: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 668: ......

Page 669: ...0 3 ECU DIESEL KYRON 2005 10 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 670: ...0 4 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 671: ...0 5 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 672: ...0 6 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 673: ...0 7 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 674: ...0 8 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 675: ...0 9 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 676: ...0 10 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 677: ...0 11 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 678: ...0 12 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 679: ...0 13 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 680: ...0 14 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 681: ...0 15 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 682: ...0 16 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 683: ...0 17 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 684: ...0 18 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 685: ...0 19 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 686: ...0 20 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 687: ...0 21 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 688: ...0 22 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 689: ...0 23 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 690: ...0 24 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 691: ...0 25 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 692: ...0 26 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 693: ...0 27 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 694: ...0 28 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 695: ...0 29 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 696: ...0 30 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 697: ...0 31 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 698: ...0 32 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 699: ...0 33 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 700: ...0 34 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 701: ...0 35 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 702: ...0 36 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 703: ...0 37 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 704: ...0 38 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 705: ...0 39 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 706: ...0 40 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 707: ...0 41 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 708: ...0 42 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 709: ...0 43 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 710: ...0 44 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 711: ...0 45 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 712: ...0 46 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 713: ...0 47 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 714: ...0 48 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 715: ...0 49 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 716: ...0 50 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 717: ...0 51 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 718: ...0 52 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 719: ...0 53 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 720: ...0 54 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 721: ...0 55 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 722: ...0 56 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 723: ...0 57 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 724: ...0 58 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 725: ...0 59 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 726: ...0 60 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 727: ...0 61 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 728: ...0 62 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 729: ...0 63 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 730: ...0 64 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 731: ...0 65 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 732: ...0 66 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 733: ...0 67 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 734: ...0 68 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 735: ...0 69 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 736: ...0 70 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 737: ...0 71 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 738: ...0 72 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 739: ...0 73 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 740: ...0 74 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 741: ...0 75 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 742: ...0 76 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 743: ...0 77 ECU DIESEL KYRON 2005 10 0000 00 ...

Page 744: ...0 78 KYRON 2005 10 0000 00 ECU DIESEL ...

Page 745: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 746: ......

Page 747: ...0 3 BRAKE KYRON 2005 10 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 748: ...0 4 KYRON 2005 10 0000 00 BRAKE ...

Page 749: ...0 5 BRAKE KYRON 2005 10 0000 00 ...

Page 750: ...0 6 KYRON 2005 10 0000 00 BRAKE ...

Page 751: ...0 7 BRAKE KYRON 2005 10 0000 00 ...

Page 752: ...0 8 KYRON 2005 10 0000 00 BRAKE ...

Page 753: ...0 9 BRAKE KYRON 2005 10 0000 00 ...

Page 754: ...0 10 KYRON 2005 10 0000 00 BRAKE ...

Page 755: ...0 11 BRAKE KYRON 2005 10 0000 00 ...

Page 756: ...0 12 KYRON 2005 10 0000 00 BRAKE ...

Page 757: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 758: ......

Page 759: ...0 3 AIR BAG KYRON 2005 10 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 760: ...0 4 KYRON 2005 10 0000 00 AIR BAG ...

Page 761: ...0 5 AIR BAG KYRON 2005 10 0000 00 ...

Page 762: ...0 6 KYRON 2005 10 0000 00 AIR BAG ...

Page 763: ...0 7 AIR BAG KYRON 2005 10 0000 00 ...

Page 764: ...0 8 KYRON 2005 10 0000 00 AIR BAG ...

Page 765: ...0 9 AIR BAG KYRON 2005 10 0000 00 ...

Page 766: ...0 10 KYRON 2005 10 0000 00 AIR BAG ...

Page 767: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 768: ......

Page 769: ...0 3 CCCS KYRON 2005 10 0000 00 0000 00 CCCS 1 CCCS ...

Page 770: ...0 4 KYRON 2005 10 0000 00 CCCS ...

Page 771: ...0 5 CCCS KYRON 2005 10 0000 00 ...

Page 772: ...0 6 KYRON 2005 10 0000 00 CCCS ...

Page 773: ...0 7 CCCS KYRON 2005 10 0000 00 ...

Page 774: ...0 8 KYRON 2005 10 0000 00 CCCS ...

Page 775: ...0 9 CCCS KYRON 2005 10 0000 00 ...

Page 776: ...0 10 KYRON 2005 10 0000 00 CCCS ...

Page 777: ...0 11 CCCS KYRON 2005 10 0000 00 ...

Page 778: ...0 12 KYRON 2005 10 0000 00 CCCS ...

Page 779: ...0 13 CCCS KYRON 2005 10 0000 00 ...

Page 780: ...0 14 KYRON 2005 10 0000 00 CCCS ...

Page 781: ...0 15 CCCS KYRON 2005 10 0000 00 ...

Page 782: ...0 16 KYRON 2005 10 0000 00 CCCS ...

Page 783: ...0 17 CCCS KYRON 2005 10 0000 00 ...

Page 784: ...0 18 KYRON 2005 10 0000 00 CCCS ...

Page 785: ...0 19 CCCS KYRON 2005 10 0000 00 ...

Page 786: ...0 20 KYRON 2005 10 0000 00 CCCS ...

Page 787: ...0 21 CCCS KYRON 2005 10 0000 00 ...

Page 788: ...0 22 KYRON 2005 10 0000 00 CCCS ...

Page 789: ...0 23 CCCS KYRON 2005 10 0000 00 ...

Page 790: ...0 24 KYRON 2005 10 0000 00 CCCS ...

Page 791: ...0 25 CCCS KYRON 2005 10 0000 00 ...

Page 792: ...0 26 KYRON 2005 10 0000 00 CCCS ...

Page 793: ...0 27 CCCS KYRON 2005 10 0000 00 ...

Page 794: ......

Page 795: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 796: ......

Page 797: ...TC 1 SELF DIAGNOSIS 1 Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds Check LED segments on the vacuum fluorescent display VFD Press OFF switch more than 5 seconds ...

Page 798: ...e digit 2 is displayed implying step 2 on the display window and the trouble diagnosis for sensors is executed If no failure exists 20 is displayed If any failure exists the appropriate trouble code is displayed as below Trouble Code The symbol in front of step number 2 means a short circuit of the blinking sensor Short circuit in the ambient air temperature sensor ...

Page 799: ...MP dial to the right to set in the trouble diagnosis step 3 Indication of Step 2 Starting self diagnosis Sensor failure code blinking 30 no failure Trouble Code 4 Set in Trouble Diagnosis Step 4 In this step check the position of actuator door check the fan speed and check the compressor operation Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window When pressing DEF...

Page 800: ...mbient air temperature Interior air temperature Intake air temperature Press Press Press 6 Set in Trouble Diagnosis Step 6 In this step the temperature can be compensated within the range of 3 C to 3 C in the control process according to the temperature to air conditioner controller The step 6 initiates when slightly rotating the fan speed switch other than TEMP switch in step 5 Step 6 Min tempera...

Page 801: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 802: ......

Page 803: ...0 3 FFH KYRON 2005 10 0000 00 0000 00 FFH 1 FFH ...

Page 804: ...0 4 KYRON 2005 10 0000 00 FFH ...

Page 805: ...0 5 FFH KYRON 2005 10 0000 00 ...

Page 806: ...0 6 KYRON 2005 10 0000 00 FFH ...

Page 807: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 808: ......

Page 809: ...0 3 P TRUNK KYRON 2005 10 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 810: ...0 4 KYRON 2005 10 0000 00 P TRUNK ...

Page 811: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 812: ......

Page 813: ...rminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symptom 3 ...

Page 814: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 815: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 816: ......

Page 817: ...0 3 STICS KYRON 2005 10 0000 00 0000 00 STICS 1 STICS ...

Page 818: ...0 4 KYRON 2005 10 0000 00 STICS ...

Page 819: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 820: ......

Page 821: ...0 3 TC KYRON 2005 10 0000 00 0000 00 TC 1 TC ...

Page 822: ...0 4 KYRON 2005 10 0000 00 TC ...

Page 823: ...0 5 TC KYRON 2005 10 0000 00 ...

Page 824: ...0 6 KYRON 2005 10 0000 00 TC ...

Page 825: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 826: ......

Page 827: ...0 3 TCU KYRON 2005 10 0000 00 0000 00 TCU 1 TCU ...

Page 828: ...0 4 KYRON 2005 10 0000 00 TCU ...

Page 829: ...0 5 TCU KYRON 2005 10 0000 00 ...

Page 830: ...0 6 KYRON 2005 10 0000 00 TCU ...

Page 831: ...0 7 TCU KYRON 2005 10 0000 00 ...

Page 832: ...0 8 KYRON 2005 10 0000 00 TCU ...

Page 833: ...0 9 TCU KYRON 2005 10 0000 00 ...

Page 834: ...0 10 KYRON 2005 10 0000 00 TCU ...

Page 835: ...0 11 TCU KYRON 2005 10 0000 00 ...

Page 836: ...0 12 KYRON 2005 10 0000 00 TCU ...

Page 837: ...0 13 TCU KYRON 2005 10 0000 00 ...

Page 838: ...0 14 KYRON 2005 10 0000 00 TCU ...

Page 839: ...0 15 TCU KYRON 2005 10 0000 00 ...

Page 840: ...0 16 KYRON 2005 10 0000 00 TCU ...

Page 841: ...0 17 TCU KYRON 2005 10 0000 00 ...

Page 842: ...0 18 KYRON 2005 10 0000 00 TCU ...

Page 843: ...0 19 TCU KYRON 2005 10 0000 00 ...

Page 844: ......

Page 845: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 846: ......

Page 847: ...0 3 TGS LEVER KYRON 2005 10 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 848: ...0 4 KYRON 2005 10 0000 00 TGS LEVER ...

Page 849: ...0 5 TGS LEVER KYRON 2005 10 0000 00 ...

Page 850: ...0 6 KYRON 2005 10 0000 00 TGS LEVER ...

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