Home
/
SSANGYONG
/
KYRON 2006.03
/
Manual

SSANGYONG KYRON 2006.03, Manual

Share

Page: 603 / 1011

SSANGYONG KYRON 2006.03 Manual Download Page 603

01-18

KYRON 2006.03

3650-01

DC 5-SPEED

4) 4th Gear (1.000)

16. Torque converter lockup clutch
A. Engine speed
B. 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 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 gear (direct connection)
Output shaft: Clockwise rotation

1.
2.
3.
4.
5.
6.
7.
8.
9.

«
...
601
602
603
604
605
...
»

Summary of Contents for KYRON 2006.03

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: ...2006 03 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 2006 03 8201 00 WIRING HARNESS 8201 00 WIRING HARNESS COMPONENTS LOCATION 1 WIRING HARNESS 2 COMPONENTS LOCATION ...

Page 16: ...0 4 KYRON 2006 03 8201 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 17: ...0 5 CONNECTOR GROUND KYRON 2006 03 8201 00 GROUND SPLICE PACK ...

Page 18: ...0 6 KYRON 2006 03 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 2006 03 8201 00 S206 S301 CAN S302 S303 ...

Page 20: ...0 8 KYRON 2006 03 8201 00 CONNECTOR GROUND 5 CONNECTOR C104 C105 C106 C101 C102 C103 ...

Page 21: ...0 9 CONNECTOR GROUND KYRON 2006 03 8201 00 C107 C108 C110 C111 C112 C114 C113 D20DT D27DT GSL ...

Page 22: ...0 10 KYRON 2006 03 8201 00 CONNECTOR GROUND C115 DSL C115 GSL C116 ...

Page 23: ...0 11 CONNECTOR GROUND KYRON 2006 03 8201 00 C201 C203 C202 C204 ...

Page 24: ...0 12 KYRON 2006 03 8201 00 CONNECTOR GROUND C205 Curtain A Bag C207 C206 ...

Page 25: ...0 13 CONNECTOR GROUND KYRON 2006 03 8201 00 C208 C209 C210 C211 Curtain A Bag C212 DSL GSL ...

Page 26: ...0 14 KYRON 2006 03 8201 00 CONNECTOR GROUND C213 C214 C301 Power Seat W Memory Manual Seat W O Memory ...

Page 27: ...0 15 CONNECTOR GROUND KYRON 2006 03 8201 00 C302 C351 C361 C371 ...

Page 28: ...0 16 KYRON 2006 03 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 2006 03 8201 00 WIRNING CONNECTOR MODE CONNECTOR UNIT CONNECTOR ...

Page 30: ...0 18 KYRON 2006 03 8201 00 CONNECTOR GROUND SWITCH CONNECTOR LAMP CONNECTOR SENSOR CONNECTOR ETC ...

Page 31: ...0 19 CONNECTOR GROUND KYRON 2006 03 8210 00 CONNECTOR 8210 00 W H ENGINE ROOM ...

Page 32: ...0 20 KYRON 2006 03 8210 02 CONNECTOR GROUND 8210 02 W H MAIN ...

Page 33: ...0 21 CONNECTOR GROUND KYRON 2006 03 8210 03 8210 03 W H FLOOR ...

Page 34: ...0 22 KYRON 2006 03 8210 10 CONNECTOR GROUND ...

Page 35: ...0 23 CONNECTOR GROUND KYRON 2006 03 8210 09 8210 09 W H ROOF 8210 10 W H TAIL GATE ...

Page 36: ...0 24 KYRON 2006 03 8210 07 CONNECTOR GROUND 8210 06 W H DRIVER DOOR 8210 07 W H PASSENGER DOOR ...

Page 37: ...0 25 CONNECTOR GROUND KYRON 2006 03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 8410 02 5 Ef1 Ef2 Ef6 Ef7 6 Ef8 Ef10 TAIL LAMP RELAY FRT FOG LAMP RELAY ...

Page 48: ...0 10 KYRON 2006 03 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 2006 03 8410 04 8410 04 I P LH FUSE RELAY BOX CIRCUIT 1 F24 F28 2 F29 F34 ...

Page 50: ...0 12 KYRON 2006 03 8410 04 POWER DISTRIBUTION 3 F35 F40 RR WIPER RELAY 4 F41 F48 ...

Page 51: ...0 13 POWER DISTRIBUTION KYRON 2006 03 8410 04 5 F49 F51 DRL RELAY RR FOG LAMP RELAY 6 F52 F55 BURGLAR HORN RELAY ...

Page 52: ...0 14 KYRON 2006 03 8410 04 POWER DISTRIBUTION 7 F56 F57 HDC RELAY FLASHER UNIT ...

Page 53: ...0 15 POWER DISTRIBUTION KYRON 2006 03 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 2006 03 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 2006 03 1461 01 1461 01 STARTING CHARGING 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 58: ...0 4 KYRON 2006 03 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 2006 03 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: ...03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 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 2006 03 8210 01 8210 01 DIAGNOSIS CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 68: ...0 14 KYRON 2006 03 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 2006 03 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 2006 03 3110 01 CIRCUIT K DTC DIAGNOSIS TROUBLE CODE OF DC5AT ...

Page 73: ...0 19 CIRCUIT KYRON 2006 03 3110 01 ...

Page 74: ...0 20 KYRON 2006 03 3110 01 CIRCUIT ...

Page 75: ...0 21 CIRCUIT KYRON 2006 03 3110 01 ...

Page 76: ...0 22 KYRON 2006 03 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 2006 03 3410 01 8 DIAGNOSTIC TROUBLE CODE ...

Page 80: ...0 26 KYRON 2006 03 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 2006 03 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 2006 03 4892 01 N ABS ESP TROUBLE DIAGNOSIS ...

Page 86: ...0 32 KYRON 2006 03 4892 01 CIRCUIT ...

Page 87: ...0 33 CIRCUIT KYRON 2006 03 4892 01 ...

Page 88: ...0 34 KYRON 2006 03 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: ...0 36 KYRON 2006 03 8810 01 CIRCUIT 8810 01 AIR BAG CURTAIN AIR BAG 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 91: ...d 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 measure the supplied power or resistance The detonator may explode due to a ...

Page 92: ...TIONAL CONDITIONS The air bag warning lamp on the instrument panel has a few operational conditions The following are the conditions When Turning the Ignition Switch to ON Position The air bag unit performs a turn on test when the ignition is turned on The air bag unit flashes the air bag warning lamp six times by supplying an intermittent ground to the warning lamp circuit After flashing six time...

Page 93: ...0 39 CIRCUIT KYRON 2006 03 8810 01 ...

Page 94: ...0 40 KYRON 2006 03 8810 01 CIRCUIT ...

Page 95: ...1 CIRCUIT KYRON 2006 03 8010 01 8010 01 CLUSTER 1 GAUGE SPEED RPM FUEL TEMP WARNING LAMP FUEL FUEL FILTER ABS ESP BRAKE HDC 4WD 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 96: ...YRON 2006 03 8010 01 CIRCUIT 2 WARNING LAMP BATT CHARGE OIL HOOD DOOR ENG CHECK AIR BAG SSPS SEAT BELT TURN SIGNAL FOG LAMP HAZARD 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 97: ...engine operating temperature the proper idling speed is 700 800 rpm The red zone danger rpm range 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 C Speedometer The speedometer indicates the vehicle speed by ca...

Page 98: ...float operation by fuel level may be defective if so replace the fuel sender Tolerance and resistance value by indicating angle E Coolant temperature gauge The coolant temperature gauge displays the coolant temperature with a pointer The angle of pointer that changes by coolant temperature is as shown below Measurement of coolant temperature sensor resistance Measure the resistance between the ter...

Page 99: ...l 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 er...

Page 100: ...0 46 KYRON 2006 03 7410 13 CIRCUIT 7410 13 POWER SEAT DRIVER W MEMORY 1 DRIVER POWER SEAT SEAT MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 101: ...0 47 CIRCUIT KYRON 2006 03 7410 13 2 ELECTRIC OUTSIDE MIRROR FOLDING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 102: ...position memory is available for up to three drivers Each driver can set his her own driver s seat outside rearview mirrors and interior rearview mirror positions and they 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 Storing Memory Settings Position the transmission shift lever...

Page 103: ...en 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 is found in the sensor during the memory recall operation Seat Memory Recall Operation When pressing the position switch with the ignition switch ON the seat and outside rearview mirrors move to...

Page 104: ...orrected This is determined when the system detects 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 12 V Operating voltage DC 9 16 V Current consumption Max 500 mA not including the load Operating temperature range 30 75 C Reserve tempe...

Page 105: ...rearview mirrors are folded Normal operation mode Mode changes between Folding and Unfolding The outside rearview mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignition switch To prevent the outside rearview mirrors from stopping during its operation the mirror operating time is extended 13 seconds when pressing the switch again ...

Page 106: ...0 52 KYRON 2006 03 7410 02 CIRCUIT 7410 02 POWER SEAT DRIVER W O MEMORY 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 107: ...0 53 CIRCUIT KYRON 2006 03 7410 04 7410 04 POWER SEAT PASSENGER 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 108: ...0 54 KYRON 2006 03 8510 52 CIRCUIT 8510 52 null ELECTRIC OUTSIDE MIRROR FOLDING W O MEMORY 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 109: ...0 55 CIRCUIT KYRON 2006 03 8510 48 8510 48 SEAT WARMER 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 110: ...0 56 KYRON 2006 03 8710 02 CIRCUIT 8710 02 STICS 1 POWER GROUND CHIME BELL BUZZER WARNING LAMP BRAKE SEAT BELT DR OPEN 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 111: ...0 57 CIRCUIT KYRON 2006 03 8710 02 2 CENTRAL DOOR LOCK CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 112: ...0 58 KYRON 2006 03 8710 02 CIRCUIT 3 TAIL LAMP HAZARD POWER WINDOW 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 113: ...0 59 CIRCUIT KYRON 2006 03 8710 02 4 DEFOGGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 114: ...0 60 KYRON 2006 03 8710 02 CIRCUIT 5 PANIC AUTO LIGHT RAIN SENSING ROOM LAMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 115: ...0 61 CIRCUIT KYRON 2006 03 8710 02 6 FRT WIPER WASHER RR WASHER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 116: ...ndicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time from switch input changing point C FUNCTIONS AND SPECIFICATION Wiper MIST and Front Washer Coupled Wiper 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key O...

Page 117: ...fter 3 cycles The auto washer switch output is overridden during the washer coupled wiper operation The auto washer switch input is overridden during the auto washer coupled wiper operation The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation When the auto INT switch input is received during the auto washer operation the aut...

Page 118: ...perating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity The wiper motor runs only when the rain sensor requires Defective Rain Sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor while the ignition key...

Page 119: ...ent interval at 0 km h 3 0 5 19 2 seconds Vehicle speed calculation The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis Pause time calculation Pause time the duration that wipers are stopped at parking position Elapsed time the duration after the wiper motor started to operate from parking position The pause time is ca...

Page 120: ...tch position After this 4 seconds the warning lamp comes on goes off or blinks according to the vehicle speed and the parking brake switch position The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 The warning light blinks and the chime buzzer in the ICM bo...

Page 121: ...the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF Headlamp Control When the system receives the remote control key after receiving the LOCK signal theft deterrent mode with the ignition switch OFF it supplies the power to the headlamp relay to turn on the headlamp turned off after 20 second...

Page 122: ...emoved and all doors are closed The armed mode is activated when the door lock switch is locked theft deterrent horn output once hazard relay output twice The theft deterrent horn and hazard relay outputs are ON when receiving the LOCK signal from the remote control key again in armed mode theft deterrent horn output once hazard relay output twice When receiving LOCK signal from the remote control...

Page 123: ...d of 30 seconds Specifications of Remote Control Key When any of switches on remote control key is pressed the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle E Switch Functions on Remote Control Key Receiver Operating requirements IGN Key OUT removed Code registration requirement Codes can be registered only through SCAN 100 Trans...

Page 124: ...0 70 KYRON 2006 03 8710 02 CIRCUIT F DIAGNOSIS TROUBLE CODE AND HELP TIPS ...

Page 125: ...0 71 CIRCUIT KYRON 2006 03 7830 03 7830 03 RR WIPER CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 126: ...0 72 KYRON 2006 03 8510 05 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 8510 05 POWER WINDOW CIRCUIT ...

Page 127: ...ing the ignition key to OFF position However the power window relay stays on for 30 seconds T2 when the ignition key is turned to OFF position while the door is opened The power window relay is turned ON again for 30 seconds T2 just for once when opening the door during its extended operation period of 30 seconds T1 The power window relay is turned OFF when closing the door during its extended ope...

Page 128: ...0 74 KYRON 2006 03 8610 06 CIRCUIT 8610 06 HORN 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 129: ...0 75 CIRCUIT KYRON 2006 03 7632 16 7632 16 CIGAR LIGHTER POWER OUTLET CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 130: ...0 76 KYRON 2006 03 7340 03 CIRCUIT 7340 03 SUN ROOF CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 131: ...linjury thesunroofsettingiscanceled When the battery voltage is disconnected the fuse is blown or the abrupt voltage drop occurs due to old battery while operating the sunroof When an undesired cancellation occurs due to mistake by a technician When parts damage shorted circuit or electric leakage occurs When keeping the sunroof switch at OPEN position B Symptoms when the sunroof setting is cancel...

Page 132: ...0 78 KYRON 2006 03 7340 03 CIRCUIT E TROUBLE DIAGNOSIS ...

Page 133: ...0 79 CIRCUIT KYRON 2006 03 8310 01 8310 01 HEAD LAMP DRL 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION HEAD LAMP DRL DAY TIME RUNNING LIGHT UNIT CIRCUIT ...

Page 134: ...0 80 KYRON 2006 03 8510 00 CIRCUIT 8510 00 HLLD HEAD LAMP LEVEL G DEVICE CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 135: ...0 81 CIRCUIT KYRON 2006 03 8320 01 8320 01 TAIL LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 136: ...s turned on and the driver s door is opened This function is not available when the ignition key is in ON position 2 BATTERY SAVER TAIL LAMP AUTO CUT The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch The tail lamp relay is turned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp ...

Page 137: ...0 83 CIRCUIT KYRON 2006 03 8410 01 8410 01 TURN SIGNAL HAZARD LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 138: ...0 84 KYRON 2006 03 8210 01 CIRCUIT 8210 01 TRAILER LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 139: ...0 85 CIRCUIT KYRON 2006 03 8310 10 8310 10 FOG LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 140: ...0 86 KYRON 2006 03 4810 01 CIRCUIT 4810 01 STOP BACK UP LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 141: ...0 87 CIRCUIT KYRON 2006 03 7770 02 7770 02 INTERIOR LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 142: ... by 30 seconds T3 when receiving the unlock signal from the remote control key again during output When a door is opened during its extended period the lamp stays on If closed operates as in step 2 The room lamp output stops immediately after receiving the lock signal from driver s door and passenger s door lock switch while the driver s door and passenger s door are closed B Rear room lamp The re...

Page 143: ...0 89 CIRCUIT KYRON 2006 03 7770 10 7770 10 AUTO DIMMING ROOM MIRROR CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 144: ...0 90 KYRON 2006 03 8910 01 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 8910 01 AUDIO CLOCK CIRCUIT ...

Page 145: ...0 91 CIRCUIT KYRON 2006 03 8930 01 8930 01 A V SYSTEM 1 A V HEAD UNIT TUNER UNIT DSP UNIT DVD CHANGER GLS ANT AMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 146: ...0 92 KYRON 2006 03 8930 01 CIRCUIT 2 DSP UNIT SPEAKER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 147: ...0 93 CIRCUIT KYRON 2006 03 8790 01 8790 01 PARKING AID CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 148: ...ure the safety distance for parking A Parking aid unit Detecting type Super sonic wave Detecting distance 25 120 cm distance between sensor and obstacle B Parking aid sensor Type Piezo ceramic element Frequency 40 KHz 2 KHz Detecting range 13 5 V Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 cm Min 60 at 50 5 cm 2 ALARM INTERVAL Alarm interval and display changes accord...

Page 149: ...ltrasonic waves Obstacles lower than the bumper ex drain ditch or mud puddle B Not defective but improperly working When the sensing portion is frozen operates normally after thawed When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned When receiving other ultrasonic signals metal sound or air braking noises from heavy commercial vehicles When a high p...

Page 150: ...0 96 KYRON 2006 03 6810 15 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 6810 15 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT ...

Page 151: ...perating condition of PTC is controlled by two step Generally ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor 1st step Initial PTC operating condition When coolant temperature 15 C PTC is operating ON When coolant temperature 15 C tow conditions decribed below must be satisfied 2nd step Coolant temperature 15 C When coolant temperature 65 C a...

Page 152: ...0 98 KYRON 2006 03 6910 01 CIRCUIT 6910 01 FFH FUEL FIRED HEATER 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 153: ...g the fuel pump still fails to ignite the heater is switched off in fault mode The controller is locked after a certain number of failed starts If the flame does out by itself during operation firstly a new start is activated If the fuel pump fails to ignite within 90 seconds after fuel pumping has started again the heater is switched off If the heater is overheated lack of water poorly vented coo...

Page 154: ...0 100 KYRON 2006 03 6910 01 CIRCUIT ...

Page 155: ...0 101 CIRCUIT KYRON 2006 03 6910 01 4 RAL TROUBLE CAUSES AND REMEDIES ...

Page 156: ...YRON 2006 03 6810 20 CIRCUIT 6810 20 FATC FULL AUTO TEMP CONTROL CIRCUIT 1 CONDENSOR FAN AIR MIX MOTOR SUN SENSOR WATER TEMP SENSOR 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 157: ...0 103 CIRCUIT KYRON 2006 03 6810 20 2 BLOWER ACTUATOR MODE INTAKE AQS SENSOR 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 158: ...s 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 If 1 Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 2 10 20 seconds 2 Indication of Step 2 Starting self diagnosis 3 Sensor failure code blinking When two sens...

Page 159: ...MP dial to the right to set in the trouble diagnosis step 3 2 Indication of Step 2 Starting self diagnosis 3 Sensor failure code blinking 30 no failure Trouble Code 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 D...

Page 160: ...tion key OFF B SYSTEM DIAGRAM This figures shows the input and output system between A C components and A C controller Air Conditioner Compressor Control by Engine ECU In case of current vehicle models the system turns ON OFF the compressor switch according to refrigerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped wit...

Page 161: ...gnition switch to ON position Measure the voltage to the sun sensor from FATC connector approx 2 5 V under sunlight and 4 8 V under shade If the voltage value cannot be measured check the circuit for open If the measured value is within the specified range replace the FATC controller Active Incar Humidity Sensor AIH Sensor The AIH sensor is installed at the driver side instrument panel undercover ...

Page 162: ...r disappears When pressing the AQS switch the AQS indicator on display window comes on and the air source selection is automatically changed to recirculation mode REC At this moment the self diagnosis and preheating mode of AQS is performed for 35 seconds 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 recirc...

Page 163: ...ition switch ON from OFF the AQS stops its operation and the indicator goes out and the display window shows the initial screen If the AQS switch is pressed in the AQS function works regardless of air conditioner controller operation The modes available AQS function AUTO mode Fan speed control dial operation mode A C switch operation At this mode the AQS system operates according to the AQS switch...

Page 164: ... Preceding Work Disconnect the negative battery cable The power transistor should be removed after removing the lower instrument panel in front of passenger seat For removal and installation of the lower instrument panel refer to the Body section Remove the lower instrument panel in front of passenger seat and disconnect the power transistor connector Unscrew the mounting screws and remove the pow...

Page 165: ...pressed Removal and Installation First remove the driver side instrument lower panel in order to remove and install mode door actuator For removal and installation of the panel refer to BODY section Remove the lower instrument panel in front of driver seat Disconnect the mode door actuator connector and remove two mounting screws Separate the mode door actuator and remove the mode door link assemb...

Page 166: ...rding to the control signal from FATC Removal and Installation Remove the driver s instrument lower panel and then disconnect the connection connector of the mode door actuator and the mounting screws 2EA Remove the in ex air door actuator Disconnect the negative battery cable and then remove the instrument panel assembly ...

Page 167: ...ng opening the damper according to the control signals from FATC Removal and Installation With the instrument panel assembly removed as shown in the above figure disconnect the air mix door actuator and unscrew two mounting screws to remove the air mix door actuator Disconnect the battery negative cable and remove the instrument panel assembly ...

Page 168: ...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 controller connector stand...

Page 169: ...ower unit and remove the Intake Sensor from the evaporator Unscrew three mounting bolts 10 mm on air conditioner module assembly and remove the sensor wire of air conditioner module Separate the blower unit from the heater unit Disconnect the negative battery cable and remove the instrument panel assembly ...

Page 170: ...0 116 KYRON 2006 03 6810 20 CIRCUIT 6810 20 AIR CON MANUAL CIRCUIT 1 COMPRESSOR MOTOR MODE INTAKE AIR MIX 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 171: ...0 117 CIRCUIT KYRON 2006 03 6810 20 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 BLOWER ...

Page 172: ......

Page 173: ...ICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE INTERVAL 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 13 14 16 17 19 ...

Page 174: ...01 2 KYRON 2006 03 0000 00 GENERAL ...

Page 175: ...01 3 GENERAL KYRON 2006 03 0000 00 0000 00 GENERAL GENERAL 1 DIMENSIONS Unit mm ...

Page 176: ...01 4 KYRON 2006 03 0000 00 GENERAL 2 SPECIFICATIONS Optional ...

Page 177: ...01 5 GENERAL KYRON 2006 03 0000 00 Optional ...

Page 178: ...lower area of cylinder block in exhaust manifold side 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 Diesel Engine The engine number is stamped on the lower area of cylinder block behind the Intake manifold ...

Page 179: ...on Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Shorten the service interval Inspect the ...

Page 180: ...icle is operated under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then change every 60 00...

Page 181: ...s 8 After completion of off road operation the drive shaft boots should be inspected 9 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain I R Use only approved Ssangyong genuine parts E...

Page 182: ...nd their related parts If necessary correct clean replenish adjust or replace Replace or change In order to secure engine long life and effective break in first oil factory filled would be recommended to drain with in 10 000 km I R 1 If vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition shorten the service interval 2 If vehicle is opera...

Page 183: ...required if the vehicle is operated under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then...

Page 184: ...ompletion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness 7 If necessary rotate and balance wheels 8 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or ...

Page 185: ...00 5 RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Keep the specified levels when adding or replacing the fluids Do not mix any different types or brands of oils or fluids This may cause damages ...

Page 186: ...01 14 KYRON 2006 03 0000 00 GENERAL 6 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 187: ...01 15 GENERAL KYRON 2006 03 0000 00 2 5 Link System Lifting Point Dotted Circles ...

Page 188: ...01 16 KYRON 2006 03 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 189: ...01 17 GENERAL KYRON 2006 03 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 190: ...01 18 KYRON 2006 03 0000 00 GENERAL 2 Components Locator ...

Page 191: ...01 19 GENERAL KYRON 2006 03 0000 00 9 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 192: ...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 193: ...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 194: ......

Page 195: ...01 3 ENGINE GENERAL KYRON 2006 03 0000 00 0000 00 ENGINE GENERAL GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 196: ...01 4 KYRON 2006 03 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 197: ... 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 198: ...01 6 KYRON 2006 03 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 199: ...01 7 ENGINE GENERAL KYRON 2006 03 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 200: ...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 201: ...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 202: ...YRON 2006 03 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 203: ...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 204: ... SYSTEM LAYOUT 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 205: ... 2006 03 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 206: ...4 KYRON 2006 03 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 207: ...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 208: ...01 16 KYRON 2006 03 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 209: ...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 210: ...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 211: ...01 19 ENGINE GENERAL KYRON 2006 03 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 212: ...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 213: ...01 21 ENGINE GENERAL KYRON 2006 03 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 214: ...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 215: ... 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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ... 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 222: ...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 223: ...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 224: ... 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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...01 41 ENGINE GENERAL KYRON 2006 03 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 234: ...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 235: ...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 236: ...E ASSEMBLY KYRON 2006 03 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 237: ... 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 238: ... 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 239: ...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 240: ...03 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 241: ...02 8 KYRON 2006 03 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 242: ...02 9 ENGINE ASSEMBLY KYRON 2006 03 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 243: ...02 10 KYRON 2006 03 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 244: ...02 11 ENGINE ASSEMBLY KYRON 2006 03 1212 01 ...

Page 245: ...02 12 KYRON 2006 03 1212 01 ENGINE ASSEMBLY ...

Page 246: ... 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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...03 8 KYRON 2006 03 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 252: ...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 253: ...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 254: ...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 255: ...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 256: ...03 13 ENGINE FUEL SYSTEM KYRON 2006 03 1881 01 6 CIRCUIT DIAGRAM ...

Page 257: ...03 14 KYRON 2006 03 1881 01 ENGINE FUEL SYSTEM ...

Page 258: ...03 15 ENGINE FUEL SYSTEM KYRON 2006 03 1881 01 ...

Page 259: ......

Page 260: ...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 261: ...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 262: ...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 263: ...04 6 KYRON 2006 03 2321 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 264: ...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 265: ...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 266: ...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 267: ...04 10 KYRON 2006 03 2321 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 268: ...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 269: ...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 270: ...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 271: ...05 6 KYRON 2006 03 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 272: ...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 273: ...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 274: ...06 5 LUBRICATION SYSTEM KYRON 2006 03 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 275: ...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 276: ...ON 2006 03 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 277: ...07 3 COOLING SYSTEM KYRON 2006 03 9210 05 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 278: ... 4 KYRON 2006 03 9210 05 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 279: ...5 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 280: ...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 281: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2006 03 1461 01 1461 01 ENGINE ELECTRICAL SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 282: ... 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 283: ...INE ELECTRIC DEVICES KYRON 2006 03 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 284: ...08 6 KYRON 2006 03 1461 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 285: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2006 03 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 286: ...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 287: ...09 4 KYRON 2006 03 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 288: ...09 5 ENGINE CONTROL SYSTEM KYRON 2006 03 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 289: ...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 290: ... 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 291: ...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 292: ...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 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ... 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 305: ...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 306: ...10 5 CRUISE CONTROL SYSTEM KYRON 2006 03 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 307: ...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 308: ...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 309: ...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 310: ...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 311: ...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 312: ...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 313: ......

Page 314: ...01 3 ENGINE D20DT KYRON 2006 03 0000 00 GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH Side View D20DT D27DT 0000 00 ENGINE GENERAL ...

Page 315: ...01 4 KYRON 2006 03 0000 00 ENGINE D20DT 2 RH side view D20DT D27DT ...

Page 316: ...01 5 ENGINE D20DT KYRON 2006 03 0000 00 3 Front view D20DT D27DT ...

Page 317: ...01 6 KYRON 2006 03 0000 00 ENGINE D20DT 4 Fan belt D20DT D27DT ...

Page 318: ...01 7 ENGINE D20DT KYRON 2006 03 0000 00 2 COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ...

Page 319: ...01 8 KYRON 2006 03 0000 00 ENGINE D20DT ...

Page 320: ...01 9 ENGINE D20DT KYRON 2006 03 0000 00 ...

Page 321: ...01 10 KYRON 2006 03 0000 00 ENGINE D20DT ...

Page 322: ...01 11 ENGINE D20DT KYRON 2006 03 0000 00 3 ENGINE CONTROLS LAYOUT 1 Ecu related componets 1 D20DT Engine ...

Page 323: ...01 12 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 324: ...01 13 ENGINE D20DT KYRON 2006 03 0000 00 2 ENGINE AND SENSORS 1 D20DT Engine ...

Page 325: ...01 14 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 326: ...01 15 ENGINE D20DT KYRON 2006 03 0000 00 4 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1 D20DT Engine ...

Page 327: ...01 16 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 328: ...01 17 ENGINE D20DT KYRON 2006 03 0000 00 5 INTAKE SYSTEM LAYOUT 1 D20DT Engine ...

Page 329: ...01 18 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 330: ...01 19 ENGINE D20DT KYRON 2006 03 0000 00 6 EXHAUST SYSTEM LAYOUT 1 D20DT Engine ...

Page 331: ...01 20 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 332: ...01 21 ENGINE D20DT KYRON 2006 03 0000 00 7 LUBRICATION SYSTEM LAYOUT 1 D20DT Engine ...

Page 333: ...01 22 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 334: ...01 23 ENGINE D20DT KYRON 2006 03 0000 00 8 COOLING SYSTEM LAYOUT 1 D20DT Engine ...

Page 335: ...01 24 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 336: ...01 25 ENGINE D20DT KYRON 2006 03 0000 00 9 FUEL SYSTEM LAYOUT 1 D20DT Engine ...

Page 337: ...01 26 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 338: ...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 339: ...01 28 KYRON 2006 03 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 340: ... 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 341: ...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 342: ...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 343: ...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 344: ...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 345: ......

Page 346: ...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 347: ...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 348: ... 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 349: ... 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 350: ...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 351: ...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 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ... 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 359: ...01 48 KYRON 2006 03 0000 00 ENGINE D20DT 17 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 360: ...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 361: ......

Page 362: ...l 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 1114 01 ENGINE ASSEMBLY 1 MAJOR 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 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...02 9 ENGINE D20DT KYRON 2006 03 1114 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 369: ...02 10 KYRON 2006 03 1114 01 ENGINE D20DT 2 Engine Performance Curve 1 Vehicle with A T Output and Torque D20DT engine D27DT engine ...

Page 370: ...02 11 ENGINE D20DT KYRON 2006 03 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 371: ...02 12 KYRON 2006 03 1114 01 ENGINE D20DT Output and Torque 2 Vehicle with M T D20DT engine D27DT engine ...

Page 372: ...02 13 ENGINE D20DT KYRON 2006 03 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 373: ...02 14 KYRON 2006 03 1114 01 ENGINE D20DT 4 TIGHTENING TORQUE ...

Page 374: ...02 15 ENGINE D20DT KYRON 2006 03 1114 01 ...

Page 375: ...02 16 KYRON 2006 03 1114 01 ENGINE D20DT ...

Page 376: ...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 377: ...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 378: ...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 379: ...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 380: ...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 381: ...03 8 KYRON 2006 03 1881 01 ENGINE D20DT 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Page 382: ...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 383: ...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 384: ...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 385: ...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 386: ... D20DT KYRON 2006 03 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 387: ...03 14 KYRON 2006 03 1881 01 ENGINE D20DT 7 Circuit Diagram ...

Page 388: ...03 15 ENGINE D20DT KYRON 2006 03 1881 01 ...

Page 389: ...03 16 KYRON 2006 03 1881 01 ENGINE D20DT ...

Page 390: ...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 391: ...04 4 KYRON 2006 03 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 392: ...04 5 ENGINE D20DT KYRON 2006 03 2321 01 2 D27DT Engine Air Cleaner Intake Manifold HFM Sensor Intercooler Cover Element Housing ...

Page 393: ...04 6 KYRON 2006 03 2321 01 ENGINE D20DT 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 394: ... flows to engine combustion chamber and intake air temperature And intake temperature sensor built in the sensor detects intake temperature Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the heating resistance Rh to 160 C that is higher temperature than intake air temperature that is measured by resistance RI Temperature se...

Page 395: ...t this sensor is most proper in controlling accurate air fuel ratio to meet the legal emission regulations This sensor measures actual intake air mass into engine very accurately during specific instant acceleration and deceleration and determines engine loads and detects intake air pulsation and air flows Main functions of HFM sensor are 1 Using for EGR feedback control 2 Using for turbocharger b...

Page 396: ...04 9 ENGINE D20DT KYRON 2006 03 2321 01 Circuit Diagram of HFM Sensor ...

Page 397: ...ygen into the engine However the intake air is heated 100 110 C during the compression process in turbo charger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine Cold air has more oxygen molecules than warm air Thus cooler air gives more power and better fuel economy 1 Intercooler ...

Page 398: ...port 2 Optimized EGR gas mixture in inlet chamber 3 Maximized intake efficiency with helical and tangential inlet port 1 Improving the swirl ratio in low and mid operating range 2 Improving the acceleration fuel economy and reducing the maintenance in low and mid operating range 4 Integrated inlet port and coolant outlet port D20DT D27DT 1 System Characteristics ...

Page 399: ... 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 400: ...05 4 KYRON 2006 03 1913 01 ENGINE D20DT D20DT D27DT HUBER EGR System for IDI Engine Including the EGR Valve Potentiometer EGR System for DI Engine ...

Page 401: ... D20DT KYRON 2006 03 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 402: ...05 6 KYRON 2006 03 1913 01 ENGINE D20DT Turbo Charger EGR Valve Muffler Exhaust Manifold Catalytic Converter DOC EGR Pipe Vacuum Modulator ...

Page 403: ...05 7 ENGINE D20DT KYRON 2006 03 1913 01 2 EXHAUST GAS FLOWS ...

Page 404: ...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 405: ...006 03 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 406: ...06 5 ENGINE D20DT KYRON 2006 03 1533 01 Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover 2 D27DT Engine ...

Page 407: ...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 408: ...06 03 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 409: ...07 3 ENGINE D20DT KYRON 2006 03 9210 05 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 410: ... 2006 03 9210 05 ENGINE D20DT Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS OF ENGINE COOLING OVERVIEW AND OPERATION PROCESS 1 D20DT Engine ...

Page 411: ...07 5 ENGINE D20DT KYRON 2006 03 9210 05 Coolant Reservoir FFH Coolant Temperature Sensor Radiator Water Pump Cooling Fan 2 D27DT Engine ...

Page 412: ... 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 413: ...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 414: ...08 3 ENGINE D20DT KYRON 2006 03 1461 01 1461 01 ENGINE ELECTRIC SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 415: ...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 416: ...YRON 2006 03 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 417: ... 2006 03 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 418: ...08 7 ENGINE D20DT KYRON 2006 03 1461 01 1 D27DT ENGINE Air Conditioner Compressor Alternator Glow Plug Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 419: ...08 8 KYRON 2006 03 1461 01 ENGINE D20DT 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 420: ...08 9 ENGINE D20DT KYRON 2006 03 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 421: ...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 422: ...N 2006 03 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 423: ...09 5 ENGINE D20DT KYRON 2006 03 1491 01 3 TOP VIEW 1 D20DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 424: ...09 6 KYRON 2006 03 1491 01 ENGINE D20DT Fuel Pressure Sensor 2 D27DT Engine Booster Pressure Sensor Injectors 5 EA Glow Plugs 5 ...

Page 425: ...09 7 ENGINE D20DT KYRON 2006 03 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 426: ...09 8 KYRON 2006 03 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 427: ... 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 428: ...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 429: ...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 430: ... 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 431: ...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 432: ...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 433: ... 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 434: ...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 435: ... 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 436: ...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 437: ... 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 438: ...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 439: ...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 440: ...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 441: ...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 442: ......

Page 443: ... 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 accelerator pe...

Page 444: ...s 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 445: ...10 5 ENGINE D20DT KYRON 2006 03 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 446: ... 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 use t...

Page 447: ... 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 runni...

Page 448: ...er 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 DECEL...

Page 449: ...e 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 speed p...

Page 450: ... 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 resul...

Page 451: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 452: ......

Page 453: ......

Page 454: ...01 4 KYRON 2006 03 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 455: ... Connecting rod 3 Resonance flap 14 Exhaust manifold 4 Cylinder head cover 15 Crankshaft 5 Exhaust camshaft 16 Engine mounting 6 Intake camshaft 17 Starter 7 Cylinder head 18 Crankcase 8 Spark plug connector 19 Oil pump sprocket 9 Valve tappet 20 Oil strainer 10 Injector 21 Oil pan 11 Exhaust valve 22 Drain plug Front View ...

Page 456: ... 03 0000 00 ENGINE INFORMATION 2 SIDE VIEW NO FUNCTION NO FUNCTION 23 Camshaft adjuster 27 Oil pump drive chain 24 Cooling fan and viscous clutch 28 Oil return pipe 25 Piston 29 Timing chain 26 Flywheel of drive plate ...

Page 457: ...They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or whe...

Page 458: ......

Page 459: ...02 3 ENGINE ASSEMBLY KYRON 2006 03 1113 01 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 460: ...02 4 KYRON 2006 03 1113 01 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 461: ...02 5 ENGINE ASSEMBLY KYRON 2006 03 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 462: ...02 6 KYRON 2006 03 1113 01 ENGINE ASSEMBLY ...

Page 463: ...02 7 ENGINE ASSEMBLY KYRON 2006 03 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 464: ...02 8 KYRON 2006 03 1113 01 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 465: ...02 9 ENGINE ASSEMBLY KYRON 2006 03 1113 01 4 FASTENER TIGHTENING SPECIFICATIONS CONT D ...

Page 466: ...ck of your vehicle Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must...

Page 467: ...03 4 KYRON 2006 03 2211 22 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 468: ...NO DATA ...

Page 469: ...ioration is discovered upon inspection of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 ...

Page 470: ...05 4 KYRON 2006 03 2420 01 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 471: ...06 3 LUBRICATION SYSTEM KYRON 2006 03 9210 01 9210 01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1 OIL CIRCULATION ...

Page 472: ...e tappet 7 Oil gallery at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chain...

Page 473: ...07 3 COOLING SYSTEM KYRON 2006 03 2110 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 474: ...07 4 KYRON 2006 03 2110 01 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 475: ...07 5 COOLING SYSTEM KYRON 2006 03 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 476: ...r the cooling system to operation The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to t...

Page 477: ...07 7 COOLING SYSTEM KYRON 2006 03 2110 01 2 COMPONENT LOCATOR ...

Page 478: ... pieces Bolt M6 4 pieces Bolt M6 4 pieces Upper radiator insulator Lower radiator insulator Plate Clip 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Inlet hose Outlet hose 3 way hose Deaeration hose reserver tank Clamp Clamp Make up hose holder Reserver tank Bolt M6 2 piece Cooling fan Viscous clutch Bolt M6 1 piece Bolt M6 3 piece 15 16 17 18 19 20 21 22 23 24 25 26 27 ...

Page 479: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2006 03 1452 01 1452 01 ENGINE ELECTRIC DEVICES GENERAL 1 GENERAL SPECIFICATIONS ...

Page 480: ...08 4 KYRON 2006 03 1452 01 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 481: ...igher current rate as the battery warms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharge...

Page 482: ... exhaust stroke requires very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These systems use the EST signal from the ECM to control the EST The ECM uses the following information Engine load mass air flow sensor manifold air pressure sensor Engine coolant temperature Intake air temperature Cranks...

Page 483: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2006 03 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 484: ...09 3 ENGINE CONTROL SYSTEM KYRON 2006 03 1522 16 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE GENERAL ...

Page 485: ...09 4 KYRON 2006 03 1522 16 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 486: ... 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 487: ...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 488: ...10 5 CRUISE CONTROL SYSTEM KYRON 2006 03 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 489: ...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 490: ...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 491: ...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 492: ...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 493: ...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 494: ...L 1 LOCATIONS OF INTERIOR UNITS AND SENSORS 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT 3 INTERIOR SWITCHES 4 AUDIO VIDEO SYSTEM 5 ELECTRIC COMPONENTS AND LAYOUT 6 FUSES AND RELAYS 7 INTERIOR FUSE BOX ELECTRIC SYSTEM ELECTRIC SYSTEM 2 4 6 8 10 12 15 ...

Page 495: ...F INTERIOR UNITS AND SENSORS Under Instrument Panel Steering Wheel Angular Sensor Immobilizer PAS Unit Driver Seat Memory Switch TCCU and TCU Steering wheel angular sensor Immobilizer Curtain air bag module Sun sensor TV antenna amplifier Door lock relay Chime bell Buzzer for PAS RK STICS TCCU TCU ...

Page 496: ...ECM Sensor Cluster Sun Roof Unit and Motor Air Bag ECU Curtain Air Bag Sensor Interior Temperature and Humidity Sensor Engine ECU and SSPS Unit Sun roof unit Sun roof motor Curtain air bag module TV antenna amplifier DSP amp TV tuner DVD changer SSPS unit under the engine ECU Sub woofer ...

Page 497: ...2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT AQS Sensor and FFH Ambient Temperature Sensor Receiver Drier and Triple Pressure Switch Horn RH FFH Assembly FFH ambient temperature sensor AQS sensor ambient temperature sensor integrated type ...

Page 498: ... ELECTRIC SYSTEM KYRON 2006 03 0000 00 IWE Vacuum Solenoid Valve 4WD Horn LH Hood Contact Switch Theft Deterrent Horn Under the Battery Fuse and Relay Box ESP Pressure Sensor Primary Secondary ABS ESP HECU ...

Page 499: ...ering Wheel Bezel Assembly on Outside Rearview Mirror Adjusting Switch Seat Position Memory Switch Driver s Door Driver s Power Window Main Switch Outside rearview mirror folding switch Outside rearview mirror adjusting switch ESP OFF switch Audio remote control switch Audio remote control switch ...

Page 500: ...Switch Bezel Assembly on Hazard Switch Center Fascia Switch Room lamp main switch Sun roof switch HDC switch Outside rearview mirror and rear glass heated switch Hazard switch TRIP switch Front defogger switch 1 2 3 4 5 Passenger seat warmer switch Driver seat warmer switch 4WD switch ...

Page 501: ...SYSTEM AV System Audio remote control switches Center speaker DVD changer DVD tape Other Audio Head Unit 6 INDASH CD TAPE RADIO CD RADIO Front speaker RH Tweeter speaker DVD changer Center speaker AV head unit Front speaker LH Tweeter speaker LH Sub woofer amplifier integrated type ...

Page 502: ...2006 03 0000 00 Location Inside of panel above glove box 6 DVD changer AV System Tweeter speaker LH Rear speaker LH Rear speaker RH Tweeter speaker TV antenna amplifier LH TV antenna amplifier RH Tuner Amp Radio antenna amplifier ...

Page 503: ...01 10 KYRON 2006 03 0000 00 ELECTRIC SYSTEM Wiring Harness Arrangement 5 ELECTRIC COMPONENTS AND LAYOUT ...

Page 504: ...01 11 ELECTRIC SYSTEM KYRON 2006 03 0000 00 Components Locator ...

Page 505: ...gement 6 FUSES AND RELAYS There are three fuse and relay boxes in this vehicle one at each side of instrument panel and one in enginecompartment The designation and capacity of relays and fuses is shown on the fuse and relay box cover 1 Fuse and Relay Box in Engine Compartment ...

Page 506: ...01 13 ELECTRIC SYSTEM KYRON 2006 03 0000 00 Connector ...

Page 507: ...MOVE AND INSTALLATION Disconnect the negative battery cable open the fuse and relay box cover in engine compartment and unscrew the mounting nuts 1 Lift the fuse and relay box assembly and disconnect connectors behind the assembly 2 Remove the fuse and relay box assembly 3 ...

Page 508: ...01 15 ELECTRIC SYSTEM KYRON 2006 03 0000 00 7 INTERIOR FUSE BOX Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 509: ...01 16 KYRON 2006 03 0000 00 ELECTRIC SYSTEM 1 Designation and Capacity Driver Side ...

Page 510: ...01 17 ELECTRIC SYSTEM KYRON 2006 03 0000 00 Passenger Side ...

Page 511: ... Scan 100 and Diagnostic Connector Scan 100 CAN module Diagnostic connector Additional cable for CAN module Additional Devices of Scan 100 Diagnosis EAS EPB Only Connection of Scan 100 Including CAN Module and Additional Cable CAN module connecting cable CAN module ...

Page 512: ...SYSTEM KYRON 2006 03 0000 00 2 Pin Arrangement of Diagnostic Connector It is installed under the instrument panel and consists of 16 pins The REKES key coding should be performed with Scan 100 3 Functions of Terminal ...

Page 513: ...01 20 KYRON 2006 03 0000 00 ELECTRIC SYSTEM 4 ELECTRICAL WIRING DIAGRAMS ...

Page 514: ...CS Super Time Integrated Control System communicates with the transmitter remote controller and other electronic systems to transmit and receive the data The STICS also includes a diagnosis function that can inspect the error for related devices PAS Buzzer Door Lock Relay Door Lock Relay STICS ...

Page 515: ... current leaks Confined with PCB waterproof and coating that requires the insulation Parasitic current below 7 0 mA When initiating the sleep mode after removing ignition key and locking the doors Voltage drop below 1 5 V Pin no 72 and 2 4 7 8 9 10 11 12 19 24 27 28 29 30 31 32 33 36 56 57 58 59 60 61 70 71 below 1 8 V Pin no 72 and 5 6 16 17 18 20 21 23 35 37 39 41 42 43 44 45 62 64 65 66 67 68 6...

Page 516: ...y DC 12 V 200 mA Inducted load 9 Door unlock relay DC 12 V 200 mA Inducted load 10 Horn relay DC 12 V 200 mA Inducted load 11 Tail lamp relay DC 12 V 200 mA Inducted load 12 Hazard warning relay DC 12 V 200 mA Inducted load 13 Power window relay DC 12 V 200 mA Inducted load 14 Rear defogger relay DC 12 V 200 mA Inducted load 15 Wiper LOW relay DC 12 V 250 mA Inducted load 16 Wiper HIGH relay DC 12...

Page 517: ...02 6 KYRON 2006 03 8710 01 STICS Input Signals ...

Page 518: ...n each function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time from...

Page 519: ......

Page 520: ...de the key communicates with the im mobilizer installed in the key box and the system per mits the engine to start after confirming the encryptedcoding from the engine ECU Refer to the informationthat follows for specific functions and their descriptions 7010 06 IMMOBILIZER SYSTEM The immobilizer unit communicates with the enginecontrol unit to enable the engine starting Transponder Battery GENERA...

Page 521: ...l is sent from the remote control key room lampcoupled function deterrent horn sounds approx 27 seconds PANIC function with ignition key in Theft Specification CR 2032 Quantity one Door button PANIC button Key plate 1 Engine start 2 Door lock unlock The doors cannot be locked by remote control if they are not closed Door and tailgate lock briefly press Door and tailgate unlock press and hold All d...

Page 522: ......

Page 523: ...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 524: ...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 525: ... 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 526: ...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 527: ...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 528: ...04 8 KYRON 2006 03 7410 13 SPWM 3 SEAT POSITION WITH MEMORY INPUT OUTPUT OF SPWM UNIT ...

Page 529: ...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 530: ...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 531: ...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 532: ... 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 533: ...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 534: ...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 535: ...6 03 8010 01 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 536: ...05 4 KYRON 2006 03 8010 01 CLUSTER 2 WARNING INDICATOR PANE ...

Page 537: ...05 5 CLUSTER KYRON 2006 03 8010 01 ...

Page 538: ...05 6 KYRON 2006 03 8010 01 CLUSTER Main Connector Sub Connector 1 CLUSTER CONFIGURATION Front View Rear View ...

Page 539: ...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 540: ...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 541: ...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 542: ...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 543: ... 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 544: ... 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 545: ...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 546: ...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 547: ...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 548: ...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 549: ...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 550: ...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 551: ... 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 552: ...05 20 KYRON 2006 03 8010 01 CLUSTER 5 CLUSTER ELECTRICAL WIRING DIAGRAMS Gauge speed RPM fuel temp Warning Lamp fuel fuel filter ABS ESP brake HDC 4WD ...

Page 553: ...05 21 CLUSTER KYRON 2006 03 8010 01 Warning Lamp batt charge oil hood door eng check air bag ssps seat belt Turn Signal Fog Lamp Hazard ...

Page 554: ...t each 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 1 LOCATIONS OF LAMPS AND SPECIFICATIONS 1 Exterior Lamps ...

Page 555: ...N 2006 03 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 556: ...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 557: ...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 558: ... 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 559: ...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 560: ... 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 for...

Page 561: ...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 562: ...nit 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 the ...

Page 563: ...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 564: ...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 565: ...fraindropsbyreceiving reflectedraysagainstsensingsection rainsensor mountingsectiononthewindshield with photodiode TheautolightsensorisIntegratedinto therainsensor refertothebelowpicture Multifunction wiper switch AUTO and sensitivity control AUTO Wiperoperatesautomaticallybyrainsensor FAST SLOW Autodelay Autospeedcontrol Apositionthatcancontrolsensitivityagainstrains onthewindshieldandtransmitswi...

Page 566: ...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 567: ...ardless 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 sensor detects the Ra...

Page 568: ...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 569: ...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 570: ... 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 571: ...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 572: ...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 573: ...09 11 RAIN SENSOR KYRON 2006 03 8610 09 3 ELECTRICAL WIRING DIAGRAM ...

Page 574: ...sition 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 5 V ...

Page 575: ...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 576: ...10 5 PAS KYRON 2006 03 8790 03 Parking Aid Unit Left Right Center Sensor Location Center sensor Right sensor Connector Left sensor Center sensor ...

Page 577: ...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 578: ...m 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 any failure du...

Page 579: ...10 8 KYRON 2006 03 8790 03 PAS 3 PAS CIRCUIT DIAGRAM ...

Page 580: ...D 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 581: ...11 4 KYRON 2006 03 8930 14 AV 1 AV SYSTEM CONFIGURATION AV System DVD Head Unit DVD Changer Audio System 6 Speakers ...

Page 582: ...11 5 AV KYRON 2006 03 8930 14 6 DISC changer TAPE RADIO CD RADIO DISC changer CD slot Tape ...

Page 583: ...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 584: ...11 7 AV KYRON 2006 03 8930 14 ...

Page 585: ...6 03 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 586: ...11 9 AV KYRON 2006 03 8930 14 4 AV SYSTEM SPECIFICATIONS AND CONTROL ...

Page 587: ...11 10 KYRON 2006 03 8930 14 AV Function Settings on Touch Panel Example ...

Page 588: ...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 589: ... 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 590: ...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 591: ...01 6 KYRON 2006 03 3650 01 DC 5 SPEED 2 AUTOMATIC TRANSMISSION DC 5 SPEED APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View ...

Page 592: ... 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 593: ...01 8 KYRON 2006 03 3650 01 DC 5 SPEED Specifications ...

Page 594: ...01 9 DC 5 SPEED KYRON 2006 03 3650 01 ...

Page 595: ... 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 596: ... 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 597: ...01 12 KYRON 2006 03 3650 01 DC 5 SPEED General Characteristics ...

Page 598: ...SPEED KYRON 2006 03 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 599: ...01 14 KYRON 2006 03 3650 01 DC 5 SPEED Shifting Elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 600: ...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 601: ...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 602: ...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 603: ...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 604: ...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 605: ...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 606: ...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 607: ...echanism 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 TSM54...

Page 608: ...02 4 KYRON 2006 03 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications 2 Tightening Torque ...

Page 609: ...02 5 M T KYRON 2006 03 3170 01 Inside N Switch 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch ...

Page 610: ...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 611: ...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 612: ...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 613: ... 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 614: ... 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 615: ......

Page 616: ...03 3 CLUTCH KYRON 2006 03 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTTENING TORQUE ...

Page 617: ... 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 consists of the clut...

Page 618: ...03 5 CLUTCH KYRON 2006 03 3010 01 3 Functions Components of Clutch Assembly Adapter Pipe Assembly Clutch Assembly Concentric Slave Cylinder ...

Page 619: ...03 6 KYRON 2006 03 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 620: ...04 3 AXLE KYRON 2006 03 4120 01 1 AXLE SPECIFICATIONS Specification Torque Gear ratio Type Size Offset Housing Specification Capacity Length Width Weight ...

Page 621: ...tion 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 622: ...W The 2007 Kyron is equipped with different types of front and rear axles As the IOP axle is installed AWD All Wheel Driver transfer case and the switchable engine mount are installed This vehicle is equipped with front IOP axle system and IRDA with new technology ...

Page 623: ...e vibration is reduced There is not much different in the rear axle system However as EAS and EPB with new technology are adopted suspension specification and rear axle module have been changed IOP axle Front Axle Conventional axle Non IOP axle 5 link type rear axle semi floating type integrated type Independent suspension type rear axle IRDA Rear Axle ...

Page 624: ...ions Before performing the wheel alignment unload all the items from the vehicle When setting the wheel alignment tools the above adjustment values should be followed The difference of the front camber and the caster at both ends should be below 30 0 5 1 2 3 ...

Page 625: ...entional 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 communicatio...

Page 626: ...06 4 KYRON 2006 03 3240 01 T C 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 627: ...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 628: ...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 629: ... 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 630: ...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 631: ...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 632: ...06 10 KYRON 2006 03 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 633: ...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 634: ... 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 635: ... 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 636: ......

Page 637: ...07 3 PROPELLER SHAFT KYRON 2006 03 3310 00 3310 00 PROPELLER SHAFT 1 SPECIFICATION ...

Page 638: ... 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 absorbs its vib...

Page 639: ...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 640: ...07 6 KYRON 2006 03 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 641: ...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 642: ...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 643: ...AFT KYRON 2006 03 3310 06 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 644: ...06 03 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 645: ... 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 646: ...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 647: ...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 648: ...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 649: ...08 3 SUSPENSION KYRON 2006 03 4411 01 1 FRONT SUSPENSION SPECIFICATIONS 2 REAR SUSPENSION SPECIFICATIONS 4411 01 SUSPENSION ...

Page 650: ...ernal 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 susp...

Page 651: ...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 652: ...09 5 ESP KYRON 2006 03 4890 01 3 SECTIONAL DRAWING Front Disc Brake Rear Disc Brake ...

Page 653: ... 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 654: ...09 7 ESP KYRON 2006 03 4890 01 2 BRAKE SYSTEM SPECIFICATIONS ...

Page 655: ...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 656: ...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 657: ... 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 658: ...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 Brake Force Distri...

Page 659: ...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 660: ...09 13 ESP KYRON 2006 03 4890 01 New T C Without speed sensor ...

Page 661: ...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 662: ... 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 663: ...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 664: ......

Page 665: ...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 666: ...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 667: ...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 668: ...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 669: ...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 670: ... 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 671: ...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 672: ...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 673: ...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 674: ......

Page 675: ...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 676: ...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 677: ...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 678: ...09 31 ESP KYRON 2006 03 4890 01 4 Input Output Signals for HDC Operation ...

Page 679: ...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 680: ......

Page 681: ...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 682: ...09 35 ESP KYRON 2006 03 4890 01 Comparison with ABS System ABS ESP Indicator ESP OFF Switch HDC Indicator HDC Switch ActiveWheelSpeedSensor ...

Page 683: ...09 36 KYRON 2006 03 4890 01 ESP 7 INPUT OUTPUT SIGNALS FOR HDC OPERATION Input Output of ESP System ...

Page 684: ...09 37 ESP KYRON 2006 03 4890 01 8 ESP HYDRAULIC CIRCUIT DIAGRAM ...

Page 685: ...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 686: ...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 687: ...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 688: ...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 689: ...09 42 KYRON 2006 03 4890 01 ESP New Transfer Case Without Speed Sensor ...

Page 690: ...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 691: ... 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 692: ...3 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 693: ...09 46 KYRON 2006 03 4890 01 ESP 13 INPUT AND OUTPUT DIAGRAM OF ABS Input Output of ABS without TPMS ...

Page 694: ...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 695: ...et 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 increases...

Page 696: ... 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 ci...

Page 697: ...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 pressure ...

Page 698: ...mbly 4 Tie rod end 2 Power steering return pipe 5 Power steering gear box pipe 3 Power steering high pressure hose and pipe 6 Power steering gear box assembly 1 POWER STEERING SYSTEM LAYOUT Feed pipe nut Steering gear box mounting bracket bolts 14 mm 2EA 30 40 Nm ...

Page 699: ...10 5 STEERING KYRON 2006 03 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 700: ...10 6 KYRON 2006 03 4610 00 STEERING Installation Drawing of SSPS Pipe bracket bolt 10 mm Pipe mounting nut Pipe bracket bolt 10 mm Gear box mounting bolt ...

Page 701: ...10 7 STEERING KYRON 2006 03 4610 00 Components Tie rod end Steering gear box Lower shaft Steering wheel Column shaft ...

Page 702: ...10 8 KYRON 2006 03 4610 00 STEERING Steering wheel Column shaft Lower shaft Steering gear box ...

Page 703: ...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 704: ...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 705: ...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 706: ...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 707: ...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 708: ...10 14 KYRON 2006 03 4610 00 STEERING 3 CIRCUIT DIAGRAM ...

Page 709: ...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 710: ...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 711: ...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 712: ...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 713: ...01 4 KYRON 2006 03 6810 15 AIR CONDITIONER 1 VENTILATION SYSTEM COMPONENTS Locations of Vents Air Duct ...

Page 714: ...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 715: ...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 716: ...01 7 AIR CONDITIONER KYRON 2006 03 6810 15 2 Components ...

Page 717: ...01 8 KYRON 2006 03 6810 15 AIR CONDITIONER 4 PTC HEATER AND FFH HEATER LAYOUT 1 PTC HEATER ASSEMBLY LAYOUT 2 FFH HEATER ASSEMBLY LAYOUT ...

Page 718: ... 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 719: ...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 720: ...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 721: ...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 722: ... 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 723: ...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 724: ...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 725: ...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 726: ... 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 727: ...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 728: ...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 729: ...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 730: ...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 731: ...01 22 KYRON 2006 03 6810 15 AIR CONDITIONER 2 Exploded View ...

Page 732: ...01 23 AIR CONDITIONER KYRON 2006 03 6810 15 ...

Page 733: ...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 734: ...01 25 AIR CONDITIONER KYRON 2006 03 6810 15 3 SPECIFICATIONS ...

Page 735: ...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 736: ...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 737: ...01 28 KYRON 2006 03 6810 15 AIR CONDITIONER 4 Circuit Diagram ...

Page 738: ...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 739: ...01 30 KYRON 2006 03 6810 15 AIR CONDITIONER 6 Specification Water Pump 7 Characteristic Curve of Water Pump 12 V ...

Page 740: ...01 31 AIR CONDITIONER KYRON 2006 03 6810 15 8 Function Diagram 9 Switching Diagram According to Temperature Changes ...

Page 741: ...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 742: ...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 743: ...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 744: ...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 745: ......

Page 746: ...N 2006 03 8810 03 AIR BAG 2 AIR BAG SYSTEM LOCATIONS AND RELATED 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 COMPONENTS ...

Page 747: ... 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 748: ...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 749: ...02 11 AIR BAG KYRON 2006 03 8810 03 ...

Page 750: ...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 751: ...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 752: ...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 753: ...02 15 AIR BAG KYRON 2006 03 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 754: ... 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 755: ... 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 756: ...02 18 KYRON 2006 03 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 757: ...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 758: ...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 759: ...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 760: ...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 761: ...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 762: ...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 763: ...02 25 AIR BAG KYRON 2006 03 8810 03 8 AIR BAG ELECTRICAL WIRING DIAGRAM ...

Page 764: ...03 3 SEAT KYRON 2006 03 7410 01 7410 01 SEAT AND SEAT BELT 1 SEAT OVERVIEW 1 FRONT SEAT DRIVER S SEAT Reclining Motor Lumbar support lever ...

Page 765: ...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 766: ...03 5 SEAT KYRON 2006 03 7410 01 Seat cushion angle adjusting lever rear Seat height control switch Seat cushion angle adjusting lever front Reclining lever Sliding lever ...

Page 767: ...03 6 KYRON 2006 03 7410 01 SEAT Location of Seat Position With Memory Unit Bottom of Driver Seat SPWM unit ...

Page 768: ...03 7 SEAT KYRON 2006 03 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 769: ...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 770: ...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 771: ...6 03 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 772: ... 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 773: ...04 5 SUNROOF KYRON 2006 03 7340 01 3 TROUBLE DIAGNOSIS ...

Page 774: ...04 6 KYRON 2006 03 7340 01 SUNROOF 1 SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Sunroof Switch ...

Page 775: ... 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 776: ...04 8 KYRON 2006 03 7340 01 SUNROOF 3 SUNROOF CIRCUIT DIAGRAM ...

Page 777: ...NO DATA ...

Page 778: ...NO DATA ...

Page 779: ...07 3 BODY REPAIR KYRON 2006 03 4110 01 4110 01 BODY REPAIR 1 DIMENSIONS ...

Page 780: ...07 4 KYRON 2006 03 4110 01 BODY REPAIR 2 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 781: ...07 5 BODY REPAIR KYRON 2006 03 4110 01 2 5 Link System Lifting Point Dotted Circles ...

Page 782: ...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 783: ... 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 784: ...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 785: ...07 9 BODY REPAIR KYRON 2006 03 4110 01 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 786: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 787: ......

Page 788: ...0 3 ECU GASOLINE KYRON 2006 03 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 789: ...0 4 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 790: ...0 5 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 791: ...0 6 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 792: ...0 7 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 793: ...0 8 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 794: ...0 9 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 795: ...0 10 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 796: ...0 11 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 797: ...0 12 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 798: ...0 13 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 799: ...0 14 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 800: ...0 15 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 801: ...0 16 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 802: ...0 17 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 803: ...0 18 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 804: ...0 19 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 805: ...0 20 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 806: ...0 21 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 807: ...0 22 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 808: ...0 23 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 809: ...0 24 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 810: ...0 25 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 811: ...0 26 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 812: ...0 27 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 813: ...0 28 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 814: ...0 29 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 815: ...0 30 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 816: ...0 31 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 817: ...0 32 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 818: ...0 33 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 819: ...0 34 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 820: ...0 35 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 821: ...0 36 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 822: ...0 37 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 823: ...0 38 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 824: ...0 39 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 825: ...0 40 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 826: ...0 41 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 827: ...0 42 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 828: ...0 43 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 829: ...0 44 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 830: ...0 45 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 831: ...0 46 KYRON 2006 03 0000 00 ECU GASOLINE ...

Page 832: ...0 47 ECU GASOLINE KYRON 2006 03 0000 00 ...

Page 833: ......

Page 834: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 835: ......

Page 836: ...0 3 ECU DIESEL KYRON 2006 03 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 837: ...0 4 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 838: ...0 5 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 839: ...0 6 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 840: ...0 7 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 841: ...0 8 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 842: ...0 9 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 843: ...0 10 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 844: ...0 11 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 845: ...0 12 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 846: ...0 13 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 847: ...0 14 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 848: ...0 15 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 849: ...0 16 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 850: ...0 17 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 851: ...0 18 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 852: ...0 19 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 853: ...0 20 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 854: ...0 21 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 855: ...0 22 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 856: ...0 23 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 857: ...0 24 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 858: ...0 25 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 859: ...0 26 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 860: ...0 27 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 861: ...0 28 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 862: ...0 29 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 863: ...0 30 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 864: ...0 31 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 865: ...0 32 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 866: ...0 33 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 867: ...0 34 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 868: ...0 35 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 869: ...0 36 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 870: ...0 37 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 871: ...0 38 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 872: ...0 39 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 873: ...0 40 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 874: ...0 41 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 875: ...0 42 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 876: ...0 43 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 877: ...0 44 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 878: ...0 45 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 879: ...0 46 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 880: ...0 47 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 881: ...0 48 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 882: ...0 49 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 883: ...0 50 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 884: ...0 51 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 885: ...0 52 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 886: ...0 53 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 887: ...0 54 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 888: ...0 55 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 889: ...0 56 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 890: ...0 57 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 891: ...0 58 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 892: ...0 59 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 893: ...0 60 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 894: ...0 61 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 895: ...0 62 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 896: ...0 63 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 897: ...0 64 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 898: ...0 65 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 899: ...0 66 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 900: ...0 67 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 901: ...0 68 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 902: ...0 69 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 903: ...0 70 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 904: ...0 71 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 905: ...0 72 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 906: ...0 73 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 907: ...0 74 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 908: ...0 75 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 909: ...0 76 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 910: ...0 77 ECU DIESEL KYRON 2006 03 0000 00 ...

Page 911: ...0 78 KYRON 2006 03 0000 00 ECU DIESEL ...

Page 912: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 913: ......

Page 914: ...0 3 BRAKE KYRON 2006 03 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 915: ...0 4 KYRON 2006 03 0000 00 BRAKE ...

Page 916: ...0 5 BRAKE KYRON 2006 03 0000 00 ...

Page 917: ...0 6 KYRON 2006 03 0000 00 BRAKE ...

Page 918: ...0 7 BRAKE KYRON 2006 03 0000 00 ...

Page 919: ...0 8 KYRON 2006 03 0000 00 BRAKE ...

Page 920: ...0 9 BRAKE KYRON 2006 03 0000 00 ...

Page 921: ...0 10 KYRON 2006 03 0000 00 BRAKE ...

Page 922: ...0 11 BRAKE KYRON 2006 03 0000 00 ...

Page 923: ...0 12 KYRON 2006 03 0000 00 BRAKE ...

Page 924: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 925: ......

Page 926: ...0 3 AIR BAG KYRON 2006 03 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 927: ...0 4 KYRON 2006 03 0000 00 AIR BAG ...

Page 928: ...0 5 AIR BAG KYRON 2006 03 0000 00 ...

Page 929: ...0 6 KYRON 2006 03 0000 00 AIR BAG ...

Page 930: ...0 7 AIR BAG KYRON 2006 03 0000 00 ...

Page 931: ...0 8 KYRON 2006 03 0000 00 AIR BAG ...

Page 932: ...0 9 AIR BAG KYRON 2006 03 0000 00 ...

Page 933: ...0 10 KYRON 2006 03 0000 00 AIR BAG ...

Page 934: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 935: ......

Page 936: ...0 3 CCCS KYRON 2006 03 0000 00 0000 00 CCCS 1 CCCS ...

Page 937: ...0 4 KYRON 2006 03 0000 00 CCCS ...

Page 938: ...0 5 CCCS KYRON 2006 03 0000 00 ...

Page 939: ...0 6 KYRON 2006 03 0000 00 CCCS ...

Page 940: ...0 7 CCCS KYRON 2006 03 0000 00 ...

Page 941: ...0 8 KYRON 2006 03 0000 00 CCCS ...

Page 942: ...0 9 CCCS KYRON 2006 03 0000 00 ...

Page 943: ...0 10 KYRON 2006 03 0000 00 CCCS ...

Page 944: ...0 11 CCCS KYRON 2006 03 0000 00 ...

Page 945: ...0 12 KYRON 2006 03 0000 00 CCCS ...

Page 946: ...0 13 CCCS KYRON 2006 03 0000 00 ...

Page 947: ...0 14 KYRON 2006 03 0000 00 CCCS ...

Page 948: ...0 15 CCCS KYRON 2006 03 0000 00 ...

Page 949: ...0 16 KYRON 2006 03 0000 00 CCCS ...

Page 950: ...0 17 CCCS KYRON 2006 03 0000 00 ...

Page 951: ...0 18 KYRON 2006 03 0000 00 CCCS ...

Page 952: ...0 19 CCCS KYRON 2006 03 0000 00 ...

Page 953: ...0 20 KYRON 2006 03 0000 00 CCCS ...

Page 954: ...0 21 CCCS KYRON 2006 03 0000 00 ...

Page 955: ...0 22 KYRON 2006 03 0000 00 CCCS ...

Page 956: ...0 23 CCCS KYRON 2006 03 0000 00 ...

Page 957: ...0 24 KYRON 2006 03 0000 00 CCCS ...

Page 958: ...0 25 CCCS KYRON 2006 03 0000 00 ...

Page 959: ...0 26 KYRON 2006 03 0000 00 CCCS ...

Page 960: ...0 27 CCCS KYRON 2006 03 0000 00 ...

Page 961: ......

Page 962: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 963: ......

Page 964: ...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 965: ...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 966: ...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 967: ...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 968: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 969: ......

Page 970: ...0 3 FFH KYRON 2006 03 0000 00 0000 00 FFH 1 FFH ...

Page 971: ...0 4 KYRON 2006 03 0000 00 FFH ...

Page 972: ...0 5 FFH KYRON 2006 03 0000 00 ...

Page 973: ...0 6 KYRON 2006 03 0000 00 FFH ...

Page 974: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 975: ......

Page 976: ...0 3 P TRUNK KYRON 2006 03 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 977: ...0 4 KYRON 2006 03 0000 00 P TRUNK ...

Page 978: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 979: ......

Page 980: ...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 981: ...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 982: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 983: ......

Page 984: ...0 3 STICS KYRON 2006 03 0000 00 0000 00 STICS 1 STICS ...

Page 985: ...0 4 KYRON 2006 03 0000 00 STICS ...

Page 986: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 987: ......

Page 988: ...0 3 TCU KYRON 2006 03 0000 00 0000 00 TCU 1 TCU ...

Page 989: ...0 4 KYRON 2006 03 0000 00 TCU ...

Page 990: ...0 5 TCU KYRON 2006 03 0000 00 ...

Page 991: ...0 6 KYRON 2006 03 0000 00 TCU ...

Page 992: ...0 7 TCU KYRON 2006 03 0000 00 ...

Page 993: ...0 8 KYRON 2006 03 0000 00 TCU ...

Page 994: ...0 9 TCU KYRON 2006 03 0000 00 ...

Page 995: ...0 10 KYRON 2006 03 0000 00 TCU ...

Page 996: ...0 11 TCU KYRON 2006 03 0000 00 ...

Page 997: ...0 12 KYRON 2006 03 0000 00 TCU ...

Page 998: ...0 13 TCU KYRON 2006 03 0000 00 ...

Page 999: ...0 14 KYRON 2006 03 0000 00 TCU ...

Page 1000: ...0 15 TCU KYRON 2006 03 0000 00 ...

Page 1001: ...0 16 KYRON 2006 03 0000 00 TCU ...

Page 1002: ...0 17 TCU KYRON 2006 03 0000 00 ...

Page 1003: ...0 18 KYRON 2006 03 0000 00 TCU ...

Page 1004: ...0 19 TCU KYRON 2006 03 0000 00 ...

Page 1005: ......

Page 1006: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 1007: ......

Page 1008: ...0 3 TGS LEVER KYRON 2006 03 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 1009: ...0 4 KYRON 2006 03 0000 00 TGS LEVER ...

Page 1010: ...0 5 TGS LEVER KYRON 2006 03 0000 00 ...

Page 1011: ...0 6 KYRON 2006 03 0000 00 TGS LEVER ...

Reviews:

No comments

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands