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SSANGYONG KYRON 2006, Repair Manual, Page: 1061 / 1105

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SSANGYONG KYRON 2006 Repair Manual Download Page 1061

BODY REPAIR

4610 / 4620

TABLE OF CONTENTS

BODY REPAIR ......................................................... 3

1. Dimensions ......................................................................... 3

2. Jack-up points ..................................................................... 4

3. Design changes for improving NVH performance .............. 6

4. Frame ................................................................................ 10

5. Body repair ....................................................................... 21

Summary of Contents for KYRON 2006

Page 1: ...GENERAL INFORMATION 00 TABLE OF CONTENTS DIMENSIONS 3 SPECIFICATIONS 4 VEHICLE IDENTIFICATION 6 MAINTENANCE SCHEDULE 9 RECOMMENDED FLUIDSAND LUBRICANTS 11 ...

Page 2: ......

Page 3: ...GENERAL CHANGED BY EFFECTIVE DATE AFFECTED VIN GENERALINFORMATION KYRON SM 2005 09 3 00 Optional Unit mm DIMENSIONS Top View Side View Front View Rear View ...

Page 4: ... 660 1 880 1 740 1 755 with roof rack 2 530 2 530 2WD 1 920 4WD 2 028 2WD 1 893 4WD 2 001 Diesel 75 D20DT 4 17 5 1 1 998 DOHC 141 ps 4 000 rpm 141 ps 4 000 rpm 310 Nm 1 800 2 750 rpm 310 Nm 1 800 2 750 rpm 750 20 rpm Water cooled forced circulation 11 5 Gear pump forced circulation 8 2 Turbocharger air cooled Semi Remote control floor change type 4 315 2 475 1 536 1 000 0 807 3 919 Electronic 5 sp...

Page 5: ...r Conditioner Electrical 3 951 2 423 1 486 1 000 0 833 3 147 1 930 Part time Planetary gear type 1 000 1 2 483 1 Hydraulic type Dry single diaphragm type Rack and pinion 36 2 32 4 Ball joint type Build up type 4 27 3 54 Semi floating type Independent type Build up type 4 27 3 54 Tandem type Vacuum assisted booster type Disc type Drum disc Cable type internal expansion Wishbone coil spring 5 link c...

Page 6: ...ON The chassis number is stamped on the frame behind the front right tire Engine Number D27DT The engine number is stamped on the lower area of cylinder block in the intake manifold side Certification Label The certification label is located on the driver s door sill Chassis Number Engine Number D20DT ...

Page 7: ... Kyron 0 Body Type 0 5 door A Trim Level A Standard B Deluxe C Super deluxe 1 Restraint System 0 No seatbelts 1 3 point seatbelts 2 2 point seatbelt K Engine Type 9 3199cc In line 6 cylinders Gasoline E32 K 1998cc common rail direct injection D20DT F 2696cc common rail direct injection D27DT S Check Digit S All area except North America 5 Model Year 3 2003 4 2004 5 2005 P Plant Code P Pyungtaek pl...

Page 8: ... area of cylinder block in intake manifold side 4 Manual Transmission Number The transmission label is affixed on the upper area of clutch housing 5 Automatic Transmission Number The transmisson label is affixed on the right area of trans mission housing 6 Transfer Case Number The transfer case label is affixed on the transfer case housing D27DT D20DT ...

Page 9: ...tioner Filter 1 Pollutant area or off road driving extended air condi tioner or heater operation Sever Conditions in Air Cleaner Element 1 Pollutant area or off road driving Initial change 5 000 km change every 10 000 km or 12 months But shorten the service interval under severe conditions Change every 60 000 km or 3 years And inspect and replen ish as necessary Inspect 10 000 km change every 150 ...

Page 10: ... or 12 months But change every 60 000 km under severe conditions Inspect 15 000 km change every 60 000 km Frequent check of oil leak Inspect 15 000 km change every 60 000 km Frequent check of oil leak Inspect frequently change every 30 000 km Inspect frequently change every 30 000 km Change every 10 000 km But shorten the service interval under severe conditions Front Rear Severe Conditions in Eng...

Page 11: ... DOT4 Ssangyong genuine oil ATF DEXRON III RECOMMENDED FLUIDS AND LUBRICANTS Engine Oil Engine Coolant Automatic Transmission Fluid Manual Transmission Fluid Transfer Case Fluid Axle Oil Brake Clutch Fluid Power Steering Fluid D20DT D27DT Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels ...

Page 12: ...MEMO ...

Page 13: ... and link 33 2 Front and rear propeller shaft 36 3 Transmission assembly 38 4 Replacing the o ring on parking pawl guide sleeve 42 5 Disassembly and reassembly DC 5 SPEED A T 46 6 Valve body 65 3650 3660 3110 SPECIAL TOOLS AND EQUIPMENT 68 VALVE BODY 72 HYDRAULIC CIRCUIT 80 1 Hydraulic circuit diagram 80 2 Hydraulic circuit 85 3 Adapter plug 91 4 Valve body 93 TCU Transmission Control Unit 99 TROU...

Page 14: ...tor 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 operat ing pressure to provide proper shifting in relation to engine power This...

Page 15: ...icle starts from 2nd gear forward and reverse to achieve smooth starting on the slippery road Downshift Manual Mode Upshift Manual Mode Selector Lever 1 2 3 4 D 1 2 3 4 D The shiftable gear is up by one step as the lever is moved to right direction The shiftable gear is down by one step as the lever is moved to left direction When the gear selector lever cannot be moved from P position to other po...

Page 16: ...AUTOTRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 3650 1 APPEARANCE AUTOMATIC TRANSMISSION DC 5 SPEED With Torque Converter Without Torque Converter Rear View Left Side ...

Page 17: ...haft 4 Disc brake B1 5 Disc clutch C1 6 Disc clutch C2 This sectional drawing is based on DC 5 speed A T 2WD model 4WD model has also same structure 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 Co...

Page 18: ...P R N D 4 3 2 1 Resistance R D Resistance Operating distance Operating current Resistance Operating distance Operating current Resistance Operating distance Operating current Operating range Type Operating voltage Switch contact Switch contact D27DT 3 595 2 186 1 405 1 000 0 831 3 167 1 926 D20DT 3 951 2 423 1 486 1 000 0 833 3 147 1 93 5 Speed Automatic Transmission 2WD 580 Nm 4WD 400 Nm 76 kg 2W...

Page 19: ...ic Transmission W Winter S Standard F1 F2 4 4 4 Single side friction plate Double side friction plate Single side friction plate Single side friction plate Double side friction plate Double side friction plate Item Mode switch One way clutch Planetary gear set Disc clutch Disc brake Number of planetary gear set pinion Front Center Rear C1 C2 C3 B1 B2 B3 ...

Page 20: ...n remains at 4th gear other than 4 5 shift when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Dynamic shift zone When operating the accelerator pedal the 4 3 shift is completed by kick down signal after comple tion of 4 3 shift 100 of pedal position When promptly operating the accelerator pedal the 4 3 shift is done in shaded area 93 of pedal position 4th gear 1 00...

Page 21: ...Downshift Lockup slipping Unlock open FAST OFF Dynamic shift zone 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 Dynamic shift zone When operating the accelerator pedal the 4 3 shift is completed by kick down signal after comple tion of 4 3 shift 100...

Page 22: ...ansmission fluid temperature is too low the shifting point gets delayed in full throttle and kick down Improves driving performance When starting the engine with cycling the ignition switch OFF and ON due to transmission trouble the selector lever should be placed in P position If starting the engine with selector lever N position the lever should be moved into P position The selector valve change...

Page 23: ...ake B1 disk assembly C1 Disk clutch assembly C2 Disk clutch assembly C3 Disk clutch assembly Brake B2 disk assembly 3 POWER FLOW Sectional View Shifting Elements Gear 1 2 3 4 5 P N 1 P N 2 R 1 R 2 F2 z z F1 z z z B3 z z B2 z z z B1 z 3 z 3 z z 3 C3 z 3 z 3 z z z z z z C2 z z z C1 z z z z z 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 24: ...gear carrier Clockwise rotation with reduced speed 5 Center ring gear Clockwise rotation 6 Center sun gear Locked by B2 Rotation with reduced speed 7 Output shaft Clockwise rotation 16 Torque converter lockup clutch A Engine speed B Transmission input shaft C 1st gear ratio D 2nd gear ratio E 3rd gear ratio F Locking elements H Rear planetary gear set L Stator M Center planetary gear set P Impelle...

Page 25: ... P Impeller T Turbine wheel V Front planetary gear set 2nd Gear D20DT 2 423 D27DT 2 186 1 Input shaft Clockwise rotation 2 Sun gear and planetary gear carrier Clockwise rotation by C1 activation 3 Rear ring gear Clockwise rotation 4 Rear sun gear Locked by F2 and B2 Planetary gear carrier Rotation with reduced speed 5 Center ring gear Clockwise rotation 6 Sun gear Locked by B2 Planetary gear carri...

Page 26: ...ter planetary gear set P Impeller T Turbine wheel V Front planetary gear set 3rd Gear D20DT 1 486 D27DT 1 405 1 Input shaft Clockwise rotation 2 Front ring gear Clockwise rotation 3 Center ring gear Clockwise rotation by clutch 2 activation direct connection 4 Center sun gear Locked by B2 Planetary gear carrier Clockwise rotation with reduced speed 5 Output shaft Clockwise rotation F2 F1 B3 B2 z B...

Page 27: ...Clockwise rotation direct connection 5 Rear ring gear Clockwise rotation 6 Rear sun gear Rotation by ring gear and planetary gear carrier direct connection 7 Center sun gear Clockwise rotation by C3 activation 8 Planetary gear carrier Clockwise rotation by center sun gear and ring gear direct connection 9 Output shaft Clockwise rotation 16 Torque converter lockup clutch A Engine speed B Planetary ...

Page 28: ...e rotation because rear planetary gear carrier rotates faster than rear ring gear increased speed 6 Center sun gear Clockwise rotation with increased speed by clutch C3 activation 7 Center planetary gear carrier Clockwise rotation increased speed 8 Output shaft Clockwise rotation increased speed 16 Torque converter lockup clutch A Engine speed B Transmission input shaft C 1st gear ratio D 2nd gear...

Page 29: ...ckwise rotation 6 Rear planetary gear carrier Locked by B3 7 Rear sun gear and center sun gear Counterclockwise rotation increased speed 8 Center ring gear Locked by B3 9 Center planetary gear carrier Counterclockwise rotation reduced speed 10 Output shaft Counterclockwise rotation 16 Torque converter lockup clutch A Engine speed B Transmission input shaft C 1st gear ratio D 2nd gear ratio E Locki...

Page 30: ...3 6 Rear sun gear and center sun gear Counterclockwise rotation increased speed 7 Center planetary gear carrier Counterclockwise rotation reduced speed 8 Output shaft Counterclockwise rotation 16 Torque converter lockup clutch A Engine speed B Transmission input shaft C 1st gear ratio D 2nd gear ratio E Locking elements H Rear planetary gear set L Stator M Center planetary gear set P Impeller T Tu...

Page 31: ...AN 2 Turning on the selector lever indicator while tail lamp is turning on 3 Turning on the back up lamp during reverse driving 4 Operating the parking reverse lock system Terminals Use For Back up lamp power supply Ignition power Selector lever unit power CAN LO CAN HI Brake switch signal Ground Self diagnosis connector Tail lamp relay Remark Connected to ABS ESP HECU engine ECU TCU instrument pa...

Page 32: ...EFFECTIVE DATE AFFECTED VIN 20 3650 Ignition switch Tail lamp relay Ignition switch TCU terminal A2 29 Self diagnostic 10 Brake switch Backup lamp Selector lever control unit Instrument panel HECU ECU Circuit Diagram 2 1 7 4 5 6 8 3 9 B1 41 B2 40 ...

Page 33: ...m R Reverse driving This position is used to reverse the vehicle N Neutral starting and towing position The engine can be started in this position And this position is used in temporary stop Depress the brake pedal for safty Selector lever moves only when the brake pedal is depressed Selector lever can be moved withoutdepressingthebrake pedal however for safety reasons the brake pedal should be de...

Page 34: ...ift 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 operation The vehicle can starts off with 2nd reverse gear gear ratio 1 92 1 93 when the W mode is selected It is very useful on icy and slippery road However in this case the W switch should be selected before placing the selector lever to...

Page 35: ...ening torque 4 8 Nm Tightening torque 4 8 Nm Tightening torque 4 8 Nm Connection Between Selector Lever and A T Tighten the bolts to the specified tightening torques as shown in the figure so that the selector lever position should be input correctly The transmission range lever and gear selector lever P R N D should be positioned in N position ...

Page 36: ...torque converter converts the mechanical energy from engine to hydraulic energy and the turbine connected to transmission input shaft converts this hydraulic energy to mechanical energy again The stator between pump and turbine increases the output torque from turbine by converting the flowing direction The stator has a torque converter area that changes the flowing direction and a fluid coupling ...

Page 37: ...e train with regard to its vibration behaviors The task of the electronic transmission control is there fore to close the clutch in all driving situations relevant to fuel consumption if possible and ensure that the engine vibrations are isolated from the drive train The characteristic curves shown in the diagram illus trate the different operating states of the torque con verter lockup clutch in ...

Page 38: ...ncreased the lockup clutch regulating valve moves up and the working pressure is applied to lockup clutch In its regulating position slipping torque converter lockup clutch pressurized a reduced volume of lubricating oil flows through the annular passage bypassing the torque converter and passing direct through the oil cooler into the transmission The rest of the lubricating oil is directed via th...

Page 39: ... down ratio Sun gear locked Ring gear driving clockwise Planet gears driven rotating clockwise Planet carrier driven revolving clockwise Direction reversal and step down ratio Planet carrier locked Sun gear driving clockwise Planet gears driven counterclockwise Ring gear driven counterclockwise Gear ratio teeth of sun gear teeth of ring gear Relatively high step down ratio Relatively low step down...

Page 40: ... gear set is thus locked and turns as a closed unit If the multiple disc clutch C2 is actuated via the piston C2a the piston compresses the disc set The ring gear V4 of the front planetary gear set is locked with the ring gear M4 of the middle planetary gear set via the externally toothed disc carrier C2b and the middle planet carrier M3 on which the internally toothed discs are seated Ring gear V...

Page 41: ...2 a number of locking elements 3 and a cage 4 for these locking elements If the inner race 2 of the freewheel is locked and the outer race 1 turns in direction A the locking elements 3 adopt a diagonal position on account of their special contours allowing the freewheel function The outer race 1 slides over the locking elements 3 with negligible friction If the rotation of the outer race 1 changes...

Page 42: ...efore pushed against the parking lock gear 6 If the tooth of the parking lock pawl 4 does not engage in a tooth space when the vehicle is stationary but rather touches a tooth of the parking lock gear 6 the cone 3 is pre tensioned by the spring 2 and positioned ready for operation If the parking lock gear 6 continues to turn the parking lock pawl 4 engages in the next tooth space To prevent damage...

Page 43: ...ously out of the gear sets returns through the opening 2 into the oil chamber If the oil level rises the oil forces the float 1 against the housing The float separates the oil chamber from the gear set chamber The lubricating oil which escapes further from the gear sets is thrown against the housing wall by the rotating parts and flows now through the upper opening arrow back into the oil chamber ...

Page 44: ... the oil temperature is approx 80 C with a scanner apply the parking brake Selector lever position R or D 4 Check the oil level with oil dipstick while engine is run ning in P position 5 Check several times with attention and add or drain the oil as required 6 After checking and adding oil install the cap in the re verse order of removal Automatic transmission fluid capacity and specification Flui...

Page 45: ...N T C REMOVAL AND INSTALLATION 1 Place the gear selector lever at D position Release the lock and remove the knob from the selector lever 2 Remove the center console upper cover and disconnect the cigarette lighter Remove the selector lever cover 1 SELECTOR LEVER AND LINK 3 Separate the selector lever pin with a flat blade screwdriver ...

Page 46: ...650 5 Disconnect the selector lever connector unscrew the mounting bolts three hexagon bolts and remove the selector lever assembly 4 Unscrew the bolt and remove the link from the shift lever Installation Notice Disconnect Connector Remove Bolts 3 Shift rod mounting nut 15 23 Nm ...

Page 47: ...FFECTED VIN AUTOTRANSMISSION KYRON SM 2005 09 35 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 6 Install in the reverse order of removal Make sure the selector lever and the shift lever are at the same position ...

Page 48: ...ect the negative cable from battery Front Propeller Shaft Transfer Case Side Front Propeller Shaft Preceding Work 2 FRONT AND REAR PROPELLER SHAFT 1 Before removing the front and rear propeller shaft make installation marks on the yoke and flange Tightening torque 81 89 Nm Front Propeller Shaft Axle Side Tightening torque 70 80 Nm ...

Page 49: ...7 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Rear Propeller Shaft Axle Side Rear Propeller Shaft Transfer Case Side Rear Propeller Shaft Tightening torque 81 89 Nm Tightening torque 70 80 Nm Rear Propeller Shaft Mounting Bracket Tightening torque 85 95 Nm ...

Page 50: ...h a wrench 3 Remove the protective cover from the service hole for torque converter mounting bolts Remove six torque con verter mounting bolts while aligning them with service hole by rotating the crankshaft bolt 1 Remove the under cover from the vehicle Service hall protective cover Torque converter mounting bolt 3 TRANSMISSIONASSEMBLY ...

Page 51: ...rvice tool from the transmission 4 Unscrew the transmission mounting bolts and carefully remove the transmission with a transmission jack Be careful not to drop the torque converter when removing the automatic transmission assembly NOTICE Apply a small amount of transmission oil on the drive flange of torque converter before installation NOTICE 6 Install in the reverse order of removal ...

Page 52: ... BY EFFECTIVE DATE AFFECTED VIN 40 3650 Others Oil Cooling Pipe Outlet Oil Cooling Pipe inlet Oil Dipstick Gauge Tightening torque 25 35 Nm Tightening torque 25 35 Nm Be careful not to damage the O ring when remov ing the dipstick gauge NOTICE ...

Page 53: ...SM 2005 09 41 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Transmission Mounting Insulator and Bracket Shift Lever Link Transfer Case Assembly Cross Member Assembly Tightening torque 28 47 Nm Tightening torque 28 47 Nm Tightening torque 85 95 Nm ...

Page 54: ...o wear or hardening of O ring on the parking pawl guide sleeve the O ring should be replaced with new one Parking Pawl Guide Sleeve Once the O rings have been removed on the parking pawl guide sleeve and the guide bushing replace them with new ones NOTICE Spring Parking pawl guide Sleeve Rubber O ring Snap ring Snap ring Parking lock lever Connected to parking lock gear Guide bushing Rubber O ring...

Page 55: ...sided collar nut on output shaft Remove the color nut on output shaft with special tool and then separate the flange from the output shaft Installation Notice Bend the collar nut to lock it during installation 3 Remove the snap ring on the parking pawl guide sleeve in the transmission housing 1 Remove the rear housing cover from the automatic transmission Tightening torque 200 Nm ...

Page 56: ... DATE AFFECTED VIN 44 3650 5 Push out the parking pawl guide bushing from inside with a proper tool 4 Remove the snap ring on the parking pawl guide bushing 6 Pull up the parking lock lever and remove the parking guide sleeve parking lock lever and spring ...

Page 57: ... L E S P ST NG A CON T C 7 Replace the O rings of the parking pawl guide sleeve and bushing Guide bushing Pull up this lever to remove the parking pawl guide sleeve Keep clean when installing the O ring Open the package of new O ring just prior to installation Especially do not work with cotton gloves wearing NOTICE ...

Page 58: ...ody Assembly 1 Adapter plug 2 Drain plug 3 Fixing bolts 4 Oil filter 5 Valve body 5 1 Valve body assembly 5 2 Body assembly 5 3 Pin 5 4 Leaf spring 5 5 Bolts 5 6 Electric kit 5 7 Solenoid valve 5 8 Lifting solenoid valve 5 9 Solenoid valve 5 10 Plate spring 5 11 Screw 5 12 Screw 5 13 Bolts 6 Oil pan 7 Magnet 5 ComponentsofValveBody ...

Page 59: ...mission housing Installation Notice 2 Unscrew the oil pan 6 fixing bolts and remove the oil pan Installation Notice 3 Remove the oil filter Disassembly and Reassembly Tightening torque 4 Nm To eliminate unnecessary working time and process prepare general tools special tools and gaskets be fore starting the work The automatic transmission is very precise equipment Keep the transmission clean and t...

Page 60: ... EFFECTIVE DATE AFFECTED VIN 48 3650 4 Unscrew the bolts and remove the valve body from trans mission housing Installation Notice Tightening torque 8 Nm 5 Disassemble and reassemble the valve body assembly Refer to Valve Body page 72 section NOTE ...

Page 61: ...CH A X L E S P ST NG A CON T C Converter Housing and Transmission Housing 1 Install the transmission assembly on the workbench 2 Remove the rear extension housing from transmission housing Installation Notice Tightening torque 30 35 Nm Transmission housing Converter housing assembly Disassembly and Reassembly ...

Page 62: ...row in 12 sided collar nut on output shaft Tightening torque 200 Nm 5 Remove the rear oil seal ring 4 Unscrew the collar nut with special tool and remove the output shaft flange Installation Notice Bend the collar nut to lock it during installation 6 Remove the circlip with a circlip pliers and remove the washer ...

Page 63: ...he puller onto inner bearing race 3 Rotate the clamping pliers counterclockwise arrow direction to tighten Puller 001 589 50 33 00 P99420041B Collet chuck 140 589 06 34 00 P99360031C 3 Remove the ball bearing from transmission housing 8 Unscrew the socket bolts separate the transmission housing from converter housing Installation Notice Tightening torque 20 Nm Gently rock the transmission housing ...

Page 64: ...AUTOTRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 52 3650 Converter Housing Assembly Oil Pump Clutch C3 Clutch C2 Clutch C1 Brake B1 ...

Page 65: ... X L E S P ST NG A CON T C 1 Remove the clutch C3 from converter housing assembly Tightening torque 16 Nm 2 Remove the clutch C2 from converter housing assembly 3 Remove the clutch C1 from converter housing assembly 4 Remove the brake B1 1 Remove the bolts on brake B1 Installation Notice Disassembly and Reassembly ...

Page 66: ...remove the oil pump Installation Notice Install two bolts on the opposite side of oil pump hous ing and tap the surface of oil pump with plastic ham mer to remove it from converter housing NOTICE Install two bolts on the opposite side of disc brake B1 and tap the surface of disc brake B1 with plastic hammer to remove it from converter housing Align the dowel pin arrow on disc brake B1 and groove i...

Page 67: ... L E S P ST NG A CON T C 1 Remove the pump gears 1 2 from pump housing 2 Check the radial seal ring 3 and replace if necessary 3 Replace the O ring 4 with new one Lubricate the pump gears 1 2 before installation Place the pump gear 2 into pump housing and install the pump gear 1 onto the pump housing chamber NOTICE ...

Page 68: ...AUTOTRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 56 3650 Transmission Housing Assembly Snap Ring Brake B3 Brake B2 Parking Lock Gear Components of Selector Lever ...

Page 69: ...ch Tightening torque 16 Nm 2 Remove the snap ring from transmission housing 3 Remove the spring washer and disc pack B3 from trans mission housing 4 Remove the fixing bolts for brake B2 from transmission housing Installation Notice Disassembly and Reassembly To make the removal of snap ring 133a easier re move the disc pack B3 while compressing it Check each disc for wear and burnt out NOTICE ...

Page 70: ...3650 5 Remove the disc brake B2 from transmission housing 6 Remove the parking lock gear 7 Remove the fixing bolts for range selector lever Installation Notice 8 Remove the range selector lever rod and detent plate Tightening torque 8 Nm Check the sealing ring for damage NOTICE ...

Page 71: ...TRANSMISSION KYRON SM 2005 09 59 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 9 Remove the snap rings from parking lock pawl 10 Remove the pin from transmission housing 11 Remove the parking lock pawl from transmission housing ...

Page 72: ...AUTOTRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 60 3650 Components of Each Assembly Clutch C1 Clutch C2 Clutch C3 1b 5a ...

Page 73: ...c pack 8 Snap ring 9 Snap ring 10 Front freewheel A Oil pressure bore Clutch C2 11 Inner multiple disc carrier clutch C1 with integrated foot gear set 12 Hollow gear 13 Snap ring 14 Axial needle bearing 15 Clutch C2 and input shaft 16 Piston 17 Inner sealing ring in piston 18 Outer sealing in piston 19 Disc spring 20 Spring retainer 21 Snap ring 22 Multiple disc set 23 Snap ring Clutch C3 24 Outer...

Page 74: ...ring 5 Spring washer multiple disc pack 6 Multiple disc pack 7 Snap ring Multi disc brake B2 8 Disc carrier B2 9 Sealing ring 10 Sealing ring 11 Piston in B2 12 Sealing ring in piston guide ring 13 Sealing ring in piston guide ring 14 Piston disc spring 15 Spring plate 16 Snap ring 17 Piston guides in B2 and B3 18 O ring 19 Multiple disc pack 20 Snap ring 21 Disc spring Multi disc brake B1 Multi d...

Page 75: ...utput shaft 1 Output shaft in center gear set 2 Needle bearing 3 Teflon ring 4 Thrust washer 5 Thrust needle bearing 6 Shim 7 Circlip 8 Rear gear set 9 Thrust washer 10 Clutch C3 11 Rear hollow shaft C Oil outlet port in clutch C3 D Oil inlet port in clutch C3 Rear freewheel and rear hollow shaft 12 Hollow shaft 13 O ring 14 Snap ring 15 Freewheel 16 Inner disc carrier and rear sun gear clutch C3 ...

Page 76: ... to the measuring bridge 2 Measure the distance from measuring bridge to the ball bearing groove on mating surface with gauge b 3 Adjust the axial play E with adjusting shim ex Distance a 49 90 mm Distance b 49 00 mm Difference 0 90 mm Axial play E 0 40 mm Shim size 0 50 mm Axial play 0 3 0 5 mm 2 Install a shim Measuring bridge 126 589 04 31 00 4 Install the radial sealing with a special tool Mea...

Page 77: ... Shift Plate A Adjusting valve operating pressure adjusting valve Lubricating pressure adjusting valve 2 3 group overlap B 1 2 4 5 shift group adjusting valve shift pressure adjusting valve control valve pressure adjusting valve shift valve pressure C 3 4 shift group D Clutch lockup control valve shift valve B2 Rear Section Filter Valve ball steel Valve ball plastic Dowel pin Filter Plastic valve ...

Page 78: ... control valve Left Section Right Section 1 Valve housing 2 Selector valve 3 2 3 overlap control valve 4 Lubricating pressure control valve 5 Operating pressure control valve 6 3 4 holding pressure shift valve 7 3 4 command valve 8 3 4 shift pressure shift valve 9 3 4 overlap control valve 8 Shift valve pressure control valve 9 Torque converter lockup clutch control valve 10 2 3 shift pressure shi...

Page 79: ...alve housing Sealing plate Shift housing Before installation make sure to insert the dowel pin into correct position NOTICE Do not forget that there are 4 plastic balls and 8 steel balls in shift housing NOTICE Check the valves for damage and replace them if necessary NOTICE 3 Remove the shift housing 4 from valve housing 2 4 Remove the sealing plate 3 5 Unscrew the bolts from shift housing and va...

Page 80: ...ber Application 126 589 01 62 00 W99360220B Handle Removal installation of torque converter 116 589 06 59 00 W99360180B Fixing plate Fixing automatic transmission 140 589 12 15 00 P99360041C Drift punch Installation of sealing ring 001 589 50 33 00 P99420041B Puller Removal and installation of transmission housing ball bearing ...

Page 81: ...r Application 140 589 34 63 00 A99360030B Mounting plate Fixing automatic transmission 140 589 06 34 00 P99360031C Collet chuck Removal and installation of transmission housing ball bearing 140 589 13 43 00 P99360021C Piston puller Removal and installation of B1 B2 and B3 pistons 126 589 02 09 00 Socket Removal and installation of collar nut for output shaft ...

Page 82: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN 70 3650 Name and Part Number Application 128 589 04 31 00 W99360242C Measuring bridge Measuring the clearance between ball bearing and parking lock gear Compressor Compressing clutch and disc brake ...

Page 83: ...9 71 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Name and Part Number Name and Part Number 126 589 12 63 00 W99360282A Funnel 140 589 15 21 00 Dipstick gauge 210 589 00 71 00 P99360012C Hand pipe 140 589 49 63 00 Filling pipe Tool for ATF checking only ...

Page 84: ...late 7 Leaf spring and socket bolt 8 Solenoid valve A 1 2 4 5 shift solenoid valve B 3 4 shift solenoid valve Shift Pressure Control Solenoid Valve 9 Solenoid valve C Shift pressure control solenoid valve D Modulating pressure control solenoid valve 10 Solenoid valve E Lockup PWM solenoid valve F 2 3 shift solenoid valve VALVE BODY 7 7 7 8 9 10 A B C D E F ...

Page 85: ... solenoid valves are sealed with two O rings against the valve body The solenoid valves are pressed against the valve body by the leaf springs Characteristics of up downshift solenoid valve The solenoid valve remains energized and therefore open until the shift process is completed according to the engine and transmission conditions If a solenoid valve is energized it opens and transmits the shift...

Page 86: ...se valves control the modulating pressure and the shift pressure by applying appropriate current to solenoid valves according to driving condition of engine and transmission When the current value from TCU is high or low accordingly the regulated pressure decreases or increases Working current Operating distance Resistance 0 1 2 A 0 6 mm 5 0 0 3 Ω 23 C Solenoid valve Line pressure Drain line Regul...

Page 87: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN AUTOTRANSMISSION KYRON SM 2005 09 75 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Circuit Diagram B3 38 B5 36 B4 37 ...

Page 88: ...ting 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 step by step in order to reduce shift shocks 1 Leaf spring 2 O ring 3 Shift plate Circuit Diagram Working current Operating distance Resistance Operating range 1 5 2 0 A 0 2 mm 2 5 0 2 Ω 25 C 3 4 5 Lockup S V 11 B3 38 B9 17 ...

Page 89: ...esses the speed sensors against the transmission housing This ensures a precise distance between speed sensors and impulse rings The speed sen sor n3 detects the speed of the front sun gear and the speed sensor n2 detects the speed of the front planetary carrier If the speed sensor is defective the transmission is oper ated in emergency driving mode Below diagram shows the detection of speed senso...

Page 90: ...s means that the temperature signal is transferred to TCU when the starter lock out contact is closed The oil temperature has a considerable effect on the shifting time and therefore the shift quality By measuring the oil temperature shift operations can be optimized in all temperature ranges Oil Temperature Sensor Circuit Diagram Oil temperature sensor AD converter Start lock out switch Oil tempe...

Page 91: ... contact This opens the reed contact and the transmission control module receives an electrical signal The transmission control module activates the starter lock out relay module This closes the electrical circuit to the starter in selector lever positions P and N via the starter lock out relay module In other words when the selector lever is in driving positions the switch contact is closed and t...

Page 92: ...AUTOTRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 80 3650 1 HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC CIRCUIT ...

Page 93: ... valve 9 One way throttle valve B Shift Housing 10 Ball change over valve 11 Ball change over valve 12 Filter screen 13 Ball change over valve 14 1 2 4 5 command valve 15 1 2 4 5 holding pressure shift valve 16 1 2 4 5 shift valve 18 1 2 4 5 overlap control valve 19 Shift pressure control valve 20 Regulating pressure control valve 21 Shift valve pressure control valve 22 Lock up clutch control val...

Page 94: ...to operate the actuator The operating pressure is the highest pressure in the hydraulic system All other pressures are derived from it The operating pressure is regulated at the operating pressure control valve depending on load modulating pressure and driving range C1 C2 pressure The spring in the operating pressure control valve adjusts a minimum pressure level base pressure Lubricating Pressure...

Page 95: ...ntrol solenoid valve The height of modulating pressure is dependent on engine load by TCU It acts on the operating pressure control valve and the pressure overlap control valve It increases the operating pressure line pressure when the load is heavy Shift Pressure P s The shift pressure is adjusted at the shift pressure control solenoid valve and shift pressure control valve 4 Additional pressure ...

Page 96: ...esponsible for the up down shifts 1 2 2 1 and 4 5 5 4 It includes 1 Clutch C1 2 Brake B1 3 Command valve 4 Holding pressure shift valve 5 1 2 4 5 shift solenoid valve 6 Pressure overlap control valve 7 1 2 4 5 shift solenoid valve Shift group C2 C3 gear change 2 3 is responsible for the up down shifts 2 3 3 2 It includes 1 Clutch C2 2 Clutch C3 3 Command valve 4 Holding pressure shift valve 5 2 3 ...

Page 97: ...lve 6 The shift valve B2 27 is held in the upper position and the 3 4 command valve 6 moves towards the right At the end face of the 3 4 shift pressure shift valve 7 the operating pressure p A is replaced by shift valve pressure p SV 1 Selector valve 5 3 4 holding pressure shift valve 6 3 4 command valve 7 3 4 shift pressure shift valve 8 3 4 overlap control valve 10 Ball valve 13 Ball valve 14 1 ...

Page 98: ...d simultaneously to the opposite face of the piston B2 B2b The brake B2 begins to activate 1 Selector valve 5 3 4 holding pressure shift valve 6 3 4 command valve 7 3 4 shift valve 8 3 4 overlap control valve 10 Ball valve 13 Ball valve 14 1 2 4 5 command valve 19 Shift pressure control valve 27 B2 shift valve B2a B2 piston B2b Opposite face of B2 piston m Annular surface p A Operating pressure p ...

Page 99: ...valve 32 The pressure on the opposite face of the piston B2 B2b drops to a residual pressure The 3 4 command valve 6 moves to the left The operating pressure p A travels via the holding pressure shift valve 5 and the 3 4 command valve 6 to the piston of brake B2 B2a 1 Selector valve 5 3 4 holding pressure shift valve 6 3 4 command valve 7 3 4 shift valve 8 3 4 overlap control valve 10 Ball valve 1...

Page 100: ... holding pressure shift valve 15 The clutch C1 is unpressurized The operating pressure from brake B1 acts against the holding pressure shift valve 15 and the end face of 1 2 4 5 shift pressure shift valve 16 14 1 2 4 5 command valve 15 1 2 4 5 holding pressure shift valve 16 1 2 4 5 shift valve 18 1 2 4 5 overlap control valve 0 Return flow to oil sump p A Operating pressure p MOD Modulating press...

Page 101: ... to brake B1 from the pressure overlap control valve 18 The B1 pressure acting on the end face of shift pressure shift valve 16 is replaced by operating pressure p A The increasing shift pressure p S on clutch C1 acts on the annular surface of the pressure overlap control valve 18 and reduces the overlap pressure controlled by the pressure overlap control valve 18 It will shift at a corresponding ...

Page 102: ...sure p A is now applied to clutch C1 via the holding pressure shift valve 15 and the command valve 14 The brake B1 is disengaged unpressurized The spring of the shift pressure shift valve 16 moves it into base position 14 1 2 4 5 command valve 15 1 2 4 5 holding pressure shift valve 16 1 2 4 5 shift valve 18 1 2 4 5 overlap control valve o Return flow to oil sump p A Operating pressure p MOD Modul...

Page 103: ...UG The adapter plug is an input and output terminal assembly for TCU to control the valve body It is installed to the valve body with 7 mm bolts To prevent oil leakage two O rings are installed on the plug 1 Remove the heat shield for adapter plug wire next to exhaust tube 2 Turn the adapter plug lock counterclockwise and disconnect the plug connector ...

Page 104: ...lug 4 Place an empty container under the adapter plug and remove the adapter plug Keep the specified tightening torque 4 Nm 0 5 Nm Otherwise it may result in unnecessary replacement of electric kit in assembly due to oil leakage Do not apply an excessive force to remove the adapter plug It may cause an internal damage to electrci kit NOTICE ...

Page 105: ...P ST NG A CON T C 4 VALVE BODY Valve body can be replaced from onboard and from removed transmission Valve Body Assembly 2 3 shift solenoid valve Valve body Electric kit Lock up PWM solenoid valve Modulating pressure solenoid valve Shift pressure solenoid valve 1 2 4 5 Shift pressure solenoid valve 3 4 shift solenoid valve ...

Page 106: ...NGED BY EFFECTIVE DATE AFFECTED VIN 94 3650 1 Remove the oil pan drain plug and drain the oil completely 2 Unscrew the six oil pan bolts T30 and carefully lower the oil pan 6 3 Carefully remove the oil filter Valve Body Replacement Onboard ...

Page 107: ...E AFFECTED VIN AUTOTRANSMISSION KYRON SM 2005 09 95 3650 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 4 Unscrew the fixing bolts T30 Valve Body Assembly 5 Carefully remove the valve body from transmission housing ...

Page 108: ...ng Installation Notice 2 Unscrew the oil pan bolts and remove the oil pan Installation Notice 3 Remove the oil filter Valve Body Replacement From Removed T M Tightening torque 4 Nm To eliminate unnecessary working time and process prepare general tools special tools and gaskets be fore starting the work The automatic transmission is very precise equipment Keep the transmission clean and tighten th...

Page 109: ...remove the valve body from transmission housing Installation Notice 5 Disassemble the valve body assembly 5 1 Unscrew the socket bolts on the solenoid valve and remove the leaf springs Installation Notice 5 2 Remove the solenoid valves from the valve body Tightening torque 8 Nm Tightening torque 8 Nm The length of socket bolts vary Be careful not to mix up NOTICE ...

Page 110: ...50 5 3 Remove the electronic control module from the shift plate Make sure to install the solenoid valves in place Check the O rings and replace if necessary NOTICE Correctly align the electronic control module onto the shift plate by using two central pins when installing NOTICE ...

Page 111: ...tic converter conditions driving habits and automatic transmission oil temperature to select a shift gear 2 Down Shift When engine speed increases excessively the down shift does not occur To get an engine brake effect during downhill driving the current gear is maintained in speed control mode 3 Engine RPM Adjustment During shifting the engine torque is reduced to optimize the shift operation by ...

Page 112: ...ctor Back up lamp W S mode signal Pos ID signal Wheel speed FR FL Wheel speed RR RL Shift pattern changes Driving force control Engine torque Max Engine torque Engine power loss Engine rpm ACC pedal position Shift pattern changes Engine control status Engine torque reduction TCU EGS ground TCU EGS power P N starting recognition Diagnosis N3 speed N2 speed Start signal Sensor power supply Sensor gr...

Page 113: ... off of various solenoid valves 2 Internal pressure in transmission increases shift shock gets bigger when changing selector lever due to maximized MP and SP 3 Lockup clutch is released 2 If the shift operation cannot be activated the driver must reset the system as follows 1 Stop the vehicle and place the selector lever to P position 2 Wait for 10 seconds after stopping the engine release hydraul...

Page 114: ...re Downshift Speed control constant 2nd gear start up control Gear status in transfer case Selector lever position Odometer I P Kick down status Selected gear Shifted status Lock up clutch status Driving position Engine torque control Dangerous status changes to emergency mode when overloading dangerous conditions and internal fault exists ATF Temperature Circuit Diagram Instrument panel Selector ...

Page 115: ...essure solenoid valve Each solenoid valve voltage CAN LOW CAN HIGH Diagnostic connector pin No 11 Starter relay 13 pin plug No 3 13 pin plug No 7 13 pin plug No 13 13 pin plug No 9 13 pin plug No 8 13 pin plug No 11 13 pin plug No 12 13 pin plug No 4 13 pin plug No 1 13 pin plug No 2 13 pin plug No 10 13 pin plug No 6 ECM HECU selector lever unit instrument panel ECM HECU selector lever unit instr...

Page 116: ...N SELECTION screen and press ENTER 4 Select KYRON in VEHICLE SELECTION screen and press and press ENTER 5 Select TCU in CONTROL UNIT SELECTION screen and press ENTER 6 Select DC 5 speed transmission 7 Select SELF DIAGNOSTICS in SELECT TEST ITEM screen 8 Determine the DTC and locate the trouble cause 1 TROUBLE DIAGNOSIS WITH SCAN 100 TROUBLE CODE AND DIAGNOSIS Diagnostic Connector Choose data list ...

Page 117: ... the trouble still exists Self diagnosis Cycle the IGN switch from OFF to ON Check and replace TCU if the trouble still exists Self diagnosis Cycle the IGN switch from OFF to ON Check and replace TCU if the trouble still exists Self diagnosis with IGN ON Cycle the IGN switch from OFF to ON Check and replace TCU if the trouble still exists Self diagnosis with IGN ON Cycle the IGN switch from OFF to...

Page 118: ...ct When 1 2 or 4 5 shift solenoid valve is defective Measure the resistance of 1 2 or 4 5 shift solenoid valve turn the IGN OFF then disconnect TCU connector TCU connector terminals B12 14 B3 38 Specified value 3 8 0 2 Ω Triggered emergency mode when the defective is detected Fixed at 2nd gear in D range Check the related harness for open short and contact When 2 3 shift solenoid valve is defectiv...

Page 119: ... 2 Ω Triggered mechanical emergency mode when the defective is detected Fixed at 2nd gear in D range Check the related harness for open short and contact Measure the resistance of lockup clutch solenoid valve turn the IGN OFF then disconnect TCU connector TCU connector terminals B9 17 B3 38 Specified value 2 5 0 2 Ω Triggered emergency mode when the defective is detected Fixed at 2nd gear in D ran...

Page 120: ... short and contact Turn the IGN OFF then disconnect TCU connector Selector lever position R or D T M Measure the resistance of oil temperature sensor TCU connector terminals B7 B8 Check the related harness for open short and contact Turn the IGN OFF then disconnect TCU connector Selector lever position R or D Measure the resistance of T M oil temperature sensor TCU connector terminals B7 B8 Check ...

Page 121: ...ommunication line H and L Check instrument cluster Check the related harness for open short and contact Check CAN communication line H and L Check TCCU TOD unit Check the related harness for open short and contact Check CAN communication line H and L Check ABS ESP unit Check the related harness for open short and contact Check CAN communication line H and L Check engine ECU Check the related harne...

Page 122: ...ontact Check CAN communication line H and L Check engine ECU Check the related harness for open short and contact Check CAN communication line H and L Check engine ECU Check the related harness for open short and contact Check CAN communication line H and L Check engine ECU Check the related harness for open short and contact Check CAN communication line H and L Check engine ECU Check the related ...

Page 123: ...rt and contact Check CAN communication line H and L Check TCCU TOD unit Check the related harness for open short and contact Cycle the IGN switch from OFF to ON Check A T system again after a certain period of driving If the trouble still exists replace A T assembly To protect transmission any shift is not available Check CAN communication line H and L Check engine ECU Check the related harness fo...

Page 124: ...TED VIN 112 3650 3 REMOVAL AND INSTALLATION OF TCU Tightening torque 10 Nm 1 Disconnect the negative battery cable 2 Slide the drive s seat and fold up the carpet 3 Unscrew the two bolts 10 mm on TCU Installation Notice 4 Disconnect the TCU connect and remove theTCU ...

Page 125: ...anual transmission 3 2 Manual transmission system 5 MANUAL TRANSMISSION 10 1 Location 10 2 System components 11 3 Shifting mechanism 19 4 Diagnostic information and procedures 26 5 Removal and installation 30 6 Disassembly and reassembly 36 7 Inspection maintenance 67 8 Special tools and equipment 70 ...

Page 126: ......

Page 127: ...le engagement the independent interlock devices are installed 2 The semi remote control type gear shift mechanism is used to prevent incorrect shifting 3 To improve the shifting performance 3 piece double cone is used for 1 2 shift 5 The clutch release system is available to use CSC Concentric Slave Cylinder or Fork type according to the vehicle model GENERAL INFORMATION The helical type gear prev...

Page 128: ...r Specification Capacity Change interval Description Tightening Torque 1 Oil drain plug filler plug 2 Backup lamp switch 24 mm 3 Extension housing bolt 14 mm 4 Extension housing spring plug 27 mm 5 Neutral switch 6 Shift top cover bolt 12 mm 7 Concentric slave cylinder adapter bolt 40 50 Nm 30 40 Nm 42 57 Nm 70 100 Nm 30 40 Nm 17 26 Nm 10 16 Nm Specifications D20DT D27DT 628 3 mm 81 mm 34 7 kg m 3...

Page 129: ...E AFFECTED VIN MANUAL TRANSMISSION KYRON SM 2005 09 5 3170 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 2 MANUAL TRANSMISSION SYSTEM Neutral Switch 0 5 mm Outside N Switch Inside N Switch N Neutral Switch 0 5 mm ...

Page 130: ...ction 5 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 6 When the gear has been smoothly shifted and the vehicle speed exceeds 3km h it returns to the previous operation interval of the engine RPM In case ...

Page 131: ...r brake pedal it converts to the stand by mode and when depressing the accelerator pedal again the HDC operates again Therefore driver may maintain a desired speed by repeat ing this depressing and releasing process of the accelerator pedal When the Inclination Exceeds 20 During the HDC Operation When depressing the accelerator pedal it converts to the HDC operation stand by mode When depressing t...

Page 132: ...witch 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 along with a loud operation noise When pressing the HDC switch the green HDC indicator on the instrument panel comes on and when the HDC operates the green HDC indictor blinks with 0 5 seconds of ...

Page 133: ...e 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 None Wire CAN Kyron model with manual transmission New Rexton model with manual transmission Manufactured after 04 09 15 BODY IN after 154600 Automatic transmission Neutral Signal Input Varia...

Page 134: ...9 CHANGED BY EFFECTIVE DATE AFFECTED VIN 10 3170 MANUAL TRANSMISSION 1 LOCATION T M Assembly Center cross member transmission insulater mounting Oil filler plug Transfer case Trasmission housing bolt 14 mm 11 T M assembly Oil drain plug ...

Page 135: ... S P ST NG A CON T C Shift Fork and Rail Combinations 2 SYSTEM COMPONENTS Gear Combinations Input shaft 4th gear 3rd gear Reverse gear Counter shaft Transmission adapter Interlock plate Reverse Fork plate 5 R shift fork 1 2 shift fork 3 4 shift fork 2nd gear 1st gear Output shaft 5th gear 3 4 rail 5 R rail 1 2 rail R Idle ...

Page 136: ...MANUAL TRANSMISSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 12 3170 Sectional View ...

Page 137: ...g 4 5 R 32 Single synchro sleeve 5th R 33 Retainer ring 3 4th 34 Adapter dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Needle bearing Reverse idler 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket Bolt 30 40 Nm 41 Retainer ring Reverse idler 42 Reverse lock nut 150 195 Nm 43 Transmission adapter 44 Input shaft spacer Bearing end play 0 0 05 mm 45 Counter spacer Bearing end...

Page 138: ... reverse 6 Backup lamp switch tightening torque 30 40 Nm 7 Shift rail 3 4th 8 Interlock bolt tightening torque 40 50 Nm 9 Shift lever 10 Interlock plate 11 Shift rail 1 2nd 12 Spring pin 6 x 25 13 Shift fork 3 4th 14 Input shaft 15 Counter shaft 16 Reverse idler assembly 17 Spring pin 6 x 25 18 Spring pin 6 x 25 19 Concentric slave cylinder adapter tightening torque 10 16 Nm 8 Bond 592 loctite 6 B...

Page 139: ...verse lock plate 3 Reverse lock bolt tightening torque 8 12 Nm 4 Stopper plate 5 Air vent tightening torque 20 35 Nm 6 Lock washer 7 TGS bushing 8 Outer spring pin 9 TGS pin 10 Lock bolt tightening torque 17 26 Nm 11 Offset lever 12 Offset lever bushing 13 Rolling plunger 14 Return spring 15 Spring plug tightening torque 70 100 Nm Offset Lever Shift Rail and 5 R Gear 1 2 shift rail 5 R shift rail ...

Page 140: ...N KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 3170 Power Flows 2nd 1st gear Counter shaft 4th gear 3rd gear 2nd gear 1st gear Reverse gear 5th gear 5th gear Reverse gear 1st gear 2nd gear 3rd gear 4th gear ...

Page 141: ...UAL TRANSMISSION KYRON SM 2005 09 17 3170 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Power Flows Cont d 3rd 4th 4th gear 3rd gear 2nd gear 1st gear Reverse gear 5th gear 4th gear 3rd gear 1st gear Reverse gear 5th gear 2nd gear ...

Page 142: ...SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 3170 Power Flows Cont d 5th Reverse gear 4th gear 3rd gear 1st gear 2nd gear Reverse gear 5th gear 3rd gear Reverse gear 4th gear 2nd gear 1st gear 5th gear Reverse idler gear ...

Page 143: ...SM Interlock System Interlock system prevents the gears from meshing over two sets Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward Interlock bolt 1 2 3 4 5 R lock 3 4 1 2 5 R lock 5 R 1 2 3 4 lock Neutral 5 R select 5 R shift 5th gear disengaged Interlock plate Inner shift lever ...

Page 144: ...the selected gear from getting out of its meshed position Offset Lever and Rolling Plunger To make the next shift easier the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected 1 Offset lever 2 Shift lever 2 Gear jump out locking device It prevents the shift lever is beyond the correct shift position while shifting 3 Shi...

Page 145: ... CLUTCH A X L E S P ST NG A CON T C Backup Lamp Switch It is normal open type switch Its circuit is formed when the reverse gear is selected 3 Guiding a control direction and preventing an over stroke Offset plate Offset lever Installation Notice Sealant Bond 592 Loctite Tightening torque 30 Nm 40 Nm NOTICE ...

Page 146: ...ion It consists of synchronizer hub sleeve ring key and spring 1 2 5 R and 3 4 synchronizer are different from each other 1 3 4 and 5 R shift Single cone type 2 1 2 shift Double cone type Improving the capacity to bigger engine torque of 1 2 shift added synchronizer inner cone and middle cone Single Cone Type Double Cone Type Be careful not to mix up the 1 2 shift synchronizer sleeve with 3 4 or 5...

Page 147: ...utch gear continues to spin until friction slows it down or stops it Thus when the driver shifts into another gear he she is trying to mesh gears that may be moving at different speeds By using synchronizers the possibility of broken or damaged teeth is reduced and shifting effort is lowered 1st step 2nd step 3rd step Spline area of synchronizer ring Spline area of sleeve Synchronizer key Sleeve P...

Page 148: ... Taper roller bearing for input shaft 2 Taper roller bearing for counter shaft End Play of Taper Roller Bearing 3 Needle bearing for reverse gear with cut out area 4 Needle bearing for 5th gear A End play A 0 0 05 mm B End play B 0 0 05 mm Taper Roller Bearing Needle Bearings Use the following spacers to adjust the end play A or B between input shaft and counter shaft Specified range of end play 0...

Page 149: ...e acts as a resistance to rotating gears Lubrication Transmission oil ATF DEXRON III Initial installation for taper roller bearing and needle roller bearing lubrication for shift rail MoS2 Grease Oil drain screw Input shaft Thrust ring 1 3 4 synchronizer 1 2 synchronizer 5 R synchronizer Lock nut Counter gear assembly Head set gear 2nd gear 1st gear 5th gear Thrust washer Output shaft 3rd gear Rev...

Page 150: ...embly Remove extension adapter or case cover Check or replace damaged parts Adjust or replace clutch Add or replace with specified oil Remove extension adapter or case cover Check or replace damaged parts Remove extension adapter or case cover Check synchronizers and gears and replace damaged parts Check or replace backup switch Replace pilot bushing Adjust idle speed to specified speed Adjust or ...

Page 151: ...ears including speedometer gear Replace if necessary Clean all exposed surfaces then check for leaks Clean or replace vent or breather Check oil level Tighten as specified Clean leaking surfaces Reapply sealant Replace oil seal Improper or low transmission oil Loose bolts or other attaching parts Improper flywheel housing to engine crankshaft alignment Noisy transmission bearing Noisy gears Leakag...

Page 152: ...ing 1st Speed Gear Bearing Reverse Idler Gear Bushing Counter Shaft Front Bearing Counter Shaft Rear Bearing Counter Shaft Thrust Bearing 5th Speed Drive Gear Bearing Slip Yoke Bushing Slip Yoke Seal Speedometer Drive Driven Gears Speedometer Driven Gear Housing Input Shaft Seal 1 2 Synchronizer Assembly 3 4 Synchronizer Assembly 5th Synchronizer Assembly Application 1 Shift Hop out 2 Shift Gear C...

Page 153: ...he oil level 2 If needed add the oil through the oil level plug hole 1 3 Fully tighten the plug and check the oil leaks 4 If the oil level is up to the bottom line 5 7 mm of plug hole it is OK 2 Oil drain plug Do not check or change the oil Immediately after driving off It may cause serious hurt NOTICE If the oil level is up to the bottom line 5 7 mm of plug hole it is OK NOTICE The oil in manual ...

Page 154: ...3170 5 REMOVALAND INSTALLATION Removal and Installation Preceding Work Disconnect the battery negative cable and remove the center console Transmission housing mounting bolt 14 mm 11EA Transfer case Cross member Center Mounting insulator Oil filler plug T M assembly Oil drain plug ...

Page 155: ... two bolts 12 mm from semi remote controller Installation Notice 1 Unscrew two bolts 12 mm and remove the change lever from shift lever Installation Notice Tightening torque 12 23 Nm Tightening torque 12 23 Nm Tightening torque 40 50 Nm 4 Unscrew four bolts 17 mm and separate the rear and front propeller shafts connected to transfer case output shaft Compress the propeller shaft and bind to torsio...

Page 156: ...sconnect the air bleeder hose neutral switch connector back up lamp switch connector and transfer case connectors 7 Unscrew two bolts 14 mm at both sides and remove the transmission mounting insulator Unscrew the mount ing bolts 14 mm 2 at both sides and remove the mounting insulator bracket Mounting Insulator Bracket Tightening torque 85 95 Nm Tightening torque 85 95 Nm Tightening torque 28 47 Nm...

Page 157: ... ST NG A CON T C When installing the transfer case make sure that the bolts are facing correct direction From transmission side upper 8 From transfer case side lower 3 NOTICE 9 Disconnect the clutch oil hose from adapter 8 Unscrew eleven bolts 14 mm and remove the transfer case with a hydraulic jack Tightening torque 38 52 Nm ...

Page 158: ...HANGED BY EFFECTIVE DATE AFFECTED VIN 34 3170 10 Support the transmission housing with a hydraulic jack and unscrew eleven transmission bolts 17 mm Tightening torque 50 60 Nm 11 Carefully lower the hydraulic jack with transmission assembly ...

Page 159: ...the alignment conditions of clutch housing as follows 1 Install the magnetic holder on pressure spring 2 Alignment check for housing bore Install a dial gauge in the housing bore Note the measurement while rotating the crank shaft for one revolution 4 Check the following parts if necessary 1 Pressure plate spring assembly 2 Disc 3 Flywheel Inspection before Installation The excessively worn compon...

Page 160: ... the offset lever 1 Remove the transmission oil drain plug hexagon 14 mm and completely drain the oil Place the removed transmission on the workbench Disassembly 3 Push the semi remote lever rearward and unscrew the mounting bolts 4 with a wrench 12 mm to remove the top cover 2 Pull out the lock washer 1 and remove the TGS pin 2 Be careful not to lose the disassembled components NOTE ...

Page 161: ...move the 5 R shift fork spring pin 6 x 28 5 Remove the bolts from the extension housing with a wrench 14 mm 7 Remove the rear ball bearing with a puller and remove the speedometer driven gear 6 Remove the extension housing with a special tool Remove the offset lever and rolling plunger with the extension housing Be careful not to drop them NOTICE ...

Page 162: ...CTED VIN 38 3170 9 Spread the retainer ring and remove the 5th counter gear with a puller 1 Pull the counter gear 5th gear retainer ring out from the ring groove with a ring pliers 10 Remove the counter reverse spacer Be careful not to stiffen the retainer ring NOTICE ...

Page 163: ...E S P ST NG A CON T C 11 Remove the 5th gear retainer ring with a ring pliers 13 Remove the 5th gear and pull out the spring pin 12 Remove the thrust washer from the shaft 14 Remove the 5th gear needle bearings 2 Be careful not to lose or mix the spring pins NOTICE Be careful not to lose or mix the needle bearings NOTICE ...

Page 164: ... R gear retainer ring from the shaft with a ring pliers 17 Remove the 5 R synchronizer hub assembly the re verse gear and the shift fork at a time Store at a safe place not to be mixed with other syn chronizer rings NOTICE Store the ring with the relevant gear to prevent in correct installation NOTICE 18 Remove the counter reverse gear ...

Page 165: ...ve the counter reverse gear needle bearing 21 Remove the transmission adapter from the surface Store the needle bearing with the relevant gear NOTICE Be careful not to damage the adapter mating surface NOTICE Do not forcefully remove the gear assembly It may damage the level grooves resulting in incorrect installation Carefully remove the gear assembly NOTICE 20 Remove the interlock bolt 17 mm ...

Page 166: ...s and remove the shift rails 2 Pull out the locking pins from shift forks 26 Remove the 3 4 gear retainer ring To prevent the bearing damage securely seat the spe cial tool before removing the intermediate taper roller bearing that is pressed in Do not use general bearing puller NOTICE Be careful not to lose or mix the retainer ring NOTICE 25 Place the output shaft assembly with the 1st gear fac i...

Page 167: ...H A X L E S P ST NG A CON T C 30 Remove the main taper roller bearing 27 Remove the 3 4 gear synchronizer hub and single syn chronizer sleeve and 3rd gear with a special tool Pull out the needle bearing 29 Remove the reverse gear inner race 28 Loose the 1 2 gear and hub and double synchronizer sleeve with a press ...

Page 168: ...nchronizer sleeve 31 Remove the inner race from 1st gear and 1st gear from 1st gear and remove the needle bearing from the shaft 34 Remove the synchronizer inner intermediate cone and outer ring in 2nd gear side Synchronizer intermediate cone Synchronizer outer ring Synchronizer inner ring Store the disassembled gears by relevant components NOTICE Synchronizer intermediate cone Synchronizer inner ...

Page 169: ...TIVE DATE AFFECTED VIN MANUAL TRANSMISSION KYRON SM 2005 09 45 3170 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 35 Remove the 2nd gear and needle bearing 36 Remove the oil seal from the extension housing ...

Page 170: ...t and dry them with compressed air Check the components for crack wear and damage 1 Case extension housing shift lever 2 Input bearing retainer 3 Counter shaft rear bearing retainer 2 Check the bearing and shaft supporting area for wear and replace if needed 3 Check the surface conditions on 1 Input shaft 2 Main shaft and gears 3 Counter shaft and 5th drive gear Inspection Before Reassembly Replac...

Page 171: ...r sleeve 11 Reverse fork and reverse idler gear sleeve 6 Check the following components for excessive wear 1 Crankshaft pilot bushing in front of input shaft 2 Clutch release bearing 3 Main shaft pilot bearing roller 4 Main shaft thrust bearing mating surface 5 Main shaft speed gear roller bearing 6 Main shaft rear bearing 7 Counter shaft front and rear bearing 7 Check the gear sets for wear in te...

Page 172: ...1 Check the speed gear clutch and synchronizer sleeve for damage in teeth surface 12 Check the engagement of synchronizer sleeve and speed gear clutch 9 Check the conditions of each synchronizer sleeve and hub 1 Engagement of hub and sleeve 2 Wear on cone clutch surface in synchronizer ring brass engaging the gears If the clearance is excessive replace it with new one Otherwise it may cause the mi...

Page 173: ... keys into 1 2 synchronizer hub and double synchronizer sleeve Install the synchronizer spring in offset so that it should not be missed out Reassembly The 1st 2nd 3rd gear needle bearings have one bear ing row and the sizes of them are same The reverse needle bearing has two bearing rows The 5th needle bearing is smaller than others and consists of two bearings NOTICE 1 2 gear double synchronizer...

Page 174: ...ediate cone and inner ring in turns 6 Install the 1st gear 4 Install the 1 2 synchronizer hub and double synchro nizer sleeve into the output shaft by using a press Make sure that the hub groove faces to 2nd gear Align the synchronizer key and the synchronizer ring groove in 2nd gear NOTICE 7 Install the 1st gear needle bearing ...

Page 175: ...gear inner race by using a press 9 Install the main taper roller bearing by using a press 10 Install the reverse gear inner race by using a press The reverse gear inner race has a step at edge NOTICE The 1st inner race doesn t have a step at edge NOTICE 11 Place the output shaft assembly with the 1st gear facing downward and install the 3rd gear needle bearing ...

Page 176: ...t three keys into 3 4 synchronizer hub and syn chronizer sleeve Install the synchronizer spring in off set so that it should not be missed out 12 Install the 3rd gear 3 4 gear synchronizer sleeve have a step at edge Place the groove in hub to face the 3rd gear and align the synchronizer key and the synchronizer ring groove in 3rd gear NOTICE ...

Page 177: ...mediate taper roller bearing by using a press Install the intermediate taper roller bearing by using a press 17 Install the input shaft along with the 4th synchronizer ring Place the input shaft to face downward on the work bench Apply the force on the inner race other than other points NOTICE Adjust the end play between retainer ring and hub to a range of 0 0 to 0 5 mm by using a feeler gauge NOT...

Page 178: ...Place the counter gear with input output shaft on the workbench 18 To relieve the load and to provide a clearance to the shaft bearing insert a special tool The reverse gear needle bearing has two bearing rows and the others consist of two bearings NOTICE 20 Install the transmission adapter on the input shaft and the counter gear ...

Page 179: ...gear 24 Insert three keys into 5 R synchronizer hub and syn chronizer sleeve Install the synchronizer spring in off set so that it should not be missed out 25 Install the 5 R gear retainer ring Place the groove in hub to face the 5th gear and align the synchronizer key and the synchronizer ring groove in reverse gear NOTICE Adjust the end play between retainer ring and hub to a range of 0 0 to 0 5...

Page 180: ...VIN 56 3170 29 Install two 5th gear needle bearings in line 27 Install the counter reverse spacer 28 Install the 5th synchronizer ring 26 Install the counter reverse gear by using a press Place the counter reverse gear with a longer protru sion facing to the adapter NOTICE ...

Page 181: ...70 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 30 Install the 5th gear 31 Install the 5th counter gear by using a press At this time place it with a longer protrusion area facing to the adapter 32 Install the counter 5th gear retainer ring 33 Install the locking ball ...

Page 182: ...l 35 Install the retainer ring 34 Install the thrust washer t 5 0 while aligning the key grooves 36 Install the inner race of counter roller bearing by using a press Adjust the end play between retainer ring and hub to a range of 0 08 to 0 22 mm by using a feeler gauge NOTICE Place it with a protrusion area facing to the 5th gear NOTICE ...

Page 183: ... 4 shift fork and shift rail while aligning the grooves Inner shift lever Interlock plate 40 Install the 3 4 gear shift fork The 1 2 and 5 R shift fork are compatible but 3 4 shift fork isn t Also the 3 4 shift fork is chamfered but 1 2 and 5 R aren t NOTICE The spring pin for locking the inner shift lever is small 6 22 and its slot should face to the shaft NOTICE The part which is longer the dist...

Page 184: ...to the shift rail 43 Partially engage the 1 2 shift fork to the shift rail 44 Install the shift lug on the 1 2 shift rail Install the re verse lock spring reverse lock plate and reverse lock bolts 42 Install the 1 2 gear shift rail in the transmission adapter Align the 1 2 gear shift lug and interlock plate mating surface NOTICE ...

Page 185: ... 47 Install the spring pin into the 1 2 shift lug 49 Install the spring pin into the 1 2 shift fork Align the 5 R shift lug and the interlock plate surface NOTICE Place the spring pin with the pin slot facing to the shaft NOTICE Place the spring pin with the pin slot facing to the shaft NOTICE Place the spring pin with the pin slot facing to the shaft NOTICE 48 Install the spring pin into the 5 R ...

Page 186: ...verse lock spring on the 1 2 shift rail 52 Install the stopper plate on the 3 4 shift rail and insert the spring pin intermediate size t 6 x 25 50 Install the spring pin into the 5 R shift fork Place the spring pin with the pin slot facing to the shaft NOTICE Place the spring pin with the pin slot facing to the shaft NOTICE ...

Page 187: ...ension housing Press down the extension housing against the adapter 53 Apply the sealant to the transmission housing 54 Install the gear assembly and the adapter to the trans mission housing 55 Install the speedometer driven gear on the output shaft and install the ball bearing by using a press Sealant Silicon sealant bulk 732 NOTICE Sealant Silicon sealant bulk 732 NOTICE ...

Page 188: ...ue Bond 592 loctite 40 50 Nm 58 Insert the offset lever into the 3 4 rail and install the spring pin 59 Apply the grease into the offset lever bushing 60 Apply the grease to the interlock bolt 17 mm and insert it into the interlock plate hole and bolt hole Installation Notice Make sure that the gear is at neutral position If not the interlock bolt cannot be inserted into the inter lock plate hole ...

Page 189: ...05 09 65 3170 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 61 Apply the grease to the top cover and install four bolts 12 mm Installation Notice Make sure that the gear is at neutral position NOTICE Sealant Tightening torque Silicon sealant bulk 732 17 26 Nm ...

Page 190: ...and remove the bracket and spacer 2 Remove the reverse idler gear and the needle bearing 3 Pull out the dowel pin and remove the reverse idler shaft BACKUP LAMP SWITCH Remove the backup lamp switch with 24 mm wrench Apply the sealant when installing TRANSMISSION ADAPTER Disassembly and Assembly Tightening torque NOTICE Reverse idler bracket bolt Reverse lock nut 17 26 Nm 70 100 Nm Tightening torqu...

Page 191: ...H A X L E S P ST NG A CON T C 2 Separate the front fork cover from the housing 3 Remove the input spacer SHIM ADJUSTMENT 1 Unscrew nine bolts 14 mm and remove the front fork cover 7 INSPECTION MAINTENANCE The shim adjustment is necessary when replacing the housings counter gear input shaft and output shaft NOTICE ...

Page 192: ...ion with the output shaft facing downward and set the special tool on the counter gear and input shaft Apply a proper force to the counter gear and input shaft so that the end plays for bearings are maximized 5 Prepare the special tools and dial gauge 4 Remove the counter spacer 7 Tighten the adjusting bolt on the special tool to hold the bearings ...

Page 193: ... sealant to the front fork cover and tighten the bolts 14 mm Measure the starting torque after installation Installation Notice End play 0 0 05 mm End play 0 0 05 mm Starting torque Sealant Tightening torque 20 25 Nm Silicon sealant bulk 732 17 26 Nm 8 Set up the dial gauge on the transmission housing surface and put the gauge needle to 0 point 9 Put the probe end of the gauge on the taper roller ...

Page 194: ...rt Number Application 661 589 04 62 00 W 99 31 007 0B Transmission fixture Removal installation of transmission W 99 31 001 1B Bearing puller Removal of pressed in interme diate taper roller bearing W 99 31 002 1B Pressure pipe Pressing of the bearing and gear W 99 31 003 1B Insert key Providing a space to input shaft bearing ...

Page 195: ... Name and Part Number Application W 99 31 004 1B Die Assembly of gears and bearings on the shafts W 99 31 005 2B Holder Measurement of taper roller bearing end play W 99 31 006 1B Dial gauge holder Measurement of taper roller bearing end play W 99 31 007 1B Drift Removal of 5 R synchronizer hub assembly reverse gear and shift fork at one time ...

Page 196: ...MEMO ...

Page 197: ...eed 22 4 4L mode 4WD low speed 23 TROUBLE SHOOTING 24 1 General diagnosis 24 MAINTENANCE AND REPAIR 25 1 Oil level check and change 25 REMOVAL AND INSTALLATION 26 1 Components location 26 2 Removal and installation of IWE Integrated Wheel End 34 SPECIAL TOOLS AND EQUIPMENT 41 TCCU TRANSFER CASE CONTROL UNIT 42 1 Major changes in TCCU 42 SYSTEM OPERATION 44 1 TCCU Transfer Case Control Unit 44 2 Tr...

Page 198: ...itional coding is required when replacing TCCU 2 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 communication 3 The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU Note In non A...

Page 199: ...G HUB SYSTEM KYRON SM 2005 09 3 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 1 STRUCTURE PART TIME TRANSFER CASE Part time transfer case Transmission Front propeller shaft Rear propeller shaft Front locking hub system IWE Rear axle IRS type Front axle ...

Page 200: ...VIN 4 3240 Components Location Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Shift motor connector Transfer case main connector Rear propeller shaft Oil filler plug Tightening torque 19 30 Nm Damper T C motor Magnet clutch power supply connector for 1 pin ...

Page 201: ... T CLUTCH A X L E S P ST NG A CON T C 2 SYSTEM LAYOUT AND FUNCTIONS System Layout CAN Communication HECU Wheel speed signal Output Magnetic clutch Motor Solenoid valve Vacuum line FL Locking hub FR Locking hub Front output shaft T C control switch TCCU Transfer case Atmo sphere Atmo sphere Indicators T C control indicator lamp ...

Page 202: ...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 Vacuum generation process in front hub actuator Booster Vacuum modulator for engine Atmo sphere Atmo sphere Vacuum pump TCCU Locking hub a...

Page 203: ...locking hub actuator so that it will not be engaged with the front 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 pres...

Page 204: ...ansfer case operates in 4WD mode During the 2WD mode the hub actuator is positioned at the drive shaft end and during the 4WD mode the hub actuator is interlocked to the drive shaft end gear and the front hub end gear The front hub assembly is connected to the tire and it drives the wheel by receiving the rotation force from the drive shaft during 4WD mode When the hub actuator is moved to the gea...

Page 205: ... from vacuum pump to hub actuator During the 2WD mode a vacuum line is established between vacuum pump and hub actuator During the 4WD mode the TCCU applies 12V to the vacuum solenoid to block the vacuum pressure This device transfers or blocks the output from drive shaft to the front wheel end according to the vacuum pressure Unlike the conventional systems the vacuum pressure to the front wheel ...

Page 206: ...pressure 4WD The locking hub actuator is engaged with the front wheel hub end gear when releasing the vacuum pressure Front hub end gear is not visible 4WD mode released Front hub end gear is not invisible 4WD mode engaged Locking hub actuator pulled out when releasing vacuum pressure Drive shaft Drive shaft Front wheel end Front wheel end Locking hub actuator pulled in when applying vacuum pressu...

Page 207: ...E DATE AFFECTED VIN PART TIME TRANSFER CASE LOCKING HUB SYSTEM KYRON SM 2005 09 11 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Front Wheel End in Vehicle with 4WD Front Wheel End in Vehicle without 4WD ...

Page 208: ...re from vacuum pump is continuously applied to the locking hub actuator If any vacuum line is leaking the 4WD system may not operate Make sure that the vacuum lines are not leaking How to check the vacuum locking hub system 1 Disconnect hub actuator vacuum line from vacuum solenoid valve 2 Connect vacuum gauge to vacuum line of hub actuator Vacuum gauge Connect vacuum gauge to vacuum line of front...

Page 209: ...cuum pres sure is released from the locking hub actuator and the drive shaft is engaged with the front wheel hub end gear Thus when releasing the vacuum pressure gauge indication 0 with a vacuum pressure gauge the drive shaft should be rotated along with the wheel During 2WD mode the vacuum pressure is applied to the locking hub actuator and the drive shaft is separated from the front wheel hub en...

Page 210: ...vacuum hose from the hub actuator and install the vacuum pressure gauge to the hub actuator Apply vacuum pressure to make sure the hub actuator maintains vacuum condition If the vacuum pressure is maintained the actuator hub component condition is OK If the vacuum pressure is not maintained replace the actuator with a new one Normal Leakage ...

Page 211: ...NG A CON T C 4 TRANSFER CASE Appearance 1 pin connector For magnetic clutch power supply Delete power supply terminal and ground for conventional speed sensor Front flange Connect to transmission output shaft Shift motor Shift motor connector Rear flange Connect to rear propeller shaft Transfer case assembly Connect to front propeller shaft Air bleeder ...

Page 212: ...HANGED BY EFFECTIVE DATE AFFECTED VIN 16 3240 Sectional Drawing Planetary gear set Oil pump Magnetic clutch 2H 4H Shift fork Lockup fork Shift motor Connect to front propeller shaft 4H 4L Shift fork Reduction shift fork Input shaft Connect to rear propeller shaft ...

Page 213: ... Position A Position B Position C Position D Position ground Control 4L 4H 2H Control 2H 4H 4L Rear view of connector Pin 1 2 3 4 5 6 7 Pin A Function Magnetic clutch coil power supply The rear speed sensor utilizes the hall effect It gen erates 0V and 5V of square type digital wave accord ing to the rotation of the wheel with teeth of transfer case rear output shaft The speed signal from rear pro...

Page 214: ...switch ON OFF 2WD 4WD switch HIGH LOW switch CAN HIGH CAN LOW Shift motor output Motor LOW HIGH Electronic magnetic clutch coil Shift motor output Motor HIGH LOW Position encoder ground Return position K Line Self diagnosis Hub solenoid 13 26 23 18 5 19 17 4 16 8 9 2 15 1 14 11 20 21 24 12 25 Position 1 Position 2 Position 3 Position 4 P A R T T I M E T C C U ...

Page 215: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE LOCKING HUB SYSTEM KYRON SM 2005 09 19 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Transfer Case Circuit Diagram ...

Page 216: ...HANGED BY EFFECTIVE DATE AFFECTED VIN 20 3240 1 POWER FLOW POWER FLOW Switch Transfer 2H 4H 4L TCCU Locking Hub Solenoid Locking Hub Operation Internal vacuum released Front Propeller Shaft Rear Propeller Shaft Rear Axle Rear Wheel Front Axle Front Wheel Transfer ...

Page 217: ...KYRON SM 2005 09 21 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Transmission Rear Axle Rear Wheel Front Axle Front Wheel 2 2H MODE 2WD Power Flow Transmission Output Shaft Rear Wheel Transfer Case Input Shaft Output Shaft Rear Propeller Shaft Rear Axle Rear Wheel ...

Page 218: ... Transmission Rear Axle Rear Wheel Front Axle Front Wheel 3 4H MODE 4WD HIGH SPEED TCCU Motor Magnetic Clutch Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive Rear Propeller Shaft Transmission Input Shaft Shift Cam Rail Fork 4WD HI Power Flow T C Output Shaft ...

Page 219: ...X L E S P ST NG A CON T C Transmission Rear Axle Rear Wheel Front Axle Front Wheel 4 4L MODE 4WD LOW SPEED Power Flow TCCU Motor Transmission Input Shaft Shift Cam Rail Fork Magnetic clutch Output Shaft Rear Propeller Shaft 4WD LO Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive Planetary Gear ...

Page 220: ...and damage Check sliding parts replace if necessary Check internal parts and replace drive chain Drain and replace with specified oil Retighten as specified Disassemble bearings and parts and check for wear or damage Replace if necessary Check for wear and damage including speed ometer gear Replace if necessary Disassemble and check for wear and damage Replace if necessary Adjust tire pressure Rep...

Page 221: ...30 Nm Oil Level Check 1 Clean the oil level plug drain plug and surroundings 2 Place a proper container under the transfer case 3 Remove the drain plug and then remove the oil level plug filler plug 4 Drain the oil and tighten the drain plug 5 Fill the oil through the oil level plug until oil begins to drip out Installation Notice Oil Change Cautions for Oil Level Check and Plugs Oil level plug Dr...

Page 222: ...1 COMPONENTS LOCATION REMOVALAND INSTALLATION Drain plug Tightening torque 19 30 Nm Front propeller shaft Shift motor connector Transfer case main connector Rear propeller shaft Filler plug Tightening torque 19 30 Nm T C motor Magnetic clutch power supply connector for No 1 pin Damper Transfer case assembly ...

Page 223: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE LOCKING HUB SYSTEM KYRON SM 2005 09 27 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Exploded View ...

Page 224: ...sembly 23 Electric coil assembly 24 Return spring 25 Shift rail 26 Shift fork 27 Shift fork assembly 28 Electric shift cam 29 Spring 30 Spacer 31 Shift shaft 32 Retaining ring 33 Transfer case assembly 34 Breather 35 Name plate 36 Output shaft 37 Dust shield 38 Magnet 39 Snap ring 40 Lower sprocket 41 Spacer 42 Chain 43 Retaining ring 44 Bearing 45 Bearing 46 Cover 47 Clip 48 Bolt 49 Clip 50 Washe...

Page 225: ...T NG A CON T C 1 Disconnect the motor connector from the transfer case 2 Remove the rear propeller shaft And separate the front propeller shaft from transfer case Transfer Case Tightening torque 81 89 Nm T C 3 Disconnect the air hose from the transfer case Installation Notice Rear Front Tightening torque 81 89 Nm T C 70 80 Nm Axle Installation Notice ...

Page 226: ... bolts 14 mm and the center bolt 14 mm and remove the transmission cross member Tightening torque 20 25 Nm Mounting insulator Bracket bolt 28 47 Nm 28 47 Nm 5 Unscrew the bolts 14 mm and remove the transfer case mounting insulator and insulator bracket Tightening torque Tightening torque 85 95 Nm Tightening torque 85 95 Nm When installing the transfer case make sure that the bolts are facing corre...

Page 227: ...VIN PART TIME TRANSFER CASE LOCKING HUB SYSTEM KYRON SM 2005 09 31 3240 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Side View Front View 7 When installing keep the tightening torque and install in reverse order of removal ...

Page 228: ...t the negative battery cable 1 Disconnect the magnetic coil clutch connector and motor connector from the transfer case 2 Unscrew the bolts and remove the transfer case motor with bracket Transfer Case Motor Bracket mounting nut Motor connector Magnetic coil clutch connector Remove two nuts to separate the bracket and motor NOTICE ...

Page 229: ...ce of the transfer case and shift motor 4 Apply sealant on the mating surface when installing new shift motor assembly 5 Install in the reverse order of removal Make sure that the mode switch selection is matched with the motor s driving position before installation Do not disassemble the shift motor since it is re placed as an assembled unit NOTICE To do that install a new shift motor on the same...

Page 230: ...ED WHEEL END Wheel Speed Sensor Preceding Work Disconnect the negative battery cable and remove the tires 2 Unscrew the two screws and remove the brake disc 1 Unscrew the two bolts 19 mm and set the removed brake caliper on the frame Front side 2WD Rear side 5 link type Rear side IRS type Note Wheel speed sensor location Tightening torque 85 105 Nm ...

Page 231: ...e hub cap and unscrew the lock nut 4 Unscrewthethreewheelendhubmountingbolts 10mm Installation Notice 5 Slightly pull the wheel end hub until the wheel speed sensor is visible Unscrew the mounting bolt 5 mm and remove the wheel speed sensor Tightening torque 100 130 Nm Replace the hub cap with a new one when installing NOTICE Tightening torque 28 30 Nm Tightening torque 6 8 Nm ...

Page 232: ...PART TIME TRANSFER CASE LOCKING HUB SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 36 3240 6 Disconnect the wheel speed sensor and the cable Disconnect connector Wheel speed sensor ...

Page 233: ...Notice 2 Pull out the upper arm lock pin and unscrew the mounting nut 19 mm At this time do not fully remove the nut Tightening torque 4 8 Nm Locking Hub Actuator Assembly Preceding Work 1 Remove the tire and the brake disc 2 Remove the wheel speed sensor 3 Pull out the steering gear linkage lock pin from the knuckle Unscrew the mounting nut 19 mm and remove the tie rod end Lock pin Tightening tor...

Page 234: ...LOCKING HUB SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 38 3240 4 Unscrew the lower arm mounting nut 22 mm 5 Remove the knuckle between upper arm and lower arm with special tool Tightening torque 140 160 Nm ...

Page 235: ...AG A T M T CLUTCH A X L E S P ST NG A CON T C 1 2 6 7 HubActuator 1 Unscrew the three bolts 10 mm on the disassembled locking hub actuator assembly and remove the hub actuator Structure of Hub Actuator Vacuum tube Vent tube Clutch ring Piston Diaphragm Spring Housing Shift seal Detail Tightening torque 8 12 Nm Shift fork ...

Page 236: ...N 40 3240 Inspection 1 Check the internal seal ring of hub actuator for damage Installation Notice Completely clean the parts and apply the grease them before installation Be careful not to damage the internal seal ring of the hub actuator 2 Replace the O ring of the locking hub end with a new one ...

Page 237: ... B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Name and Part Number Application 661 589 01 37 00 W 99 31 001 1B Pliers Removal installation of carrier assembly in transfer case DW 220 080 W 99 31 005 0B Oil seal installer Installation of oil seal to transmission case SPECIAL TOOLS AND EQUIPMENT ...

Page 238: ...hrough the CAN communication 3 Delete the pin related to the speed sensor from TCCU pins 4 Change the transfer case wiring connector from No 4 pin to No 1 pin Power and ground related to the speed sensor 5 ThenewTCCUisavailabletoinstallonthevehiclewiththeconventionalDIengineparttimeTCCU Pin Arrangement TCCU TCU 1 MAJOR CHANGES IN TCCU TCCU controls the 4WD system and is located under the driver s ...

Page 239: ...etecting shift motor position 2 position These lines are sharing the information among the related units through the CAN communication The differences from the conven tional part time T C models are that the speed sensing type tone wheel in T C has been eliminated and the speed signal comes from the ABS ESP HECU or the instrument panel Supplying the voltage to clutch coil for all shifting operatio...

Page 240: ...s depressed manual transmission or the selector lever is selected to the N position automatic transmission TCCU must recognize the clutch pedal signal or N signal 3 Changethe4WDswitchininstrumentpanelfrom4Hto4L 4 The 4WD LOW warning lamp in meter cluster flickers during this process then goes out when the shift is completed 5 The 4WD CHECK warning lamp comes on when the system is defective 1 TCCU ...

Page 241: ...cators 4WD LOW and 4WD HIGH come on for 0 6 seconds 2 TCCU starts diagnosis by operating clutch and hub solenoid for 1 5 seconds 3 The shift operation is controlled to move only toward selector switch position if the selector switch position is not met with shift motor position code when the ignition switch is turned to ON Function of indicating lamp during shifting 1 As the operation of shift mot...

Page 242: ...is completed regardless of the ignition power If there are not operating signals from the position sensor the shifting failure due to timeout occurs This failure appears when the shifting time between 2H and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift Once the shifting time exceeds the specified time TCCU cannot properly supply the voltage to shift motor and is oper...

Page 243: ...otor does not try to operate which happens 1 5 seconds after completion of 2H 4H shift and 3 seconds after completion of 4H 4L shift 2 When the timeout occurs TCCU cuts off the voltage to shift motor and operates the compensation mode Position Encoder Test 1 When the system detects a fault in shift motor for over 1 second the 4WD CHECK warning lamp comes on and the trouble code is stored into the ...

Page 244: ...der the steering wheel 2 The transfer case system is malfunctioning when 1 The 4WD CHECK indicator remains on after 0 6 second when turning the ignition switch ON 2 The 4WD CHECK indicator continuously comes on during driving 3 Connect Scan I to the diagnostic connector and read the defective code with the ignition switch ON refer to Diagnosis Table 4 After repairing erase the defective code store...

Page 245: ...6 Mode change 2H Pin No 4 Ground 4H No contact Open 4L Pin No 16 Ground Voltage at TCCU pin No 11 11 15 V EMC resistance 2 5 Ω Check the relevant connectors for contact Replace TCCU if necessary When the hub control circuit is open or short to ground over 0 2 second Replace TCCU if necessary When TCCU detects the motor failure for 1 second Check the relevant harnesses for contact Replace TCCU if n...

Page 246: ...evant harnesses for short TCCU pin No 18 Check the relevant connectors for contact Check the shift motor Short to ground for position encoder 2 in shift motor Check the relevant harnesses for short TCCU pin No 5 Check the relevant connectors for contact Check the shift motor Short to ground for position encoder 2 in shift motor Check the relevant harnesses for short TCCU pin No 19 Check the releva...

Page 247: ... E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Removal and Installation of TCCU 1 Slide the drive s seat and fold up the carpet 2 Unscrew two nuts on the TCU Installation Notice Tightening torque 10 Nm TCCU 3 Disconnect the TCCU connect and remove the TCCU Be careful not to apply any impact to TCCU body NOTICE ...

Page 248: ...MEMO ...

Page 249: ...UTCH 3010 TABLE OF CONTENTS GENERAL 3 1 Function and overview 3 2 Specifications 8 3 Trouble diagnosis 9 4 Maintenance 10 CLUTCH ASSEMBLY 12 1 Removal and installation 12 2 Special tools ane epuipment 22 ...

Page 250: ......

Page 251: ...e flywheel and the other is the clutch pressure plate The clutch pressure plate is fitted into a clutch steel cover which is bolted to the flywheel 2 Driven Elements 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 diaph...

Page 252: ... VIN 4 3010 Functions Components of Clutch Assembly Cross Sectional View of Clutch Assembly A Adapter Pipe Assembly B Clutch Assembly C Concentric Slave Cylinder 1 Transmission housing 2 Clutch disc assembly 3 Clutch disc cover assembly 4 Bolt 5 Washer 6 Bolt ...

Page 253: ...ation an oil pressure is produced within the master cylinder and transmitted as follows concentric slave cylinder clutch cover clutch disc When releasing the clutch pedal it returns to its original position through the motion of the clutch cover and the spring within the cylinder and the clutch operation stops The piston in cylinder returns to its original position Clutch Master Cylinder and Reser...

Page 254: ...ng the clutch pedal the concentric slave cylinder pushes the pressure plate diaphragm and sepa rates the pressure plate The advantages of using the diaphragm spring the pressure varies only a little even when the clutch disc facing is considerably worn out its structure is simple and the pedal effort is small Clutch Assembly 1 Pendant type clutch pedal leverage effect is applied to reduce the effo...

Page 255: ...10 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Mounting on Dash Panel Clutch pipe mounting clip Tube Master cylinder oil chamber Models without ABS ESP Models with ABS ESP Clutch pipe mounting clip Tube Master cylinder oil chamber Oil chamber Oil chamber ...

Page 256: ... bolt Stopper bolt 49 59 Nm 21 27 Nm 10 16 Nm 20 25 Nm 20 25 Nm 15 18 Nm 8 18 Nm 16 22 Nm 8 18 Nm 16 22 Nm Description Specification Hydraulic Suspended Diesel engine equipped vehicle 140 mm 5 10 mm Single dry diaphragm 240 155 4 0 mm 263 cm2 2 Free 9 4 10 mm When loaded 9 0 0 3 mm Min 720 kg 28 4 mm φ 17 04 mm 7 0 mm 706 mm2 DOT3 or DOT4 Operating type Clutch pedal Clutch disc Clutch cover assemb...

Page 257: ... clutch pedal free play Faulty operation of clutch pedal Worn or damaged clutch disc Vibration or excessive run out of disc Rust or wear of clutch disc spline Oily facing Burnt diaphragm spring Excessive clutch pedal free play Excessive clutch pedal free play Faulty clutch release cylinder Worn disc excessive run out damaged lining Dirty or burred splines on input shaft or clutch disc Damaged clut...

Page 258: ...bleed the air and fluid from the fluid line 5 Repeat step 3 through 4 until no more air bubbles are in the escaping fluid Air Bleeding 4 MAINTENANCE Keep the fluid level over MAX in reservoir during bleeding operation Do not let the fluid contact a painted surface NOTICE Clutch fluid DOT 3 4 Plastic tube Clutch Air bleed This work has to be done by two service persons After bleeding check the clut...

Page 259: ... checking the clutch assy Remove the transmission and place the zig set 4 pieces between the clutch cover and diaphram spring around refer to the picture How to identify SAT clutch specification Identify the SAT clutch with compensation device arrow on clutch cover Installation of Special Zig Service Instruction How to Use Special Tool To prevent early wear and slip in clutch disc always use the d...

Page 260: ...ts 1 Clutch pedal 2 Clutch master cylinder 3 Clutch hydraulic pipe 4 Clutch fluid chamber 5 Clutch hydraulic hose 6 Adapter 7 Clutch housing 8 Concentric slave pipe 9 Concentric slave cylinder 10 Clutch cover 11 Clutch disc A A Connection CLUTCH ASSEMBLY 1 REMOVALAND INSTALLATION ...

Page 261: ...onnect the clutch fluid hose from the adapter 2 Remove the transmission assembly 3 Insert the centering pin special tool into center spline Loosen the clutch cover bolts 1 2 turns in cross sequence until the spring tension is released Installation Notice Tightening torque 24 3 Nm Hose connection clip mounted Do not remove the bolts at a time or clutch cover may be damaged or deformed NOTICE ...

Page 262: ... BY EFFECTIVE DATE AFFECTED VIN 14 3010 4 Unscrew the bolts and remove the clutch cover pressure plate and clutch disc Pressure plate Clutch disc T M installation mark Be careful not to drop the pressure plate and clutch disc NOTICE ...

Page 263: ...d remove the adapter and oil pipe 3 Unscrew three bolts and remove the concentric slave cylinder assembly on the input shaft of cylinder 4 Install in the reverse order of removal Keep the specified tightening torque Concentric Slave Cylinder Tightening torque 20 25 Nm Tightening torque 10 16 Nm Before installation clean all the components Do not re use the used clutch fluid Apply a small amount of...

Page 264: ...unscrew two clutch master cylinder mounting nuts 10 mm 4 Disconnect the clutch master cylinder push rod from the clutch pedal and remove the clutch master cylinder 5 Install in the reverse order of removal and check air bleeding and clutch pedal operation after installation Clutch reservoir hose Nipple Brake and clutch fluid reservoir Clutch master cylinder Clutch master cylinder Clamp Tightening ...

Page 265: ...mounting nut 12 mm and remove the pedal box assembly Installation Notice Dash panel Cylinder module assembly Hexagon flange nut Stud bolt 1EA Pedal box assembly Tightening torque 8 18 Nm Tightening torque 8 18 Nm Pin Snap pin Stud bolt on clutch pedal side Stud bolt on clutch pedal side Push rod on clutch master cylinder side Clutch pedal Hexagon flange nut Clutch pedal mounting hole Push rod on m...

Page 266: ... Height B Maximum pedal stroke 140 mm Height from carpet 181 5 mm Free play 5 15 mm To adjust the pedal free play loosen the lock nut F of the master cylinder and turn the push rod until the free play is correct NOTICE To adjust the pedal stroke loosen the lock nut C of the stopper bolt D and turn the stopper bolt until the stroke is correct After adjustment tighten the lock nut NOTICE Apply long ...

Page 267: ...15 18 Nm Master cylinder Primary oil pipe Concentric slave cylinder adapter 3 Unscrew the supply pipe bolt and remove primary oil pipe from clutch fluid chamber 4 Unscrew the pipe bolt and remove the secondary clutch fluid pipe from concentric slave cylinder adapter 5 Install the pipes Be careful not to mix the pipes Oil chamber Secondary clutch fluid pipe Make sure to bleed the air from the syste...

Page 268: ...ar crack and discoloration 3 Check the strap plate rivet for looseness and replace the clutch cover if necessary 2 Clutch Disc 1 Check the facing for rivet looseness sticks oil and grease 2 Measure the rivet head depth If it is out of limit re place the disc 3 Clutch Disc Run Out 1 Measure the clutch disc run out and if it is out of limit replace the disc Unevenness limit 0 8 mm Wear limit 0 3 mm ...

Page 269: ...G A T M T CLUTCH A X L E S P ST NG A CON T C 4 Pressure Plate 1 Check the pressure spring for wear 5 Concentric Slave Cylinder 1 Check any heat damage abnormal noise poor rotation and wear of the concentric slave cylinder bearing The excessively worn components should be replaced NOTICE ...

Page 270: ...H KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 22 3010 2 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application D9930 0010C Zig set diaphram spring Support diaphram spring when disassembled ...

Page 271: ...NT AXLE ASSEMBLY 6 REMOVAL AND INSTALLATION 8 5 LINK TYPE REAR AXLE 15 1 Location 15 2 Removal and installation 18 INDEPENDENT SUSPENSION TYPE REAR AXLE 24 1 Overview 24 2 Exploded view 26 3 IRDA Independent Rear DriveAxle 28 4 Removal and installation 30 5 Trouble diagnosis 32 ...

Page 272: ......

Page 273: ...RVIEW Compared to previous models in addition to existing 5 link suspension the IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle The below figures for rear axle show the rear axle with the independent type suspension 4WD A T IRDA Independent Rear Drive Axle Front Axle GENERAL Rear Axle ...

Page 274: ...0 mm Steel casting steel aluminum cover SAE 80W 90 1 4 L 448 0 mm 681 9 mm 45 kg A T 1 4 L Independentsuspension 5 164 Nm Hypoid 218 mm diameter Less than 30 mm Aluminum die casting SAE 75W 90 Synthetic 1 5 L 412 mm 292 mm 30 kg 5 link φ 243 8 mm Steel casting steel aluminum cover SAE 80W 90 1 9 L 469 0 mm 1717 7 mm 100 kg Rear axle Location Gear Oil D27DT 3 91 D20DT 4 27 D27DT 3 31 D20DT 3 54 ...

Page 275: ... 09 5 4120 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C FRONT AXLE Location Sectional Diagram Tire wheel Knuckle From vacuum pump To air Axle shaft Brake disc Cap lock nut Tire fixing bolt Tightening torque 28 32 Nm Tightening torque 120 140 Nm ...

Page 276: ...RONT AXLE ASSEMBLY Front Disc Wheel end Assembly Wheel speedo cable Locking hub actuator Brake disc Knuckle Brake disc Front wheel speed sensor cable Disc dust cover Axle Shaft Assembly Axle shaft assembly Wheel speed sensor cable Front disc assembly Locking hub actuator ...

Page 277: ...PENSION STEERING AIRCON T C Front Axle Housing Assembly Front axle housing Front axle Axle mounting bracket Air bleed hose Nut Axle mounting lower bushing Axle mounting bracket Axle mounting lower bushing Axle mounting bolt Axle mounting upper bushing Axle mounting lower bushing Axle mounting bolt Axle mounting bolt ...

Page 278: ... the locking hub actuator when installing the front disc and the hub end assembly Caution REMOVAL AND INSTALLATION 1 Removal of the front tire Remove the front tire wheel caps Unscrew five wheel nuts 21 mm in diagonal direction and remove tires Installation Notice Wheel cap Tightening torque 120 140 Nm Seal ring ...

Page 279: ...Disconnect the wheel speed sensor cable and connector and disconnect the vacuum hose from the locking hub actuator Brake hose Vacuum hose LH 3 Brake disc caliper Unscrew two mounting bolts 19 mm and remove the brake disc caliper Set the removed caliper on the vehicle frame Installation Notice RH Tightening torque 85 105 Nm Connector Be careful not to damage the vacuum hose ...

Page 280: ... from knuckle and then remove the front disc and the wheel end assembly 3 Loosen the upper arm 1 and the tie rod end 2 and remove the assembly Hub bearing cap Removal and Installation Tightening torque 28 32 Nm The hub bearing cap and the lock nut are not reusable Always replace them with new ones after removal NOTICE Lower arm 3 Tightening torque 150 170 Nm Tightening torque 110 130 Nm Tie rod en...

Page 281: ... SM 2005 09 11 4120 B R A K E A I R B A G A T M T CLUTCH A X L E SUSPENSION STEERING AIRCON T C 4 Remove the axle shaft Components Drive shaft Boot band Ball joint Boot out board Boot band Housing in board Seal Boot band Boot in board Shaft Boot band ...

Page 282: ...e the propeller shaft and secure it to frame 3 Unscrew the four bolts 17 mm on the axle housing and remove the axle mounting bracket Installation Notice 2 Removal of mounting bolt Unscrew the mounting nut 22 mm at right side and remove the axle mounting bolt Installation Notice Tightening torque 95 142 Nm Tightening torque 80 100 Nm ...

Page 283: ... four bolts on mounting bracket 17 mm to remove the mounting bracket Tightening Torque 5 Place a safety jack under the axle housing and remove the axle mounting bolts 22 mm Installation Notice Tightening torque 95 142 Nm Mounting nut 22 mm Bracket bolt 17 mm 95 142 Nm 80 100 Nm Remove the power steering hose mounting bracket before removing the left pin bolt Otherwise it cannot be removed due to i...

Page 284: ...y Be careful not to damage the left and right seals in axle housing when removing the axle mounting bracket and axle assembly NOTICE Front axle housing Front axle Axle mounting bracket Air bleed hose Nut Axle mounting lower bushing Axle mount ing bracket Axle mounting lower bushing Axle mounting bolt Axle mounting upper bushing Axle mounting lower bushing Axle mount ing bolt Axle mounting bolt ...

Page 285: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE KYRON SM 2005 09 15 4120 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 1 LOCATION 5 LINK TYPE REAR AXLE ...

Page 286: ...AXLE KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 4120 Components Axle Shaft Rear Axle Disc type Axle Yoke Drum Type Axle Shaft Axle Housing Axle Housing ...

Page 287: ...cifications Specifications Front View Rear View Description Axle shaft type Axle housing type Differential Final gear ratio Oil Specification Semi floating type Build up type Type Gear type DI engine M T D20DT D27DT DI engine A T D20DT D27DT Capacity Specification Conventional Hypoid 4 27 3 91 3 54 3 31 1 9 L SAE 80W 90 or API GL 5 ...

Page 288: ... Brake Type Preceding Works Remove the tire 1 Unscrew the two mounting bolts 19 mm and remove the brake disc caliper Set the removed caliper on the vehicle frame Caliper mounting bolt 85 105 Nm 2 Unscrew the mounting bolt 10 mm and disconnect the wheel speed sensor cable Installation Notice Tightening torque 6 8 Nm ...

Page 289: ... E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 3 Unscrew the adjusting nut of the parking brake cable equalizer to loosen the parking brake cable 4 Remove the lock pin and disconnect the parking brake cable 5 Remove the brake disc Lock pin Adjusting nut Parking brake cable ...

Page 290: ...Y EFFECTIVE DATE AFFECTED VIN 20 4120 6 Remove the plastic plug from the axle shaft flange 7 Unscrew the four flange lock bolts 17 mm on the axle housing flange and remove the axle shaft Installation Notice Tightening torque 50 64 Nm ...

Page 291: ...ks Remove the tire 1 Remove the wheel speed sensor A the air breather lock nut B the parking brake cable C and the disc brake caliper D from the rear axle A Wheel Speed Sensor 10 mm 1EA LH RH B Air Breather Lock Bolt 10 mm 1 EA C Parking Brake Cable LH RH D Disc Brake Caliper LH RH Tightening torque 6 8 Nm Tightening torque 6 8 Nm Tightening torque 85 105 Nm ...

Page 292: ...bolt nut 17 mm nut 10 mm bolt D Mounting bracket bolts of stabi lizer bar 14 mm 2 EA LH RH E Propeller shaft F Upper arm bolt nut 22 mm Tightening torque 150 180 Nm Tightening torque 150 180 Nm Tightening torque 80 100 Nm Tightening torque 40 60 Nm Tightening torque 70 80 Nm Tightening torque 150 180 Nm Assembly mark F Upper arm A Lateral rod D Stabilizer mounting bracket B Lower arm C Shock absor...

Page 293: ...VE DATE AFFECTED VIN AXLE KYRON SM 2005 09 23 4120 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 3 Carefully lower the safety axle to remove the rear axle assembly from the vehicle frame Rear View Front View ...

Page 294: ...FFECTED VIN 24 4120 1 OVERVIEW Introduction Compared to previous models in addition to existing 5 link suspension the IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle INDEPENDENT SUSPENSION TYPE REAR AXLE ...

Page 295: ...ght Specifications Type Size Offset Specification Capacity Independent suspension 5 164 Nm 4 27 3 91 D20DT D27DT 3 54 3 31 D20DT D27DT Hypoid 218 mm diameter Less than 30 mm Aluminum die casting SAE 75W 90 Synthetic 1 5 L 412 mm 292 mm 30 kg 5 link φ 243 8 mm Steel casting steel aluminum cover SAE 80W 90 1 9 L 469 0 mm 1717 7 mm 100 kg Rear axle Description Gear Oil M T A T ...

Page 296: ...t connector 20 Cover fan bolt 21 Dowel pin 22 Pinion spacer 23 Pinion head bearing assembly 24 Pinion shim 25 Pinion gear 26 Output shaft 27 Output shaft snap ring 28 Shaft seal assembly 29 Differential case side bearing snap ring 30 Differential bearing race 2 EXPLODED VIEW 1 2 3 4 5 6 7 8 9 12 11 13 14 15 16 17 18 20 21 25 24 23 22 34 39 40 41 42 43 44 45 38 36 37 35 30 31 32 33 29 28 27 26 10 1...

Page 297: ...005 09 27 4120 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Sectional Drawing Tightening torque 250 350 Nm Rear axle assembly Ball joint Boot Rear axle shaft Ball joint Boot Hub bearing Parking brake Back plate Lock nut Wheel Tire Brake disc ...

Page 298: ...Caulk the nut after tightening Axle Shaft Assembly Tightening torque 250 350 Nm Rear axle shaft Axle shaft Hub plane washer Lock nut Mounting bolt axle side IRDA Axle Mounting Bolt 30 mm 1 EA Brake Disc Lock Nut 30 mm 1 EA Tightening torque 95 142 Nm Tightening torque 250 350 Nm Tightening torque 70 80 Nm ...

Page 299: ...B R A K E A I R B A G A T M T CLUTCH A X L E SUSPENSION STEERING AIRCON T C Axle Housing Mounting Bracket Bolt Axle Housing Mounting Bolt Tightening torque 9 11 Nm Axle Housing Bracket Mounting Bolt Rear axle bracket Rear axle Rear axle bracket Tightening torque 9 11 Nm ...

Page 300: ...AND INSTALLATION 2 Make an alignment mark on the flanges of the axle shaft and the axle housing Unscrew the six bolts Torx 10 mm and remove the axle shaft while lowering the axle shaft flange 1 Loosen the locked positions and remove the lock nut 24 mm Alignment mark Tightening torque 250 350 Nm Tightening torque 70 80 Nm ...

Page 301: ... L E S P ST NG A CON T C 4 Unscrew the mounting bolt 30 mm and carefully lower the safety jack with axle housing assembly Measure the backlash between the drive pinion and ring gear Specified value 0 15 0 20 mm Backlash Check 3 Unscrew the two axle housing mounting bolts 22 mm Tightening torque 95 142 Nm ...

Page 302: ...ng crack Worn or damaged oil seal Worn or damaged tooth of pinion or side gear Wear of pinion shaft Excessive backlash of pinion gear and side gear Excessive end play of axle shaft Incorrect contact of side gear and differential case Axle housing crack Distortion or poor installation of drive pinion oil seal Damaged or torn drive pinion oil seal Loosened bearing collar Worn or damaged universal jo...

Page 303: ...ent backlash Tooth can be damaged or broken under heavy load Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred Adjust backlash Decrease backlash Select proper shin to move the drive pinion toward the ring gear toward toe Adjust backlash Increase backlash Sele...

Page 304: ...MEMO ...

Page 305: ...lation 8 4 Coil spring shock absorber assembly 10 5 Stabilizer bar 12 6 Lower arm 14 5 LINK RIGID TYPE REAR SUSPEN SION 19 1 Overview 19 2 System layout 20 3 Trouble diagnosis 25 4 Removal and installation 26 IRS TYPE REAR SUSPENSION 32 1 Overview 32 2 Specifications 34 3 Trouble diagnosis 34 4 Removal and installation 36 ...

Page 306: ...the load delivered from the tire to the knuckle This enables to absorb the vari ous impacts according to the load shapes and to ensure the drivability The suspension is the device to connect the axle and vehicle frame It absorbs the vibrations and impacts from road surface which enhances the comforts driving force braking force and drivability 1 Suspension type Double Wishbone 2 Component Knuckle ...

Page 307: ...rolling at the same rate when meeting bumps but it also affects handling A section of spring steel rod is wound in a spiral pattern or shape coil provides a cushion to ab sorb road imperfections and returns the vehicle to a predetermined ride height It is amajor con tributor to a vehicle s handling balance and ride quality Higher spring rates and shorter overall lengths are commonly used to lower ...

Page 308: ...oil resistance This provides better drivability even though the structure is complicated This vehicle uses the gas shock absorber with cylindrical double tube 1 This vehicle uses the strut type shock absorber This shock absorber is connected to the piston rod in the strut This relieves the vertical vibrations of vehicle to provide ride comforts prevents the spring break en hances drivability and e...

Page 309: ...CH A X L E S P ST NG A CON T C 1 Lower spring seat 2 Yoke bracket 3 Rebound stopper 4 Cylinder 5 Piston 6 Shock absorber assembly 7 Spring 8 Yoke 9 Boot 10 Bumper stopper 11 Spring seat rubber 12 Upper spring seat 13 Rubber 14 Rubber 15 Spacer 16 Washer 17 Nut 18 Bolt Sectional Drawing of Shock Absorber ...

Page 310: ...s is should be below 30 96 5 5 mm Description Suspension type Spring type Shock absorber type Stabilizer type Toe in Camber Caster Wheel alignment Height H Front axle shaft assembly Steering gear box assembly Lower Arm Assembly Shock Absorber Yoke Lower arm on knuckle nut Tightening torque 140 160 Nm Upper Arm Assembly Shock Absorber Coil Spring Knuckle Assembly Stabilizer Bar Assembly 2 SYSTEM LA...

Page 311: ...ar link upper nut Tightening torque 30 50 Nm Stabilizer bar link lower nut Tightening torque 110 130 Nm Coil spring mounting nut Tightening torque 60 80 Nm Upper arm on frame bolt nut Tightening torque 110 130 Nm Stabilizer bar mounting clamp bolt Tightening torque 30 45 Nm Lower arm on frame bolt nut Tightening torque 180 190 Nm Lower arm on shock absorber yoke nut Tightening torque 150 170 Nm ...

Page 312: ...g it 1 Remove the tires Remove the wheel cap and loosen the wheel nuts in several steps Installation Notice 2 Upper arm nut 19 mm knuckle side Preceding Works 1 Wheel speed sensor cable Remove the wheel speed sensor cable and the con nector from the upper arm Remove the split pin first and then remove the mounting nut Tightening torque 120 140 Nm Replace the split pin with a new one when installin...

Page 313: ...T NG A CON T C 3 Upper arm bolt nut frame side 4 Upper arm Separate the upper arm from the frame first and then separate it from the knuckle with a special tool Remove the upper arm mounting bolts and nuts LH RH Upper Arm Assembly Castle nut Bolt nut Upper arm 12 mm bolt 12 mm nut Split pin Tightening torque 110 130 Nm ...

Page 314: ...m 3 EA At first unscrew the two upper mounting nuts in engine compartment Tightening torque 60 80 Nm Unscrew the upper mounting nut 14 mm under the wheel house Tightening torque 60 80 Nm Unscrew the lower nut of coil spring shock absorber yoke from the lower arm Do not com pletely remove the nut Remove the tire and the upper arm Preceding Work Stabilizer link 12 mm Shock ab sorber yoke 24 mm Engin...

Page 315: ...BAG A T M T CLUTCH A X L E S P ST NG A CON T C 3 Remove the coil spring shock absorber Coil Spring Assembly Coil spring Shock absorber Yoke When installing the yoke to the coil spring shock absorber make sure that slot B and protru sion A are aligned Lock bolt Tightening torque 100 120 Nm ...

Page 316: ...e two bracket mounting bolts 14 mm and remove the stabilizer bar assembly Tightening torque 30 50 Nm Unscrew the lower mounting nut 12 mm and up per mounting nut 10 mm to remove the stabilizer bar link assembly Stabilizer bar Bushing Mounting bracket Tightening torque 30 45 Nm Tightening torque 110 130 Nm Remove the tires Preceding Work ...

Page 317: ...tabilizer Bar Assembly Nut Bushing Link Bracket Bracket Bushing Stabilizer bar Link Bushing Nut Link Nut Tightening torque 30 50 Nm Washer Bushing Washer 7 10 mm 1 Be cautious of the direction of the bushing and washer when installing 2 Be cautious of the marks on the front stabilizer bar LH RH when installing LH yellow mark RH white mark NOTICE ...

Page 318: ...1 Remove the tires 2 Make an alignment mark on the camber adjusting bolt of lower arm frame side Wheel Alignment Specification 2 2 mm 0 19 0 3 the difference between both ends is should be below 30 4 4 0 5 the difference between both ends is should be below 30 Description Toe in Camber Caster Front Rear ...

Page 319: ...nnect the SSPS solenoid valve connector 4 Loosen the steering gear box by unscrewing the steering gear box mounting bolts arrows and remove the camber adjusting bolts Interference between camber bolt and steering gear box Interference between camber bolt and steering gear box Be careful not to damage the SSPS solenoid valve connector NOTICE ...

Page 320: ...r nut of stabilizer bar link and the lower nut of coil spring shock absorber yoke Tightening torque 180 190 Nm Before removing lower arm assembly make the alignment marks on the mounting nut 14 mm on the frame and camber adjusting bolt 14 mm 1 The lower arm mounting bolts nuts on the frame LH RH Lower link nut 12 mm Tightening torque 1 Lower link nut 110 130 Nm 2 Lower shock absorber yoke nut 150 ...

Page 321: ... mm and re move the lower arm from knuckle end bolt with special tool 4 Place a safety jack under the lower arm and un screw the lower shock absorber yoke bolt Re move the yoke while raising the safety jack with lower arm Components 5 Remove the lower arm assembly from the vehicle Knuckle lower mounting nut 14 mm Tightening torque 140 160 Nm Tightening torque 50 70 Nm ...

Page 322: ...SUSPENSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 4510 MEMO ...

Page 323: ...balance of the vehicle when turning and mini mizes the vehicle s slope when the wheels are moving up and down separately It absorbs the vertical vibration of the vehicle body It enhances the ride comforts and prevents the fatigue break of the spring 4 Shock Absorber It is installed between the rear axle and body frame It relieves the vibrations and impacts deliv ered from wheels to vehicle body 5 ...

Page 324: ...ON KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 20 4510 Shock Absorber Coil Spring Seat Upper Lower Arm Link Stabilizer Bar Axle Housing 2 SYSTEM LAYOUT Upper Arm link Stabilizer Bar Link Lateral Rod ...

Page 325: ...S P ST NG A CON T C Lateral rod 22 mm 165 Nm Shock absorber lower 7 mm 10 mm 80 100 Nm Lower arm 22 mm 150 180 Nm Upper arm 22 mm 150 180 Nm Shock absorber upper 2 mm 30 45 Nm Stabilizer bar link lower 17 mm 12 mm 60 80 Nm Stabilizer bar link upper 17 mm 14 mm 30 45 Nm Stabilizer bar link lower 17 mm 12 mm 40 60 Nm ...

Page 326: ...SUSPENSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 22 4510 Location Lateral Rod Assembly Coil Spring Assembly Shock Absorber Assembly ...

Page 327: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION KYRON SM 2005 09 23 4510 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Stabilizer Bar Link Upper Lower Arm Assembly Stabilizer Assembly ...

Page 328: ...SUSPENSION KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 24 4510 Installation Drawing Front View Rear View ...

Page 329: ...l spring Damaged tire Worn bushing Deformed arm assembly Worn bushing Bent or broken coil spring Excessive resistance of lower arm ball joint Insufficient tire pressure Faulty power steering Worn or loosened lower arm bushing Worn or broken coil spring Replace Replace Re tighten Replace Replace Replace Pressure adjust Replace Tighten as specified torque Replace Replace Replace Replace Replace Repl...

Page 330: ... SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 26 4510 4 REMOVALAND INSTALLATION System Layout Upper arm Stabilizer bar Stabilizer bar link Rear suspension assembly Shock absorber Lateral rod Coil spring Lower arm ...

Page 331: ...ove the rear suspension components in order 1 Remove the coil spring using a special tool Removal of Components 1 Unscrew the lateral rod mounting nut 22 mm on axle Installation Notice 2 Unscrew the lateral rod mounting bolt nut 22 mm on frame Installation Notice 2 Remove the lateral rod Tightening torque 165 Nm Tightening torque 165 Nm ...

Page 332: ...tabilizer bar to remove the stabilizer bar 1 Unscrew the stabilizer bar link mounting nuts upper lower and remove the link Installation Notice 2 Remove the mounting cap bracket and bushing from the stabilizer bar LH RH Installation Notice Tightening torque 40 60 Nm Tightening torque Protrusion of upper bolt 30 45 Nm 7 12 mm ...

Page 333: ...G A CON T C 4 Remove the shock absorber between the frame and the axle 1 Remove the upper mounting nut 17 mm and the shock absorber bolt 6 mm as shown in the figure Installation Notice 2 Remove the lower bolt nut 17 mm Installation Notice Tightening torque 80 100 Nm Tightening torque Protrusion of upper bolt 30 45 Nm 27 mm ...

Page 334: ...r arm between frame and the axle A Unscrew upper arm mounting bolt nut 22 mm on axle B Unscrew upper arm mounting bolt nut 22 mm on frame Tightening torque 150 180 Nm Tightening torque 150 180 Nm The fuel tank should be removed before removing the rear left bolts upper arm and lower arm NOTICE ...

Page 335: ... from the frame and the axle 1 Remove the wheel speed sensor cable 1 and the parking cable 2 mounting bolt 12 mm when removing the lower arm 3 Unscrew lower arm mounting bolt nut 22 mm on axle Installation Notice 2 Unscrew lower arm mounting bolt nut 22 mm on frame Installation Notice Mounting bolt Tightening torque 150 180 Nm Tightening torque 150 180 Nm ...

Page 336: ...nsion and RIGID type It consists of coil spring shock absorber upper arm track rod thrust link and stabilizer bar Overview 1 OVERVIEW IRS TYPE REAR SUSPENSION This is installed between the rear axle and body frame It relieves the vibrations and im pacts delivered from wheels to vehicle body The spring should be installed as the red mark is over the yel low mark Coil Spring Red Yellow 69 5 mm ...

Page 337: ...lling at the same rate when meet ing bumps but it also affects handling This relieves the vertical vibra tions of vehicle to provide ride comforts prevents the spring break enhances drivability and extends the life span of steering components Upper Arm This is connected to the knuckle and body frame and controls the longitudinal load to the vehicle Stabilizer Bar Coil Spring Link This is connected...

Page 338: ...ed or worn wheel bearing Damaged shock absorber Damaged tire Over inflated tire Faulty shock absorber Loosened wheel nut Bent or broken coil spring Damaged tire Worn bushing Deformed arm assembly Worn bushing Bent or broken coil spring Excessive resistance of lower arm ball joint Insufficient tire pressure Faulty power steering Worn or loosened lower arm bushing Worn or broken coil spring Replace ...

Page 339: ...replace the wheel bearing with a new one 1 Release the parking brake 2 Raise the rear wheel and rotate it several times 3 Remove the tire 4 Hook a spring gauge on a hub bolt and pull it Read the scale on the gauge at the point when the drum starts to move It is preload 5 Check if the preload is within the specified range 1 Release the parking brake 2 Raise the rear wheel 3 Check if the wheel beari...

Page 340: ... 130 Nm Body 110 130 Nm Knuckle 140 160 Nm Stabilizer bar link 40 60 Nm Stabilizer bar mounting bracket bolt 40 60 Nm Stabilizer bar link 40 60 Nm Stabilizer bar link 40 60 Nm Coil Spring Track Rod Stabilizer Bar Knuckle 11 13 Nm Body 150 170 Nm Upper Arm The spring should be in stalled so that the red mark is over the yellow mark Red Yellow ...

Page 341: ... 09 37 4520 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Body 110 130 Nm Knuckle 120 150 Nm Thrust Link Wheel Speed Sensor Coil Spring Link Knuckle 110 130 Nm Body 150 170 Nm Body 30 45 Nm Coil spring link 60 80 Nm Shock Absorber Mounting bolt 6 8 Nm ...

Page 342: ...r and set the removed caliper on the frame 17 mm 2 bolts 3 Unscrew the two stabilizer bar mounting bracket bolts 14 mm from body frame and remove the stabilizer bar Rear Suspension Module Tightening torque 40 60 Nm Tightening torque 120 140 Nm Remove and tighten the wheel nuts in several steps in a crisscross sequence Tightening torque 85 105 Nm Mounting bracket ...

Page 343: ...l to compress the coil spring Remove the coil spring and spring seat while pulling down the coil spring link 6 Unscrew the bolt 10 mm and remove the parking brake cable and wheel speed sensor 4 Installthespecialtooltothecoilspringandcompressthecoilspringwiththetool Unscrewtheuppernut 17mm onthe shockabsorber Tightening torque 30 45 Nm Tightening torque 6 8 Nm ...

Page 344: ...ts body side 22 mm 4 EA and the axle housing hexagon nut 22 mm 1 EA Unscrew the thrust link mounting bolt nut 14 mm on body A Axle housing mounting nut 22 mm Tightening torque 95 142 Nm B Thrust link bolt nut on body Tightening torque 150 170 Nm C Sub frame coil bolt front 14 mm Tightening torque 95 142 Nm D Sub frame bolt rear 14 mm Tightening torque 95 142 Nm ...

Page 345: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION KYRON SM 2005 09 41 4520 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 8 Lower the safety jack and remove the sub frame from the vehicle ...

Page 346: ...r suspension Shock Absorber Assembly 2 Unscrew the shock absorber lower bolt nut bolt 14 mm nut 17 mm on coil spring link Preceding Work Remove the tire 1 Compress the coil spring with special tool and unscrew the shock absorber upper nut on body frame 17 mm 1EA Tightening torque 30 45 Nm Tightening torque 60 80 Nm ...

Page 347: ...ession force of coil spring by loosening the lower shock absorber bolt nut and remove the coil spring and upper spring seat Preceding Works 1 Remove the tires 2 Unscrew the bolt and lower the stabilizer bar 1 Compress the coil spring with special tool Upper spring seat Coil spring Red Yellow The spring should be installed so that the red mark is over the yellow mark NOTICE ...

Page 348: ...4 mm and remove the stabilizer bar bracket 2 Unscrew the bolt nut 14 mm on the link and stabilizer bar and remove the stabilizer bar Also unscrew the bolt 12 mm on the knuckle and remove the link Bushing Bolt Bracket Stabilizer bar Link mounting nut Tightening torque 40 60 Nm Stabilizer bar mounting nut Tightening torque 40 60 Nm Tightening torque 40 60 Nm ...

Page 349: ...M 2005 09 45 4520 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 3 Install the stabilizer link Be cautious of the installing direction LH RH Link Link Link mounting nut Bracket and bushing Bracket and bushing Stabilizer bar Link Link mounting nut ...

Page 350: ... tool to the coil spring Upper Arm Unscrew the bolt nut and remove the upper arm Upper Arm Knuckle Side 19 mm 1EA bolt nut Tightening torque 140 160 Nm Stabilizer Bar Link upper 12 mm 1EA nut Tightening torque 40 60 Nm Upper Arm 19 mm 1EA nut Tightening torque 110 130 Nm Upper Arm 19 mm 1EA bolt nut Tightening torque 110 130 Nm ...

Page 351: ...ke an alignment mark on toe in adjusting nut Thrust Link on Body Thrust Link Unscrew the bolt nut and remove the thrust link Thrust Link on Knuckle Upper Arm 19 mm 1EA bolt nut Tightening torque 110 130 Nm Track Rod on Sub Frame 22 mm 1EA bolt nut Tightening torque 150 170 Nm 17 mm 1EA nut Tightening torque 150 170 Nm Track Rod on Knuckle 19 mm 1EA bolt nut Tightening torque 110 130 Nm ...

Page 352: ...ly Preceding Works 1 Remove the tires 2 Unscrew the bracket bolts and lower the stabilizer bar 3 Remove the coil spring Make an alignment mark on camber adjusting nut bolt before removing them Camber Adjustment 1 Bolt and nut lower shock absorber 2 Bolt and nut knuckle 22 mm Bolt and nut sub frame 22 mm Bolt Nut on Lower Shock Absorber Knuckle Side Rear Suspension Module Side Tightening torque 120...

Page 353: ...TEERING SYSTEM 4610 4620 TABLE OF CONTENTS GENERAL INFORMATION 3 1 Overview 3 2 System layout 4 SSPS SPEED SENSING POWER STEERING 8 1 General information 8 2 Trouble diagnosis 15 3 Removal and installation 24 ...

Page 354: ......

Page 355: ...eering 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 cannot be generated a driver can steer the vehicle without power assist but it needs very high steering force In this case the operati...

Page 356: ...ower steering gear box assembly Power steering gear box pipe Power steering high pressure hose and pipe Feed pipe nut Tightening torque 40 50 Nm SSPS Solenoid Valve Return hose and pipe Gear box pipe Power steering high pressure hose and pipe cannot be replaced With SSPS Power steering return pipe Power steering pump assembly Tie rod end Power steering gear box ...

Page 357: ... 2005 09 5 4610 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Installation Drawing of SSPS Pipe bracket bolt 10 mm Tightening torque 9 14 Nm Pipe bracket bolt 10 mm Tightening torque 9 14 Nm Gear box mounting bolt Pipe mounting nut Tightening torque 20 26 Nm ...

Page 358: ...ing torque 40 60 Nm Tightening torque 20 25 Nm Lower shaft Tightening torque 18 25 Nm Tightening torque 30 40 Nm Tie rod end Tightening torque 7 11 Nm Tightening torque 20 25 Nm Tightening torque 65 80 Nm Tightening torque 70 90 Nm Steering wheel Column shaft Steering gear box Tightening torque 45 50 Nm ...

Page 359: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM KYRON SM 2005 09 7 4610 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Column shaft Lower shaft Steering gear box Steering wheel ...

Page 360: ... 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 pres sure solenoid valve located in the gear box to optimize the steerability In other words the steering wheel gets lighte...

Page 361: ...ration 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 ˆ œ fi IG Power Ground CAN HIGH CAN LOW Solenoid Valve SSPS CONTROL UNIT Meter Cluster SSPS warning lamp Trouble Diagnosis Spool Spring...

Page 362: ...d 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 current Specifications Solenoid Valve Location Cannot be replaced Description V...

Page 363: ...off and the manipulation of steering wheel becomes lighter 2 In medium and high speed driving 1 The shaft operating force of solenoid rod is reduced due to the reduction of output current from the SSPS control unit 2 The coil spring pulls the PCV spool toward solenoid valve to open it 3 The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to rea...

Page 364: ... 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 3 When a trouble occurs in the system the SSPS control unit generates a trouble code using fail safe function Pin No 1 2 3 4 5 6 7 8 Function Ignition Power Supply CAN HIGH Solenoid Solenoid Ground Warning Lamp SSP...

Page 365: ...ses Also it provides light steerability with high current as the vehicle speed decreases 1 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 working pressure from oil pump A port is not able to flow to the reacti...

Page 366: ... 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 Solenoid valve Connector B Port Spool Spring Steering gear box Right cylinder Left cylinder Valve body Pinion valve Balance line Pressure Filter PCV Plu...

Page 367: ...nnector and install the ammeter between the sole noid valve connector and the wiring harness SSPS solenoid valve 2 When the vehicle speed is at 0 km h check whether the electric current for solenoid is in specified range and check that the current is reduced as the vehicle speed increases 2 TROUBLE DIAGNOSIS Do not ground the solenoid terminal NOTICE Current 0 9 1 1 A vehicle speed at 0 km h Vehic...

Page 368: ...No 5 terminal Check the continuity between 2 connectors in steering gear box solenoid Damaged or disconnected wiring between ECU and SSPS solenoid valve connector Repair solenoid valve connector Check solenoid valve connector or replace ECU Poor contact in SSPS solenoid valve connector Poor contact in SSPS solenoid valve connector or defective ECU Is the resistance between terminal No 1 and No 2 m...

Page 369: ...on needs much more force due to no cur rents to SSPS solenoid NOTICE Trouble VIG 17 V VIG 8 V PW 30 vehicle speed 0 km h Faulty EEPROM Read Write PWM management error Detected current 1 28 A When solenoid is disconnected Target current detected cur rent 0 2 A and VIG 13 V No CAN messages 1 sec 1 sec 60 sec 1 sec 1 sec 1 sec 2 sec 30 sec C1104 C1105 C1212 C1604 C2203 C1623 Solenoid current 0 A Sole...

Page 370: ...POWER STEERING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 4610 Circuit Diagram SSPS Control Unit BrB LG BG G B Cluster B11 Diagnosis 12 LG BrB BG G SSPS Solenoid LgY GB GB LgY YR ...

Page 371: ...ned steering gearbox mounting bolt Damaged or binding steering ball joint Worn or damaged front wheel bearing Damaged wheel or tire Faulty suspension system Loosened steering gearbox mounting bolt Faulty steering gear Steering column interference Loosened steering linkage Damaged or loosened oil pump drive belt Loosened oil pump bracket Loosened oil pump mounting bolt Air in system Faulty oil pump...

Page 372: ... 1 000 rpm 3 Install the spring scale on the circumference of the steer ing wheel and measure the steering effort in both directions Steering effort below 3 0 kg Inner Outer Specified value 36 20 32 40 Steering Effort Check Steering Angle Check 1 Place the front wheel on a turning radius measuring tool 2 Turn the steering wheel to the its both ends and mea sure the maximum steering angle If the fr...

Page 373: ... at idle speed 7 Turn the steering wheel several times so that the oil temperature reaches to normal operating level oil temperature 50 80 C 8 Fully close the valve in pressure gauge and measure the oil pressure 9 Measure the oil pressure with the gauge valve fully open 10 If the pump pressure is in specified range the pump is normal If not replace the power steering pump Oil Pump Pressure and Oil...

Page 374: ... the level is between MAX and MIN level it s normal If it is over 5 mm bleed air from the system Checking 1 Place the vehicle on a flat ground and start the engine and let it run at idle speed 2 Turn the steering wheel several times so that the oil temperature reaches to normal operating level oil temperature 50 80 C 3 Place the steering wheel at straight ahead direction 4 Measure the oil level in...

Page 375: ...rn the steering wheel to its both ends repeatedly until any bubble cannot be seen in the reservoir 4 If any bubble is not found anymore add the specified oil into the reservoir to the specified level Checking 1 Start the engine and repeat the second and third step above 2 This process should be performed to check if air still exists in the power steering system AIR BLEEDING Position the gear shift...

Page 376: ...f engine ECU located in the passenger foot wall Preceding Work Disconnect the negative battery cable 1 Remove the engine ECU under the floor carpet SSPS Control Unit If the SSPS solenoid valve is defective the power steering assembly should be replaced NOTICE 2 Disconnect the SSPS control unit connector and separate the SSPS control unit from engine ECU ...

Page 377: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM KYRON SM 2005 09 25 4610 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C SSPS Control Unit ...

Page 378: ...storemovetheinstrumentlowerpanel Steering Column Shaft Preceding Work Disconnect the negative battery cable and place the tires to straight ahead direction Removal and Installation 1 Unscrew the screws at both sides of steering wheel and remove the horn pad air bag module Disconnect the airbag module connector Tightening torque 40 60 Nm Make an alignment marks on the column shaft and steering whee...

Page 379: ...ST NG A CON T C 4 Remove the protective panel and undercover from the lower panel and remove the upper lower column covers 5 Disconnect the contact coil and connector from the column shaft and remove the contact coil assembly Align the alignment marks when installing Contact coil mounting screw Inlet portDisconnect the connector ...

Page 380: ...RON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 28 4610 Unscrew the mounting screws Disconnect the connectors 6 Disconnect connectors and remove the combination switch from the steering column Combination Switch Assembly ...

Page 381: ...A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 7 Unscrew the bolts and nuts and remove the steering column shaft assembly while pulling down it Mounting Bolts 3 EA Mounting Bolts 2 EA Tightening torque 20 25 Nm Tightening torque 20 25 Nm Tightening torque 18 25 Nm Lower Shaft Mounting Bolt 1 EA ...

Page 382: ...ower lock bolt in underbody 3 Remove the lower shaft 2 Remove the lower shaft mounting nuts on floor Installation Notice Tightening torque 7 11 Nm Lower Shaft Assembly Tightening torque 18 25 Nm Tightening torque 18 25 Nm Install the lower shaft so that the lock bolt can be in serted into the point without spline Be cautious of the alignment marks NOTICE ...

Page 383: ...Gear Box Preceding Works 1 Disconnect the negative battery cable 2 Remove the tire 1 Remove the cotter pin and lock nut Remove the tie rod from steering knuckle by using a special tool 661 589 13 33 00 W 99 44 002 0A Ball Joint Puller Tightening torque 35 45 Nm 2 Remove the SSPS connector 3 Unscrew the lower bolts and remove the lower shaft and gear box ...

Page 384: ...m Supply and Return Pipes Gear Box Mounting Gear box Cross Member Gear box Mounting Clamping Bolt Tightening torque 30 40 Nm Tightening torque 70 90 Nm Tightening torque 70 90 Nm Plug the pipe openings with caps Be careful not to spill the oil on the floor and vehicle body NOTICE Tighten the center bolt nut first and then tighten the left mounting bolt with the specified tightening torque NOTICE ...

Page 385: ...p 1 Remove the drive belt 3 Unscrew the nuts and remove the pump assembly with bracket Installation Notice Tightening torque 20 23 Nm 2 Disconnect the power steering return hose and remove the high pressure pipe nut Installation Notice Tightening torque 40 50 Nm High pressure pipe Return hose Plug the openings so that power steering fluid doesn t leak out NOTICE ...

Page 386: ...MEMO ...

Page 387: ...SP system related precautions 27 10 Hydraulic circuit diagram 28 11 Hydraulic pressure for each ESP operating range 29 12 Hydraulic circuit of HBA Hydraulic Brake Assist 31 13 Components description 32 14 Bleeding ESP system 46 15 ABS ESP trouble diagnosis 48 ABS SYSTEM 60 1 General information 60 2 Configuration of ABS system 63 3 Input and output diagram 64 4 Hydraulic circuit of ABS 65 5 ABS ci...

Page 388: ...isc Rear Disc 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 WhenABS ESP is installed on the 5 link type suspension the solid disc disc thickness approx 10 4 mm is installed When ABS ESP is installed on the independent suspension the ventilated disc disc ...

Page 389: ...CTIVE DATE AFFECTED VIN ABS ESP SYSTEM KYRON SM 2005 09 3 4890 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Sectional Drawing Front Disc Brake Rear Disc Brake Two internal cylinders One internal cylinder ...

Page 390: ...trument 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 In vehicle without ABS In vehicle with ABS ESP KY...

Page 391: ...ake pad Disc plate thickness Wear limit of disc plate I D O D of disc plate Type Operation type I D of drum Capacity Specification NON ABS 5 link suspension 2 x φ 43 mm 10 5 mm 2 mm 26 mm 24 mm φ 294 φ 184 mm Drum type φ 254 mm 55 x 243 x 5 φ 23 81 mm 5 link suspension Solid disc type φ 42 9 mm 10 mm 2 mm 10 4 mm 8 5 mm φ 299 φ 220 mm Independentsuspension IRS Ventilated disc type φ 42 9 mm 10 mm ...

Page 392: ...d s friction material Therefore for some time after the brake disk pad replacement the brake system poorly operates or noise abnormal sound occurs due to the partial contact This is the noise Creep groan that occurs when in both the automatic and manual transmission slightly releasing the brake pedal in the neutral gear at downhill roads It frequently occurs at the low braking power and low speed ...

Page 393: ...urns and prevents the vehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed auto matically by switch operation when driving slowly on steep hills over 10 about 5 71 degree Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Brake Fo...

Page 394: ...s Appearance of wheel speed sensor Location Layout of relevant components 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 Conventional T C New T C HDC Switch Active Wheel Speed Sensor ESP HECU With speed sensor Without speed sensor ...

Page 395: ...nding 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 Cautions When R...

Page 396: ... ring prevents moisture 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 Rubber O ring Please refer to the part time transfer case section for more specific information Rubber seal ring Internal steel spr...

Page 397: ...g voltage 9 16 V Integrated yaw rate sensor and lateral sensor Also used for sensing G value for HDC Hill Descent Control Analog Output ABS ESP beside of brake booster Mounted in each wheel 4EA Front airgap 0 335 0 945 mm Rear airgap 0 309 0 958 mm In steering wheel Behind the center audio in instrument panel Under master cylinder When the ESP system is added to the ABS system some devices will be...

Page 398: ...ng the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering Understeering is when the steering wheel is steered to a certain angle during driving and the front tires slip to ward the reverse direction of the desired direction Generally vehicles are designed to have under steering The vehicle can return back to inside of cornering line ...

Page 399: ...iving direction and the driver can steer the vehicle as he or she intends ESP Control As the single track vehicle model used for the calculations is only valid for a vehicle moving forward ESP intervention never takes place during backup The ESP system includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the bra...

Page 400: ...e is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating Only ESP operating No braking by driver ESP Conventional brake ABS not operating ESP ABS brake ESP TCS Engine Control Operations Understeering Control Oversteering Control ESP auto brake ESP auto brake ESP auto brake E n g i n e c o n t r o l Driver foot brake operatio...

Page 401: ...ing according to pres sure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals When the sys tem is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels The brake pressure value and the ...

Page 402: ...ensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns Assess whether vehicle condition meets ARP operation condition Adjust with ARP function Driving conditions Yaw rate value Comparative data processing Actuator operation Other reference values Steering wheel angle sensor ESP AREA ARP AREA The vehicle drivin...

Page 403: ...itch and the green HDC indicator comes on When the G sensor within the sensor cluster detects a slope level exceeding 10 the ESP s HDC function operates When this occurs the green HDC indicator flashes along with a loud operation sound When you press the HDC switch the green HDC indicator comes on and when the HDC operates the green HDC indictor flashes at 0 5 second of interval The G Sensor withi...

Page 404: ...d in 4L mode Forward and reverse driving 3 km h HDC Hill Descent Control System Operating Conditions 1 When HDC switch is turned ON 2 Gearshift lever position Forward Reverse Manual transmission operates in the 1st gear or reverse gear position does not operate in neutral position Automatic transmission operates in any position except for P parking or N neutral positions and and The vehicles with ...

Page 405: ...s changed to stand by mode When depressing the accelerator pedal again HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by operating the accelerator pedal 5 Vehicle position control function in ESP and HBA function are not in operation The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP functio...

Page 406: ...il the vehicle reaches the speed condition given in step 4 or or or or or Vehicle with manual transmission Sensing at the neutral switch Vehicle with automatic transmission Sensing at the selector lever unit NOTICE 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...

Page 407: ...ongitudinal acceleration sensor Sensor cluster When depressing brake pedal during HDC operation 1 If the slope level is between 10 and 20 HDC is deactivated 2 If the slope level exceeds 20 HDC function is still activated and the brake pressure is added Brake pedal switch 1 RPM 2 Engine torque 3 Gas pedal module monitoring gas pedal depression When depressing accelerator pedal dur ing HDC operation...

Page 408: ...OFF ON OFF OFF Blinking ON Not available Stand by In operation System overheat HDC switch OFF HDC system error HDC switch ON The HDC switch is turned ON but HDC system is in stand by mode because the operating requirements are not met HDC system is operating The HDC switch is turned ON and the operating requirements are met HDC is operating with operating sound High brake system temperature over 3...

Page 409: ... Below is the summary of precautions to remember 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 driv...

Page 410: ... EFFECTIVE DATE AFFECTED VIN 24 4890 7 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 Motor pump Valve body ...

Page 411: ...ST NG A CON T C 1 2 3 4 5 ABS ESP Indicator ESP OFF Switch Remark Comparison with ABS System No Name ESP Component HECU Pressure sensor Wheel speed sensor Sensor cluster Steering wheel angle sensor 0 0 0 0 0 ESP system contains ESP OFF switch and HDC switch 0 N A 0 N A N A HDC Indicator HDC Switch Active Wheel Speed Sensor ...

Page 412: ...und Signal Ground Signal Ground Signal Ground Signal Ground Power source Signal Ground Power source STN Ground ST2 ST1 IG1 6 25 29 15 11 41 2 47 16 9 31 This line is used to send the error code to diagnostic connector when an ABS related component is defective Sending and receiving the informa tion such as speed signal of ABS HECU from to ECUs through CAN communication In ESP equipped vehicle the ...

Page 413: ...make sharp turns or drive 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 4 During the HDC operation a loud noise and the vehicle vibration may occur from the HECU and the brake system but this is a norm...

Page 414: ...mary circuit Damper secondary circuit Separation valve NO Shuttle valve Low pressure accumulator Damping chamber Pump Separation valve NO Shuttle valve FR inlet valve NO FL inlet valve NO RR inlet valve NO RL inlet valve NO FR outlet valve NC FL outlet valve NC RR outlet valve NC RL outlet valve NC Wheel FR Wheel FL Wheel RR Wheel RL ...

Page 415: ... 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 un changed conditions For details refer to Hydraulic Pressure for each ESP Operating Range 11 HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE ESP Hydraulic unit in idling and normal braking po sition In this position the ...

Page 416: ... 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 gets locked ESP unit circuit when the pressure is maintained ESP unit circuit when the pressure is increased Outle...

Page 417: ...g 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 wheel starts ...

Page 418: ...U ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ESP 6 valve for ABS and they cannot be disassembled 2 Comparison ESP HECU and ABS EBD HECU 1 HECU installed in a vehicle ABS HECU ESP HECU 3 Other components Rear RH only applicable to ESP ESP ECU HECU Pump Motor Valve Body Secondary Rear RH and LH Rear LH when ESP is applied Front RH Primary Front LH ...

Page 419: ... primary and secondary master cylinder pipes from HECU Tightening torque 1 Disconnect the control unit connector 3 Disconnect the front and rear wheel brake pipes Tightening torque Removal and Installation Be careful not to damage the HECU pipes and nut threads when reinstalling NOTICE HECU to each hydraulic line 13 20 Nm Master cylinder to HECU 13 20 Nm ...

Page 420: ...sensor 3 Second pressure sensor 4 Hydraulic pipe in primary circuit 5 Hydraulic pipe in secondary circuit 6 Inside of pressure sensor 7 Connector 1 2 3 Supplying voltage Location Specifications 4 75 5 25 V Output voltage 0 25 4 75 V This is linearly changed from 0 5 V brake not applied to 4 75 V brake applied Output range 0 170 bar ...

Page 421: ...20 bar 2 Pressure changes over 1500 bar sec 3 Vehicle speed over 7 km h ESP unit Description Pressure Sensor Circuit The sensor consists of two ceramic disks one of which is stationary and the other movable The distance be tween these disks changes when pressure is applied The pressure sensors operate on the principle of changing capacitance a The distance S between the disks and thus the capacita...

Page 422: ...essure sensor 4 Place an empty container under the pressure sensors to collect the oil 5 Remove the primary and secondary pressure sensors When installing Removal and Installation Tightening torque 33 37 Nm 6 Install in the reverse order of removal 7 Bleed the brake system after installation 3 Remove the fuel filter bracket to remove the pressure sensor ...

Page 423: ...w rate acceleration around the vertical axis of the vehicle and transmits it through the CAN communication line to the ESP unit using the electronic signal Especially the longitudinal acceleration sensor detects the slope level of the driving road and provides important information for the HDC operation Location Specification sensor cluster yaw rate sensor lateral acceleration sensor Longitudinal ...

Page 424: ...ateral longitudinal and yaw rate sensors is transmitted to ESP unit via two CAN lines The supplied voltage from ESP unit is approx 5 V with ignition key ON and the output range through CAN line is approx 0 2 4 8 V When a sensor is faulty the sensor cluster produces an output signal of 0 V fail safe function The ESP control operates when a divergence occurs between the vehicle yawing and the steeri...

Page 425: ...L E S P ST NG A CON T C Preceding Work Disconnect the battery negative cable 2 Remove the AV head unit assembly Removal and Installation 1 Remove the center fascia panels left right Remove four screws Remove three screws before removal AV head unit may have different connectors according to the specifications NOTE ...

Page 426: ...unscrew the cluster mounting bolts When installing Tightening torque 7 9Nm 4 Install in the reverse order of removal The installing direction and location are very impor tant when installing the sensor cluster Make sure that there are not any foreign material and interfer ence with floor carpet on the mounting surface NOTICE ...

Page 427: ...handle and sends the steering angle signal to ESP HECU 1 SWAS Steering Wheel Angle Sensor 2 Combination switch assembly Specifications SWAS Steering Wheel Angle Sensor Location Working voltage Max output current Detected max angular velocity Working temperature Supplying voltage Output voltage HI Output voltage LO 9 16V 10 mA 1500 S 30 75 C 9 16V battery voltage Approx 3 50V 3 0 4 1V Approx 1 50V ...

Page 428: ... pulse from the 3 terminals Then the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle speed And the other pulse is used for checking the alignment of the steering wheel Working voltage 9 16 V Duty Approx 50 Low V 1 3 2 0 V Number of pulse per revolution 45 Pulses 1 rev High V 3 0 4 1 V STN Detects the center value of steering wheel ST1 an...

Page 429: ...aches a certain limitation a beep sounds to warn the driver The ESP warning lamp goes off when ESP function is deactivated Even when the ESP is operated for a very short period of time the ESP warning lamp blinks minimum of 4 times every 175 milliseconds ESP OFF Switch Location ESP operation including TCS ON OFF ON OFF 175ms 175ms ESP warning lamp Min 4 times ESP OFF Switch ESP Warning Lamp Blinki...

Page 430: ... is still operated The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch is pushed for over approximately 150 ms while the ESP system is not operating The detailed operation procedures are as follows 1 The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms 2 The switch returns to normal position when the OFF switch is ...

Page 431: ...FF Switch Monitoring 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 NOTICE Push Release 10 sec 3 5 sec Cancellation of ESP OFF mode Turning the ESP warning lamp off Detect failure ESP operation HI LO ON OFF ESP function including TCS ESP warning lamp ON OFF Return to switch signal Reset ...

Page 432: ...aliper and place an empty container under the screw 4 Bleed the air in each wheel by using diagnostic device At this time the modulator motor runs for 180 seconds 5 Simultaneously run the oil supply device to supply oil and depress the brake pedal repeatedly This procedure needs at least 3 persons for doing below jobs 1 Collect the bleeding oil into the container 2 Depress the brake pedal repeated...

Page 433: ...AIR BLEEDING TEVES ABS ESP REAR RIGHTAIR BLEEDING 1 OPEN THR BLEED SCREW 2 CONTINUALLYPUMPING BRAKE PEDAL PUMP MOTOR VALVEACTIVATING 3 TOTALACTIVE TIME 180 Sec DO YOU STARTAIR BLEEDING Yes No AIR BLEEDING TEVES ABS ESP REAR RIGHTAIR BLEEDING ACTIVATING PUMP MOTOR VALVE THE WHEEL MUST BE BLEED UNTILE THERE IS FOAMLESS AND BUBBLE FREE BRAKE FLUID SEEN AT THE BLEED SCREW TIME xxx Sec BUBBLE FREE FOAM...

Page 434: ...sor and tooth wheel Different number of teeth in tooth wheel Action Check the wheel speed sensor connector Check HECU connector Check air gap and tooth wheel mounting Specified air gap 0 335 0 945 mm Check the number of teeth 48 in tooth wheel 1 C1021 5021 Cause Defective front RH wheel speed sensor Short or poor contact wire to sensor Action Check the wheel speed sensor connector Check HECU conne...

Page 435: ...nsor and tooth wheel Different number of teeth in tooth wheel Action Check the wheel speed sensor connector Check the HECU connector Check air gap and tooth wheel mounting Specified air gap 0 309 0 958 mm Check the number of teeth 48 in tooth wheel 1 C1041 5041 Cause Defective rear LH wheel speed sensor Short or poor contact wire to sensor Action Check the wheel speed sensor connector Check the HE...

Page 436: ...ge check between ESP unit terminal No 2 and ground Specified voltage 1 3 4 1V STN voltage check between ESP unit terminal No 12 and ground Specified voltage 1 3 4 1V Sensor Monitoring ABS X O X O Defective Components Descriptions Trouble Code System Function Sensor cluster C1073 5073 C1074 5074 Sensor cluster electrical Sensor cluster internal 1 C1073 5073 Cause Operating voltage exceeds specified...

Page 437: ...e harness and connector 2 C1202 5202 Cause Mechanical defective in ESP OFF switch Defective ESP OFF switch harness short to ground Action Check the harness and connector for ESP OFF switch X O Brake disc C1111 5111 Disk temperature is high Cause Overheated brake disk due to braking force over 500 C Action Stop driving for a period of time after turning off the ESP Battery C1101 5101 C1102 5102 Bat...

Page 438: ...bnormal sensor data Action Check the sensors Initialize the sensors O O HECU C1401 5401 HECU hardware Cause Internally defective HECU Defective A D converter internal voltage regulator and controller Defective sensor and short to supplying voltage line Abnormal temperature sensor signal Action Replace the HECU Motor pump C1302 5302 Defective motor pump Cause Too low below 6 0 V or no supplying vol...

Page 439: ...ause Short to CAN communication line Overload to CAN communication Action Action Check the TCU Check the CAN communication line Check the TCU connector 3 C1604 5604 Cause Short to CAN communication line Overload to CAN communication Action Action Check the TCCU Check the CAN communication line Check the TCCU connector 4 C1605 5605 Cause Short to CAN communication line Overload to CAN communication...

Page 440: ...0 CAN signal error EMS C1612 5612 Signal from engine ECU is abnormal Cause Engine ECU is defective Signal from engine ECU error Action Check engine ECU Check ECU S W version CAN Communica tion Monitoring ABS ESP X O Defective Components Descriptions Trouble Code System Function ...

Page 441: ...ng Wheel Angle sensor Pressure Sensor Primary Pressure Sensor Secondary EBD Control BTCS Control Engine TCS Control ESP Control ESP TCS OFF Switch ABS Control Stop Lamp Switch O O O O O O O O O O O O O O O O O O O O O O O O X Fixed Value 0 X Fixed Value 0 X Fixed Value 0 X Fixed Value 0 X Fixed Value 0 O X X X X O O 1 km h 1 km h 1 km h 1 km h 0 1V 0 01 g Straight ahead 0 01 g Left Turn 0 5 deg s ...

Page 442: ... Outlet Valve 1 RR Inlet Valve 2 RR Outlet Valve 2 TCS Valve Primary 3 TCS Valve Secondary 3 ESV Valve Primary 3 ESV Valve Secondary 3 Motor Pump Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non operation Operation Non ...

Page 443: ...GITUDINALACCELSENSOR 4WD only DO YOU START INITIALIZE Yes No CONDITION ENGINE IS NOT RUNNING VEHICLE STATUS IS FLAT DO NOT PUT THE BRAKE PEDAL PROCEDURE MUSTBE FOLLOWTHEABOVE CONDITION IF YOU START INITIALZE SENSOR ADAPTTOAUTOMATIC Initialize both the primary and secondary pres sure sensors when initializing a pressure sensor Steering wheel angle sensor The steering wheel angle sensor automaticall...

Page 444: ...UTLETVALVE 5 REAR ESP REAR LEFT INLET VALVE 6 REAR ESP REAR LEFT OUTLET VALVE 7 REAR RIGHT Only ESP INLET VALVE 8 REAR RIGHT Only ESP OUTLET VALVE 9 1st TCS VALVE Only ESP 10 2nd TCS VALVE Only ESP 11 1st ESV VALVE Only ESP 12 2nd ESV VALVE Only ESP 13 PUMP MOTOR Select one of the above items FRONT LEFT INLET VALVE ON ACTIVE YES KEY OFF STOP NO KEY OTHER ITEM ACTIVE TIME Max 10 Sec CONDITION IG ON...

Page 445: ...Y EFFECTIVE DATE AFFECTED VIN ABS ESP SYSTEM KYRON SM 2005 09 59 4890 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Clearing Code CLEAR VARIANT CODE VEHICLE CODING CLEAR DO YOU START TO CLEAR YES NO ...

Page 446: ...f 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 New Transfer Case ABS SYSTEM Without Speed Sensor With Speed Sensor ...

Page 447: ...cks 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 Wheel Speed Sensor Front Wheel Speed Sensor Rear Wheel Speed ...

Page 448: ... ring prevents moisture 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 Rubber O ring Please refer to the part time transfer case section for more specific information Rubber seal ring Internal steel spr...

Page 449: ...mponents of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor HECU Valve body and ECU integrated type B Plunger C Can bushing Front Wheel Speed Sensor for 4WD Rear Wheel Speed Sensor ABS warning lamp Front wheel speed sensor FR Front wheel speed sensor FL Rear wheel speed sensor RL Rear wheel speed sensor RR ABS HECU Motor ...

Page 450: ...eel rotates Sending and receiving the information suchasspeedsignalofABSHECUfrom to ECUs through CAN communication 4 32 1 41 15 11 45 34 36 43 46 33 37 42 2 47 16 3 INPUT AND OUTPUT DIAGRAM Input Output of ABS without TPMS Battery hydraulic valve and ECU power supply Battery pump supply power IG1 Brake switch CAN HI CAN LO Wheel speed sensor FL Wheel speed sensor FR Wheel speed sensor RL Wheel spe...

Page 451: ... 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 Wheel FR Wheel FL Wheel RR Wheel RL Secondary circuit Primary circuit Master cylinder Inlet valve FR Low press...

Page 452: ... This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels In order to prevent from hydraulic pres sure increases the inlet valve is closed and the outlet valve is opened Also the oil is sent to the low pressure cham ber and the wheel speed increases again The ABS ECU operates the pump to circulate the oil in the low pressure ...

Page 453: ...N SM 2005 09 67 4890 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 6 COMPONENTS AND LOCATION Wheel Speed Sensor Front for 4WD Wheel Speed Sensor Rear Primary master cylinder Front RH wheel Rear RH LH wheel Front LH wheel Secondary master cylinder ...

Page 454: ...unger during motor operation the system pressure is generated in the left cylinder At this time the right plunger is expanded by spring force and the expanded volume of the right cylinder draws the brake fluid 1 Motor pump 2 Valve body Pumping 3 ECU Including Solenoid Valves HECU controls the hydraulic valves by supplying or cut ting off the voltage to solenoid valves depending on the wheel speed ...

Page 455: ... Disconnect the ABS hydraulic unit connector 3 Disconnect the primary and secondary master cylinder pipes from HECU Tightening torque 4 Disconnect the front and rear wheel brake pipes Tightening torque 8 REMOVALAND INSTALLATION HECU Assembly Master cylinder HECU 20 24 Nm HECU Each hydraulic line 15 19 Nm Be careful not to damage the HECU pipe and nut thread when reinstall NOTICE ...

Page 456: ...n the reverse order of removal 7 After reinstallation add some oil and perform the brake air bleeding HECU mounting nut 4 8 Nm When you install a new HECU to the vehicle coding is executed automatically Thus no additional coding is necessary NOTICE Do not attempt to disassemble the HECU assembly Wrap the opening of pipes and HECU to prevent contamination NOTICE ...

Page 457: ...ording to the magnetic field by using four resisters and supplying the 12 V power supply to the sensor Front wheel speed sensor Rear wheel speed sensor This sensor contains 1 Four resistance 2 Supply voltage from HECU 12 V 3 Internal printed circuit board The system uses the wheatstone bridge that detects and compares the changes in each resistance value Before passing through the comparison measu...

Page 458: ...9 CHANGED BY EFFECTIVE DATE AFFECTED VIN 72 4890 1 Disconnect the front wheel speed sensor connector 2 Remove the front brake disc Loosen the hub end bolts do not remove and disconnect the wheel speed sensor Front Wheel Speed Sensor ...

Page 459: ...t Keep the specified tightening torque and air gap Tightening torque When Installing Front wheel speed sensor Airgap 6 8 Nm 15 20 Nm 0 475 1 453 mm 0 1 0 7 mm 2WD 4WD Tighten the bolts with the specified tightening torque Otherwise the air gap between the wheel speed sensor and wheel rotor may be out of specified value and this may cause an incorrect input value to HECU NOTICE ...

Page 460: ...g bolt 10 mm Remove rear wheel speed sensor Keep the specified tightening torque and air gap Tightening torque When Installing Wheel speed sensor Airgap mm 6 8 Nm 0 037 1 175 5 link 0 489 1 039 IRS Tighten the bolts with the specified tightening torque Otherwise the air gap between the wheel speed sensor and wheel rotor may be out of specified value and this may cause an incorrect input value to H...

Page 461: ...g system operation process 6 4 Air bag module and other components 8 5 Electrical wiring diagram 16 6 Air bag system deploy firing loop 17 7 Air bag deployment signal output crash out 18 8 Air bag warning lamp operational conditions 19 9 Reminder for air bag related component replacement 20 10 Servicing the air bag system 21 11 Diagnosis 31 ...

Page 462: ......

Page 463: ...r s seat belts retract seat belts Curtain air bag G sensors 1 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 bag only the air bag at the side of collision deploys not both Replacement parts when the front air bags deploy the air bag units ...

Page 464: ... 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 8810 2 LOCATIONS AND RELATED COMPONENTS LH When the curtain air bag LH deploys RH BPT Belt Pretensioner Curtain air bag collision G sensor When the curtain air bag RH deploys ...

Page 465: ...nal for 5 seconds Air bag warning lamp PAB Passenger Air Bag Air Bag Unit SDM The collision G sensor is installed inside 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...

Page 466: ... on the Instru ment Panel Diagnosis Connector DC DC Converter Sends out signals to operate the front air bags and the seat belt pretensioners This sensor detects any longitudinal lat eral deceleration occurring when vehicle collides Then the sensor supplies the data to the micro controller Longitudinal Lateral Direction Collision G Sensor Security Circuit Battery Load Dump Protection When the init...

Page 467: ...imultaneously and their seat belt pretensioners also simultaneously retract their seat belts The air bag unit monitors conditions of the air bags and the seat belt pretensioners When any error occurs it stores the failure diagnostic code or turns on the air bag warning lamp on the instrument panel The collision G sensors for the curtain air bags are installed at the bottom of left and right B pill...

Page 468: ...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 Air bag cover 2 Air bag housing 3 Air bag cushion approx 50 liters 4 Inflator approx 190 ...

Page 469: ...he 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 inflates the air bag cushions curtain air bags independently operate i...

Page 470: ...osives and the gas generator 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 When the Curtain Air Bag Deploys Curtain air bag mounting point Inflator ...

Page 471: ...DATE AFFECTED VIN AIR BAG SYSTEM KYRON SM 2005 09 11 8810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Components Sectimal view b b Sectimal view a a Tightening torque 8 10 Nm a a b b Tightening torque 8 10 Nm ...

Page 472: ...n 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 Belt Pretensioner Driver Side Belt Pretensioner Passenger Side Belt pretensioner LH Belt pretensioner RH Curtain air bag G sensor Tightening torque 35 55 Nm ...

Page 473: ...oner reel assembly 2 Reel bracket 3 Ring upper stay 4 D ring 5 Bending tongue 6 Tongue stopper 7 Mini anchor 8 D bolt 9 Washer 10 Fiber washer 11 Rivet 12 ID label 13 Plastic washer 14 Steel washer 15 D bolt 16 Label 17 D bolt 18 Spacer 19 Bush 20 Mini anchor cover Components Belt Pretensioner 7 6 5 4 3 1 2 17 20 18 19 10 16 15 14 9 13 12 8 11 10 9 ...

Page 474: ...AIR BAG SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 14 8810 Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 475: ...h 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 Signal terminal Ground Tightening torque 9 Nm 1 Nm Connector Passenger s Side ...

Page 476: ...AIR BAG SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 8810 5 ELECTRICAL WIRING DIAGRAM ...

Page 477: ... the basic inner resistance of the air bag related module and the basic instant current necessary for a firing Air bag module Driver passenger air bag DAB PAB Belt pretensioner BPT Curtain air bag CAB Resistance at 30 85 C Firing current for 2msec at 35 C 2 0 3 Ω 1 2 Amp 2 15 0 35 Ω 0 8 Amp 2 0 3 Ω 1 0 Amp Please do not connect a tester to any air bag connector or single item to measure the suppli...

Page 478: ...omatic door unlock function that cancels the automatic door lock mode Automatic Door Unlock Crash unlock unlock when colliding ING KEY SW 1 AIR BAG DEPLOYMENT SIGNAL DOOR UNLOCK RELAY T1 200 ms T2 40 ms T3 5 sec T2 T1 T3 ON OFF ON OFF ON OFF Deployment signal output Crash out 200 ms Reminder for door lock unlock control The unlock function by the air bag signal takes priority over any other lock u...

Page 479: ...warning lamp will turn off if no more malfunctions have been detected When Turning the Ignition Switch to the ON Position When the air bag unit detects any malfunctions in its unit When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second Then the waning lamp stays on When the Air Bag Unit Rec...

Page 480: ...eded repairs also slightly vary between the front air bags and the curtain air bags The following are the differences Replacement parts 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 ba...

Page 481: ...P ST NG A CON T C 10 SERVICING THE AIR BAG SYSTEM DAB Driver Air Bag Preceding Work Disconnect the negative battery cable 1 Remove the air bag module assembly from steering wheel 2 Disconnect all connectors and remove the air bag assembly Components Front View Rear View Release the hook before disconnecting the connector ...

Page 482: ...ter position when installing Components Align the arrows when installing If the contact coil is not properly aligned the steering wheel may not be able to rotate com pletely during a turning Restricted turning abil ity may cause the vehicle to crash Improper alignment of the contact coil also may make the SIR system inoperative preventing the air bags from deploying during a crash Turn the contact...

Page 483: ... CLUTCH A X L E S P ST NG A CON T C Preceding Work Disconnect the battery nagative cable and remove the instrument panel assembly For details refer to Body section 1 Remove the lower air duct from the removed instrument panel assembly PAB Passenger Air Bag 2 Unscrew five nuts on the air bag module 10 mm ...

Page 484: ...FECTIVE DATE AFFECTED VIN 24 8810 3 Remove the air bag module assembly from the instrument panel Components Retainer Air bag cushion Inflator Air bag module housing The air bag module cannot be removed Below pic ture is only for reference WARNING ...

Page 485: ...B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Preceding Work Disconnect the battery negative cable and remove the instrument panel assembly For details refer to Body section 1 Disconnect the connector of the curtain air bag while releasing the hook CAB Curtain Air Bag ...

Page 486: ...AIR BAG SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 26 8810 2 Remove the handle bracket and then remove the curtain air bag assembly Components ...

Page 487: ...g Work Disconnect the negative battery cable Air Bag Unit SDM 1 Remove the center fascia driver s lower panel passenger s lower panel and center console For details refer to Body section 1 Center fecia LH RH 2 Driver s lower panel 3 Passenger s lower panel 4 Center console 2 Remove the AV head unit assembly For details refer to AV System section ...

Page 488: ... 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 28 8810 3 Unscrew the screws on the instrument panel and remove the relevant components power socket shift lever cover Mounting Screw Same at Both Sides Power Socket Cover Mounting Screw ...

Page 489: ...st be replaced Please do not attempt to de lete the failure code with scan I 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 pre vent any damage Please do not connect a tester to any air bag con nector or single item to measure the supplied power or resistance The detonator may exp...

Page 490: ...ponents Tightening torque 9 Nm 1 Nm The body panel has guiding holes to ensure its cor rection 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 Because the gap between the installation bolt and the sensor is small grind the bolt locking socket to around 1 5 mm before ...

Page 491: ...e Check if curtain air bag sensor is short to battery voltage or ground Check if curtain air bag sensor is defective Check battery condition below 10 6 V for 16 seconds resumes when the voltage is normal level for 9 6 seconds Check driver air bag connector Check driver air bag wiring including clock spring Check air bag unit terminals for damage Resistance of squib over 6 1 Ω Check driver air bag ...

Page 492: ...ector Check driver pretensioner wiring Check air bag unit terminals for damage Resistance of squib below 0 8 Ω Check driver pretensioner connector Check driver pretensioner wiring Check air bag unit terminals for damage Resistance of squib below 2 kΩ Check driver pretensioner connector Check driver pretensioner wiring Check air bag unit terminals for damage Resistance of squib below 2 kΩ Check pas...

Page 493: ...urtain air bag wiring Check air bag unit terminals for damage Resistance of squib over 4 3 Ω Check passenger curtain air bag connector Check passenger curtain air bag wiring Check air bag unit terminals for damage Resistance of squib below 0 6 Ω Check passenger curtain air bag connector Check passenger curtain air bag wiring Check air bag unit terminals for damage Resistance below 2 kΩ Check passe...

Page 494: ...amage Check passenger curtain air bag connector Check passenger curtain air bag wiring Check air bag unit terminals for damage Check passenger curtain air bag connector Check passenger curtain air bag wiring Check air bag unit terminals for damage Resistance below 250 Ω Check passenger curtain air bag connector Check passenger curtain air bag wiring Check air bag unit terminals for damage Resistan...

Page 495: ...system AQS 26 9 Air conditioner module sensors and actuators30 10 Removal and installation 40 AIR CONDITIONING SYSTEM 6810 6910 6810 TABLE OF CONTENTS FFH FUEL FIRED HEATER SYSTEM 61 1 Overview 61 2 FFH layout 62 3 Specifications 64 4 FFH operating process 65 5 Components and functions 70 6 Removal and installation 75 7 Trouble diagnosis 82 PTC Positive Temperature Coefficient SYSTEM 86 1 Overview...

Page 496: ...to FATC controller Sun Sensor Instrument Panel Upper Left A function that turns on off the air source selection and air quality system AQS Sensor and Ambient Temperature Sensor This sensor is installed at the front bottom of engine compartment This changes the air source mode by detecting the air pollution AQS Switch AQS sensor Compressor AIR CONDITIONING SYSTEM 1 SYSTEM LAYOUT AND COMPONENTS Ambi...

Page 497: ...dition to control the air conditioner Engine ECU Passenger Footstep A sensor that detects coolant tem perature and transmits to engine ECU Coolant Temperature Sensor On Engine Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Receiver Drier LH Front Air Conditioner Module Assembly Inside of Instrument Panel Air mix door actuator Coolant temperature sensor Mode door ac...

Page 498: ...AIR CONDITIONING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 6810 2 VENTILATION SYSTEM Locations of Vents Air Duct ...

Page 499: ...ITIONER MODULE WIRING AND LAYOUT Front Air Conditioner Module Wiring Layout Air Duct Layout Air source door actuator Blower motor Power transistor Air conditioner controller unit Air mix door actuator Intake sensor Coolant temperature detection sensor Mode door actuator Main wire connector Active incar sensor interior temperature sensor and humidity sensor ...

Page 500: ...ule And Sensors Locations Coolant Temperature Sensor Power Transistor Blower Motor Interior temperature and humidity sensor Air Source Door Actuator Air Conditioner Filter Mode Door Actuator Intake Sensor A C Controller Unit Interior Temperature Sensor Interior Humidity Sensor Power transistor Blower motor ...

Page 501: ...urce door case A C filter Heater core Mode door actuator Mode door link assembly Mode door Heater unit case right Heater unitcase left Air mix door actuator A C cable assembly Power transistor Coolant temperature detection sensor Interior Ambient door actuator Blower motor assembly Intake sensor Blower unit case upper Blower unit case lower Evaporator Lower duct ...

Page 502: ...AIR CONDITIONING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 8 6810 PTC Heater and FFH Heater Layout FFH Heater Assembly Layout PTC Heater Assembly Layout PTC ...

Page 503: ...M T CLUTCH A X L E S P ST NG A CON T C 4 AIR CONDITIONER CONTROLLER UNIT Functions of Full Automatic Air Conditioner Controller 2 1 7 8 9 10 3 5 4 6 11 1 TEMP switch 2 AUTO switch 3 OFF switch 4 AMB switch 5 Mode switch 6 Blower switch 7 AQS switch 8 FRE switch 9 Defroster switch 10 A C switch 11 VFD Display ...

Page 504: ...ompressor door mode air source door air mix door and blower motor automatically Active Incar Humidity Sensor AIH Sensor The AIH sensor is installed on the air conditioner controller unit It is a sensor that detects interior temperature and humidity Display Window VFD Each switch mode appears as a symbol on the fluorescent display and malfunction of each sensor in air conditioner control system is ...

Page 505: ...rs refer to AQS and ambient temperature sensor Defroster Switch When pressing this switch the airflow direction will be changed to windshield and door glasses the air conditioner operates automatically and outside air comes in At this moment the defroster indicator air conditioner indicator and fresh air mode indicator come on When pressing the switch again the air conditioner returns back to norm...

Page 506: ...AIR CONDITIONING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 12 6810 Full Automatic Air Conditioner Controller Interior temperature and humidity sensor ...

Page 507: ... the TEMP DIAL is set under 18 0 C this shows Lo If it is set over 32 0 C this shows Hi 1 2 17 4 5 18 14 13 19 20 15 16 3 6 12 11 10 9 8 7 REC FRE FR DEF FAN speed 0 FAN speed 1 FAN speed 2 FAN speed 3 FAN speed 4 FAN speed 5 FAN speed 6 FAN speed 7 FAN speed 8 MODE VENT MODE B L MODE FOOT MODE D F AUTO AUTO A C A C AQS AMB OFF IGN ON OFF IGN OFF TEMPDIAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 508: ... D F mode 20 C 55 C and AUTO mode 55 C When the coolant temperature sensor is defective the heating control function is cancelled after 500 seconds Level OFF 1 2 3 4 5 6 7 8 Control voltage 0 V 4 V 4 25 V 4 5 V 4 75 V 5 V 5 25 V 5 5 V 5 75 V Level 9 10 11 12 13 14 15 16 17 Control voltage 6 V 6 25 V 6 5 V 6 75 V 7 V 7 25 V 7 5 V 7 75 V 8 V Level 18 19 20 21 22 23 24 25 26 Control voltage 8 25 V 8 ...

Page 509: ...thermo AMP temperature is below 2 C COMP ON when it is over 4 C When theAMB button is pressed the ambient tempera ture is displayed for 5 seconds When the vehicle stops while driving the ambient temperature before stop is displayed The air flow is directed to VENT according to the amount of sunload In VENT and B L modes the blower voltage increases within 2 5 V Cooling Start Airflow Control Maximu...

Page 510: ...oes out Fan Speed Control Switch The fan speed can be adjusted in 4 stages A C operation indicator Bi level Mode The air flows towards front windshield and floor and the indicator comes on Vent Mode The air flows towards face and the indicator comes on Foot Mode The air flows towards floor and the indicator comes on Manual air conditioner controller controls the fan speed air distribution directio...

Page 511: ...ure can be adjusted by rotating the switch Clockwise direction red Higher temperature Counterclockwise direction blue Lower temperature Higher temperature Lower temperature Recirculation indicator Defroster Switch When pressing this switch the airflow direction will be changed to windshield and door glasses the air conditioner operates automatically and outside air comes in At this moment the indi...

Page 512: ...ø ÜÁøÀÔ Turn the ignition switch to OFF position and press OFF switch for more than 5 seconds within 10 seconds Self Diagnosis 1 Starting Self Diagnosis 1 Press OFF switch more than 5 seconds 2 Check LED segments on the vacuum fluorescent display VFD 5 SELF DIAGNOSIS ONLY FOR FATC AIR CONDITIONER ...

Page 513: ...e right to set in the trouble diagnosis step 2 3 Sensor failure code blinking 2 2 2 2 2 First sensor failure code blinks twice 21 21 21 21 21 Second sensor failure code blinks twice 2 5 2 5 2 5 2 5 2 5 When two sensors are defective 10 20 seconds Trouble Code 21 21 21 21 21 Short circuit in the ambi ent air temperature sensor 2 Set in Trouble Diagnosis Step 2 21 21 21 21 21 Code 0 1 2 3 4 Malfunct...

Page 514: ...is displayed If any failure exists the appropriate trouble code is displayed Trouble Code 1 Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 3 21 21 21 21 21 3 3 3 3 3 30 30 30 30 30 2 Indication of Step 2 Starting self diagnosis 3 Sensor failure code blinking 30 no failure 3 Set in Trouble Diagnosis Step 3 Code 1 2 3 4 5 Malfunction Defective VENT Defective B L FOOT D...

Page 515: ...e Intake air temperature Mode door Interior Ambient door Air mix door Blower Compressor 41 Displayed Number 5 Set in Trouble Diagnosis Step 5 51 51 51 51 51 VENT REC F COOL 4 5 V ON B L REC F COOL 10 5 V ON B L 20 FRE F HOT 8 5 V OFF FOOT FRE F HOT 8 5 V OFF D F FRE F HOT 8 5 V ON DEF FRE F HOT MAX ON 42 43 44 45 46 In this step check the position of actuator door check the fan speed and check the...

Page 516: ...ording 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 43 43 43 43 43 61 61 61 61 61 Step 6 Min temperature compensation value 3 3 3 3 3 o o o o o C C C C C Max temperature compensation value 61 61 61 61 61 2 Compensates the temperature by turning TEMP dial 6 Set in Trouble Diagnosis Step 6 3 3 3 3 3...

Page 517: ...ine ECU turns off air conditioner compressor as below in addition to above conditions 1 Coolant temperature below 20 C 2 Coolant temperature over 115 C 3 For approx 4 seconds after starting the engine 4 When engine speed is below 650 rpm 5 When engine speed is over 4 500 rpm 6 During abrupt acceleration for the vehicle equipped with manual transmission Setting temperature Compressor control AQS se...

Page 518: ...rough windshield and changes it into current and then sends the signal to FATC controller 1 Remove the sun sensor and measure the current between terminals under sunlight 2 Measure the current again under shade It is in normal conditions if the measured value is less than the measured value under sunlight 3 Turn the ignition switch to ON position 4 Measure the voltage to the sun sensor from FATC c...

Page 519: ...d 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 Humidity sensor Active incar sensor interior temperature sensor Active Incar Humidity Sensor AIH Sensor The AIH sensor is installed at the driver side ...

Page 520: ...election to recirculation mode when polluted air is detected throughAQS sensor The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears Components of AQS 8 AIR QUALITY SYSTEM AQS Press the AUTO switch AQS sensor and ambient temperature sensor AQS sensor Connector Ambient temperature sensor ...

Page 521: ...tion to fresh air mode 4 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 Changed to recirculation mode from fresh air mode AQS indicator comes on AQS switch ...

Page 522: ...UTOA C ON TEMP switch ON Adjusting fan speed control dial Mode change MODE switch AUTOA C ON TEMP switch ON Adjusting fan speed control dial Mode change MODE switch Pressing AQS switch Pressing AQS switch AQS ON AQS OFF Memory return when system OFF 6 TheAQS is turned off 1 When pressing the defroster switch 2 When pressing the recirculation mode switch If the ignition switch is turned off with AQ...

Page 523: ... K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 1 Disconnect the negative battery cable and remove headlamps 2 Disconnect theAQS sensor connector unscrew two bolts 10 mm and remove theAQS sensor assembly Install in the reverse order of removal Removal and Installation Connector AQS sensor ...

Page 524: ... addition if the resistance is extremely high or low replace the sensor 2 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 3 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 4 If the volt...

Page 525: ...tive battery cable and remove the instrument panel assembly 1 Disconnect the connector from the removedA C module assembly and then remove the bracket screw on heater pipe 2 Remove the heater pipe bracket and separate the water temperature sensor from bracket Removal and Installation The water temperature sensor should be removed after removing the air conditioner module assembly ...

Page 526: ...ATC If the power transistor defect code DTC 6 appears check as below 1 Turn the ignition switch to ON position 2 Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6 3 The specified voltage value in each stage Air conditioner power transistor 4 If the voltage is out of specified value check the circuit for open If the circuit is in normal condition replace the...

Page 527: ...cable 1 Remove the lower instrument panel in front of passenger seat and disconnect the power transistor connector 2 Unscrew the mounting screws and remove the power transistor Removal and Installation The power transistor should be removed after removing the lower instrument panel in front of passen ger seat For removal and installation of the lower instrument panel refer to the Body section ...

Page 528: ...ections 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 The air flows towards face Vent mode The air flows towards face and foot Bi level mode The air flows towards foot Foot mode The air flows towards front windshield and foo...

Page 529: ...ate the mode door actuator and remove the mode door link assembly Windshield mode door lever Vent Bi level Foot Defroster and foot Face mode door lever Foot mode door lever 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 Make sure that the mode door link mo...

Page 530: ...ontrol signal from FATC Preceding Work Disconnect the negative battery cable and then remove the instrument panel assembly 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 Removal and Installation In ex air door actuator location In ex air actuator component ...

Page 531: ...roperly by closing opening the damper according to the control signals from FATC Preceding Work Disconnect the battery negative cable and remove the instrument panel assembly 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 Removal and Installation Air mix door actuator l...

Page 532: ...o 1 and 2 on the connector 2 Check whether the output voltages ON approx 12 V off 0 V 3 If the voltage value is out of the specified value replace the Intake Sensor If the circuit is in normal condition check as below 4 Turn the ignition switch to ON position and turn on the air conditioner by pressing theA C button And measure the voltage between terminal A12 and A11 on the FATC controller connec...

Page 533: ...nstrument panel assembly 1 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 2 Separate the upper case and lower case of blower unit and remove the Intake Sensor from the evaporator Mounting Bolt at Bottom of A C Module Removal and Installation Blower unit Heater unit side Evapora...

Page 534: ...rument panel assembly 1 Disconnect the heater hose A from the engine compartment and remove theA C high low pressure pipe mount ing nuts Remove the mounting nut and loosen the coolant reservoir A Inner outer heater hose and clamp B A C joint pipe mounting nut 1 Collect the air conditioner refrigerant before removing the air conditioner module dispose the wasted refrigerant to designated place 2 Dr...

Page 535: ...NING SYSTEM KYRON SM 2005 09 41 6810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 2 Unscrew four mounting screws on A C module assembly in engine compartment 3 Carefully remove the A C module assembly Behind vaccum pump 1 Behind FFH pump 3 ...

Page 536: ... CONDITIONING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 42 6810 A C Module Mounting Location Mounting locations inside of vehicle Mounting locations on backide of A C module Front View ...

Page 537: ...er switch assembly Air Controller Switch And Active Incar Humidity Sensor Preceding Work Disconnect the negative battery cable and remove the center fascia panel assembly 1 With the center fascia panel removed unscrew two mounting screws from theA C controller switch assembly 2 Disconnect the connectors from theA C controller switch assembly Air Controller Switch Assembly ...

Page 538: ...E DATE AFFECTED VIN 44 6810 Active In Car humidity Sensor Disconnect the sensor connector unscrew two mounting screws and remove the sensor from the air conditioner controller switch Remove Mounting Screw Disconnect Connector Active in car sensor humidity sensor ...

Page 539: ... K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Air Duct Assembly Preceding Work Disconnect the negative battery cable and remove the instrument panel assembly 1 Unscrew the mounting screws one at each side and four in center area and remove the front air duct Air Duct On Instrument Panel ...

Page 540: ...YRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 46 6810 2 Unscrew the mounting screws one at each side and remove the left and right air ducts 3 Unscrew the mounting screws one at each side and remove the upper air duct ...

Page 541: ...ing Work 1 Disconnect the negative battery cable and remove the center fascia panel and center lower panel 2 Remove the center console assembly 1 Unscrew two center mounting screws in floor air duct 2 Unscrew the mounting bolts and remove the air duct Vehicle with Foot Parking Brake Vehicle with Hand Parking Brake Mounting Screws Lower Air Duct Assembly Floor Air Duct ...

Page 542: ...Driver side lower air duct is installed behind the lower instrument panel Remove it according to the procedures for removal of lower panel 2 Passenger side floor air duct is located under the air conditioner module Floor air duct LH Floor air duct RH Air conditioner module assembly Mounting screw Floor air duct ...

Page 543: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN AIR CONDITIONING SYSTEM KYRON SM 2005 09 49 6810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C MEMO ...

Page 544: ...t grille out of the instrument panel Side Vent Grille The driver side vent grille is located on the outside mirror switch bezel assembly Unscrew four mounting screws and remove the vent grille assembly Left side vent grille Removal Installation Vent Grille Assembly Preceding Work Disconnect the negative battery cable The vent center grille and the vent side grille should be removed after removing ...

Page 545: ... L E S P ST NG A CON T C Center vent grille Right side vent grille Right side vent grille Side Vent Grille 1 Unscrew the mounting screws with the front air duct removed 2 Pull the vent grille out of instrument panel Center Vent Grille Center vent grille is mounted on the center facia panel with four screws two at each side ...

Page 546: ... bumper assembly 3 Drain the coolant Store the collected A C refrigerant and coolant into the designated container 1 Remove the air cleaner duct Unscrew two mount ing screws release the cleaner hose clamp and remove the duct 2 Remove the pipes from the radiator oil cooler for automatic transmission Installation Notice Tightening torque 25 35 Nm Removal and Installation ...

Page 547: ...ses from the inter cooler 4 Remove the inlet outlet hoses and return hose from the radiator Return Hose LH RH Radiator Inlet Hose 5 Remove the air conditioner hose and pipe at condenser side High pressure Pipe Compressor Side Low pressure Pipe Receiver Dryer Side Tightening torque 16 23 Nm Plug the pipe openings with a seal caps after disconnecting the high low pressure pipes ...

Page 548: ...w the mounting bolt 10 mm and remove the front support panel 6 Disconnect the ambient temperature switch con nector and theAQS sensor connector and remove the ambient temperature switch 7 Unscrew three mounting bolts 10 mm and re move the hood latch mounted on the front end panel and support panel ...

Page 549: ...2005 09 55 6810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 10 Unscrew three mounting bolts 10 mm and then remove the front end panel 9 Unscrew four bolts and remove the radiator mount ing bracket 11 Remove the mounting clips and remove the radiator assembly ...

Page 550: ...ANGED BY EFFECTIVE DATE AFFECTED VIN 56 6810 13 Unscrew the upper and lower mounting bolts 10 mm and remove the inter cooler from the radiator 12 Remove the outlet pipe from the inter cooler Remove Two Mounting Bolts 10 mm Inter Cooler Assembly ...

Page 551: ...STEM KYRON SM 2005 09 57 6810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C 14 Remove the oil cooler pipes for automatic transmission from the radiator assembly 15 Unscrew five mounting bolts 10 mm and remove the air conditioner condenser assembly ...

Page 552: ...ery cable 2 Collect the air conditioner refrigerant 1 Disconnect the connector from the receiver dryer 2 Unscrew the mounting nuts on the receiver dryer and remove the high low pressure pipes 3 Unscrew the mounting bolt and remove the receiver dryer The oil rings on the pressure pipes should be replaced with new ones once removed Tightening torque 20 30 Nm ...

Page 553: ...sconnect the negative battery cable and collect the air conditioner refrigerant 1 Remove the cooling fan belt from the engine 2 Disconnect the connector from the compressor 3 Unscrew the flange nuts of pressure pipes and compressor mounting boltsandremovethecom pressor assembly Tightening torque 18 27 Nm Tightening torque 16 23 Nm Tightening torque 18 27 Nm Tightening torque 16 23 Nm ...

Page 554: ...0 6810 Receiver drier Liquid pipe Liquid hose Suction hose Joint pipe assembly Piping Layout of Air Conditioner and Heater Suction hose Discharging hose Compressor A C condenser assembly Liquid hose Receiver drier Liquid pipe Heater outlet hose Heater inlet hose Joint pipe assembly ...

Page 555: ...hile 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 oper ated or stopped by driver s intention The FFH system is automatically operated by the coolant temperature and the amb...

Page 556: ...bracket assembly 3 FFH bracket assembly 4 FFH water pump bracket 5 FFH NO 3 inlet hose 6 FFH NO 2 inlet hose 7 FFH pipe assembly silencer 8 Ambient temperature switch 9 FFH fuel pump 10 Fuel pump bracket 11 Fuel pipe NO 1 12 Fuel pipe NO 2 13 Fuel pipe NO 3 14 Tube clip mounting 15 Tube clip mounting 16 Intake hose 17 Clamp 18 FFH NO 1 inlet hose ...

Page 557: ...anger 12 Upper bush for fuel pipe 13 Lower bush for fuel pipe 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 To...

Page 558: ...of the heat flow Heat flow Fuel consumption per hour Mean electric power consumption Rated voltage Lower voltage limit An undervoltage protection device in the controller switches the heaters off at approx 10 volt Upper voltage limit An overvoltage protection device in the controller switches the heaters off at approx 15 volt Tolerable operating pressure Minimum water flow through the heater Fuel ...

Page 559: ...the ambient temperature at repeat operation should be below 1 C and the coolant temperature should be below 75 C Above graph shows the FFH control process while the FFH is operating The control element is coolant temperature as shown in the graph The FFH is operated in HI mode high output approx 5 000 W until the coolant temperature reaches at 80 C and starts to be operated in LO mode low output a...

Page 560: ...erature risk to person or material sensitive to temperature from radiation and direct contact Before working on the coolant circuit disconnect the negative battery cable and wait until all compo nents 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 coola...

Page 561: ... K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C The FFH has various sensors in FFH unit and the FFH unit is connected to the water pump the fuel circulation pump and the ambient temperature sensor switch that provides important signals for the initial and repeat operations Circuit Diagram ...

Page 562: ... fuel pump fails to ignite within 90 seconds after fuel pumping starts the start procedure is repeated as described If after a further 90 sec onds fuel pumping the fuel pump still fails to ignite the heater is switched off in fault mode The con troller is locked after a certain number of failed starts 2 If the flame does out by itself during operation firstly a new start is activated If the fuel p...

Page 563: ...D BY EFFECTIVE DATE AFFECTED VIN AIR CONDITIONING SYSTEM KYRON SM 2005 09 69 6910 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Function Diagram Switching Diagram According to Temperature Changes ...

Page 564: ...omponent 1 Control and overheating sensor 2 Mounting spring Check controller and overheating sensor Check the control and overheating sensor with a digital multimeter If the resistance according to the changes of flame sensor temperature is out of specified values the flame sensor is defective Specified value 120 0 38 110 0 50 100 0 67 90 0 91 80 1 25 70 1 75 60 2 48 50 3 60 40 5 33 30 8 06 20 12 ...

Page 565: ...r housing 4 Mounting screw 1 The surface sensor and cable harness make up one component 1 Surface sensor 2 Mounting spring 120 0 62 100 1 02 90 1 32 80 1 75 70 2 34 60 3 19 50 4 41 40 6 20 30 8 90 20 13 03 10 19 53 0 30 00 Temperature C Resistance W Surface Sensor Check Surface Sensor Check the surface sensor with a digital multimeter If the resistance of flame sensor is out of specified values th...

Page 566: ...6910 1 Glow plug 2 Combustion chamber with flame pipe 1 Jacket 2 Combustion chamber housing 3 Insulation washer 4 Seal combustion chamber combustion air fan 5 Seal combustion chamber heat exchanger 1 Flame sensor 2 Graphite bush 3 Bush Glow Plug Combustion Chamber Housing Flame Sensor ...

Page 567: ...flame sensor is out of specified values the flame sensor is defective 1 Jacket 2 Combustion chamber 3 Combustion chamber housing 4 Insulation washer 5 Seal combustion chamber combustion air fan 6 Seal combustion chamber heat exchanger Specified value Temperature C Resistance W 250 1941 200 1758 150 1573 130 1498 100 1385 90 1347 80 1309 50 1194 30 1097 20 1062 10 1022 0 1000 50 803 350 2297 300 21...

Page 568: ...xchanger 3 Jacket 4 O ring 5 Seal combustion chamber heat exchanger 1 Jacket 2 Combustion chamber with flame tube 3 Heat exchanger 4 Seal combustion chamber heat exchanger 5 O ring for heat exchanger 1 Heat exchanger 2 Jacket 3 Stopper 4 Groove bottom of heat exchanger Combustion Chamber Heat Exchanger Heat Exchanger ...

Page 569: ...ng Work Disconnect the negative battery cable Fuel Pump The FFH is an auxiliary device that automatically operates or stops according to the coolant temperature and the ambient air temperature In initial operating stage the fuel pump generates the operating sound and the FFH heater produces white smoke These are normal states to fill the fuel into the FFH fuel line After replacing the FFH related ...

Page 570: ... AFFECTED VIN 76 6910 1 Disconnect the fuel pump connector with the vehicle lifted 2 Disconnect the fuel hose from fuel pump 3 Unscrew the bracket mounting bolt 10 mm and remove the fuel pump assembly Plug the hose opening with a seal cap to prevent oil leakage NOTICE ...

Page 571: ...L E S P ST NG A CON T C Preceding Work Disconnect the negative battery cable and remove the right headlamp 1 Remove the ambient temperature sensor from holder 2 Disconnect sensor connector while pushing the connector pin Ambient Temperature Switch The ambient temperature switch should be re moved after removing the headlamp ...

Page 572: ...IR CONDITIONING SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 78 6910 Preceding Work Disconnect the negative battery cable FFHAssembly FFH Assembly FFH Coolant Circulation Pump Assembly ...

Page 573: ...A X L E S P ST NG A CON T C 2 Remove the hose and pipe from the fuel pump 1 Disconnect the FFH coolant circulation pump A connector and FFH connector B 3 Unscrew the hose clamps on the FFH coolant circulation pump and remove the inlet and outlet hoses Plug the hose openings with seal caps to pre vent oil leakage NOTICE ...

Page 574: ...IN 80 6910 4 Unscrew five bracket nuts 10 mm and remove the FFH coolant circulation pump assembly 1 Unscrew three mounting nuts at bottom of coolant reservoir Front Mounting Nut FFH Exhaust Pipe Side FFH Assembly 2 Unscrew the mounting nuts from the FFH coolant circulation pump ...

Page 575: ...e fuel is sprayed out connect the fuel pipe to FFH assembly and keep the engine running for 1 minute 4 Connect the ambient temperature switch connector 1 Connect the ambient temperature switch connector as shown in picture A 2 Check if the fuel comes out after engine started as the FFH fuel supply hose is disconnected Picture B Fuel Feeding Operation Otherwise FFH system could make white smoke wit...

Page 576: ...6910 7 TROUBLE DIAGNOSIS Connect Scan 100 to the diagnostic connector located at the lower instrument panel 1 Select KYRON in VEHICLE SELECTION 2 Select FFH FUEL FIRED HEATER in CONTROL UNIT SELECTION 3 Select the trouble code out of check items FFH Heater Trouble Diagnosis Precedure ...

Page 577: ... surface sensor and con trol overheating sensor is too large Prerequisite for this trouble code display is that the heater is in operation and the water tem perature at the overheating sensor has reached min 80 C check cooling system Check temperature sensor and overheating sensor replace if nec essary Heater does not operate The controller is locked Delete trouble code to release controller lock ...

Page 578: ...combustion air and flame sensor Check exhaust gas and combustion air Check fuel quantity and fuel supply Clean or replace filter in fuel pump Fault no more starting attempt allowed Check exhaust gas and combustion air system Check fuel quantity and fuel supply Check flame sensor see trouble code 64 and 65 Fault no more starting attempt allowed Check exhaust gas and combustion air system Check fuel...

Page 579: ...age in radiator Leakage in coolant auxiliary tank Leakage in heater core Leakage in joint junction of coolant hose Leakage in defective coolant hose Leakage in water pump gasket Leakage in water pump sealing Leakage in water inlet cap Leakage in thermostat housing Insufficient tightening torque of cylinder head bolt Damaged cylinder head gasket The coolant leakage Check the coolant level Excessive...

Page 580: ...o the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required Alternator of 12V 75A 90A has changed to 12V 140A Non operational Condition During engine cranking When too low battery voltage Below 11V During preheating process of glow plugs PTC Relay and Fuse PTC Relay 2 PTC Heater 1 40A PTC POSITIVE TEMPERATURE COEFFICIENT SYSTEM PTC Heater 3 40A...

Page 581: ...s of PTC P T C Heater Heating type Element Advantages Air heating type Ceramic PTC BaTio3 1 Stable output regardless of voltage changes 2 Block the overcurrent with switch effect of PTC element 3 High heating capacity in a moment 4 Excellent durability of heating element against high current 2 COMPONENTS Spring clip PTC Ceramic Connector Radiator Element Frame ...

Page 582: ... coolant temperature 15 C tow conditions described below must be satisfied PTC OFF Condition 1 Air conditioner blower switch OFF 2 Ambient temperature sensor error wiring short or open 3 When engine cranking 4 Battery voltage is lower than 11V 5 When preheating the engine Glow indicator ON 3 PTC OPERATING PROCESS PTC Operating ON Condition The operating condition of PTC is controlled by two step G...

Page 583: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN AIR CONDITIONING SYSTEM KYRON SM 2005 09 89 6810 B R A K E A BAG A T M T CLUTCH A X L E S P ST NG A CON T C Electrical Wiring ...

Page 584: ...E AFFECTED VIN 90 6810 Preceding Work Disconnect the negative battery cable and the instrument panel 4 REMOVALAND INSTALLATION 2 Unscrew two mounting bolts and remove the PTC assembly from the A C module assembly 1 Disconnect the PTC connector while pulling out it A ...

Page 585: ...TABLE OF CONTENTS RKSTICS REKES STICS STICS 3 1 Overview 3 2 Specifications 4 3 Functions and specifications 8 4 Trouble shooting 18 5 Diagnosis trouble code and help tips 47 6 Electrical wiring diagrams 49 ...

Page 586: ......

Page 587: ...E A T A CRUISE E L 1 OVERVIEW The RKSTICS REKES STICS 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 RKSTICS REKES STICS STICS Door Lock Relay PAS Buzzer Door Lock Relay RK STICS ...

Page 588: ...Max operating humidity Resistible voltage Insulating resistance Parasitic current Voltage drop DC 12 0 V DC 9 0 V 16 0 V 30 C 80 C 40 C 85 C 95 24 V No heat and fire due to the current leaks below 7 0 mA below 1 5 V below 1 8 V Should operate normally within this range 9 5 V 16 0 V only for auto hazard lamp function Should operate normally within this range Confined with PCB waterproof and coating...

Page 589: ...rning relay Power window relay Rear defogger relay Wiper LOW relay Wiper HIGH relay Front washer motor Rear washer motor relay Headlamp relay Front defogger relay DC 12 V 350 mA Inducted load DC 12 V 16 W Lamp load DC 12 V 8 W Lamp load DC 12 V 1 2 W Lamp load DC 12 V 1 2 W Lamp load DC 12 V 1 2 W Lamp load DC 12 V 1 2 W Lamp load DC 12 V 200 mA Inducted load DC 12 V 200 mA Inducted load DC 12 V 2...

Page 590: ...PEN ON BAT GND OFF OPEN Approx 5 1 V 9 2 V ON GND PWM OFF OPEN ON GND DATA OFF BAT ON GND DATA OFF BAT KWP2000 ON GND DATA OFF BAT KWP2000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 IGN1 IGN2 ALT_D Key reminder door ajar warning switch Driver s door switch Passenger s door switch Rear door switch Tailgate switch Hood switch Driver s door lock unloc...

Page 591: ...or 1 0 second after IGI 1 ON The time indicated in each function does not include the vehicle speed calculating time 2 20 ms target input Wiper motor A S parking terminal 3 100 ms target input switch All switches except wiper motor A S parking terminal Chattering of Input Signals Time Tolerance 1 If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms 2...

Page 592: ...holding the switch When re leasing the switch it returns to the rear wiper operate position Rear Wiper Operation Rear Wiper Stops Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch When releasing the switch it returns to OFF position Continuous wipe fast operation Stop the operation When pulling up the lever the wiper operates once and the wiper lever returns...

Page 593: ...imes immediately after turning off the washer switch Wiper MIST and Front Washer Coupled Wiper KEY IN IGN2 SW WASHER SW WIPER MOTOR PARKING WIPER LOW RELAY ON OFF ON OFF ON OFF ON OFF T1 0 3 T2 0 1 0 59 sec T2 T1 KEY IN IGN2 SW ON T1 0 3 sec T2 over 0 6 sec T3 one wiper cycle T1 T2 T3 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the igniti...

Page 594: ...ch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off 2 It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation Rear Washer Motor Control T1 within 0 3 sec T2 0 1 0 59 sec T3 over 0 6 sec T4 3 cycles T5 pause T1 T1...

Page 595: ...h OFF the washer motor output is activated for 1 second If the system recognizes this output the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second Then the wiper relay output is deactivated after 3 cycles T1 over 100 ms T2 1 0 0 1 sec T3 within 0 3 sec T4 4 cycles T5 3 cycles T6 0 5 0 1 sec T1 T2 T2 T5 T4 T3 T6 KEY IN IGN2 SW ON OFF INT SW AUTO A...

Page 596: ...dden during the auto washer coupled wiper operation 4 The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation 5 When the auto INT switch input is received during the auto washer operation the auto washer operation stops and the auto INT operation is activated KEY IN IGN2 SW ON OFF INT AUTO WITCH ON OFF FRONT WASHER SW ON OFF AU...

Page 597: ...E E L Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout Multi function wiper Switch RKSTICS Wiper Motor Rain Sensor Auto Light Sensor Wiper parking Wiper LO Wiper HI INT Auto SW Auto washer SW Washer SW Volume Resistance LIN Local Interconnect Network communication N C Numerical Control 4 1 2 3 IGN 1 15 ...

Page 598: ...he wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal T1 1 cycle T1 T1 T1 Rain sensing unit auto light integrated type Multifunction wiper switch AUTO and sensitiv ity control A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting sec tion on the...

Page 599: ... the rain sensor even during the washer coupled wiper s operation Rain Sensing Sensitivity Control 1 The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased while the ignition key is in the ON position the wiper switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain senso...

Page 600: ...on and the wiper switch is in ON position The wiper motor runs only when the rain sensor requires 2 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 The wiper motor runs only when the rain sensor requires SEN 2 SEN 2 WIPER PARKING IGN Operation GND St...

Page 601: ...gnal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 2 The wiper relay LOW is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position T1 1 cycle T1 T1 1 cycle T1 SENSI...

Page 602: ...the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity Symptom 3 The wiper operates 3 or 4 times at high speed abruptly Symptom 2 It rains but the system does not work in the AUTO position 1 Check whether the multifunction wiper switch is in the AUTO position 2 Check the power to the sensor Check the conditions of the ...

Page 603: ... in the AUTO position with the ignition switch ON 2 Rain detected headlamp If it rains heavy which requires the highest INT speed the headlamps are turned on automatically 3 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 ...

Page 604: ... to ON 3 Intermittent interval at 0 km h 3 0 5 19 2 seconds 2 Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 1 41 km h 3 VOLUME calculation The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis 4 Pause time calculation 1 Pause time the duration...

Page 605: ...ning ON time even when the INT switch is turned off 2 IGN 2 switch ON INT switch OFF Resume the intermittent time when turning ON 3 IGN 2 switch OFF INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective 1 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is ON INT switch ON or Wa...

Page 606: ...K for 5 seconds after the driver s door is opened and the door lock switch is changed to LOCK while the ignition key is in ignition switch 2 The system outputs UNLOCK for 5 seconds T2 when the door lock switch is changed to LOCK from UN LOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch 3 If the UNLOCK conditions are met the UNLOCK output shoul...

Page 607: ...ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated 5 This function does not work if the vehicle speed is over 10 km h 1 DR PS RR DOOR LOCK SW T GATE LOCK SW 2 DR or PS or RR DOOR SW All Door Lock Prevention Function when a Door is Opened T1 within 0 5 sec T2 5 0 sec T3 OFF during T2 output 1 ...

Page 608: ...hen turning off the tail lamp and closing the driver s door 3 The system outputs UNLOCK for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open 4 This function is not available when the ignition key is in the ON position Mark Lamp Left on Warning T1 0 8 sec 0 1 sec T2 5 sec 0 5 sec T1 T1 T2 T2 IGN1 ON OFF TAIL LAMP R...

Page 609: ...es off when closing the door under step 1 3 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on 4 The warning light blinks when a door is open while the vehicle speed is over 10 km h 5 The warning light goes off when closing the door under step 3 6 The warning light comes on when the vehicle speed is below 10 km h under step 3 Door Ajar Warning T2 0...

Page 610: ... the seat belt is fastened before turning the ignition key to the the ON position the warning light in the indicator display blinks however the chime buzzer does not sound 2 The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to the OFF position 3 The chime buzzer stops and the seat belt warning light stays on for the specified duration w...

Page 611: ...me buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on 5 The warning light goes off and the chime buzzer stops when turning off the parking brake switch under step 4 6 Thewarninglightcomesonandthechimebuzzerstopswhenthevehiclespeedgoesdownbelow10km hunderstep4 7 This funct...

Page 612: ...ors 3 The decaying operation must have greater than 32 steps per one second 4 The room lamp output should stop immediately after turning on the ignition key during the decaying operation 5 The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed 6 The front room lamp and center room lamp output period ...

Page 613: ...om lamps come on when pressing the room lamp main switch 3 12V 10W 2EA 12V 10W 1EA Front Room Lamp Center and Luggage Room Lamp Center Room Lamp Door coupled type Luggage Room Lamp Lamp OFF Center Room Lamp Lamp ON Luggage Room Lamp Tailgate coupled type Tailgate Driver s seat Center Room Lamp The center room lamp comes on while the switch is at the door coupled position when the door is open The ...

Page 614: ...e ignition key is turned to the ON position 4 The output stops when receiving the lock signal from the remote control key under armed mode T1 10 sec 1 ON IGN KEY ON OFF IGN KEY OFF 2 OPEN Dr or Ps DOOR OPEN CLOSE Dr Ps DOOR CLOSE T1 T1 Key cylinder with key hole illumination Without immobilizer With key hole illumination With immobilizer With key hole illumination Ignition Key Hole Illumination Fo...

Page 615: ...FF 1 The tail lamp is turned on or off according to the operations of the tail lamp switch 2 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 3 The tail lamp relay is turned on when inserting the ignition key into the ignition switch 4 The tail lamp relay is turned off auto cut when opening and c...

Page 616: ... output for 12 minutes This can be done only once 4 The output is OFF when the IGN 2 switch is OFF Rear Defogger Timer Tailgate and outside rearview mirror heated glass switch Press this switch to turn on the tailgate and the outside rearview mirror heated glass It will operate for about 12 minutes Windshield heated glass switch Press this switch to turn on the windshield heated glass It will oper...

Page 617: ...ies the power to the headlamp relay to turn on the headlamp turned off after 20 seconds 2 The output is OFF when receiving the LOCK signal from the remote control key while outputting the headlamp relay However other signals other than LOCK are overridden 3 The output is OFF when inserting the ignition key and turning it to the ON position while outputting the headlamp relay Headlamp Control T1 20...

Page 618: ...lock switch to the lock position 2 The door lock system outputs UNLOCK for 0 5 seconds when positioning the driver s or passenger s door lock switch to the unlock position 3 LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other functions 4 All door lock signals are UNLOCK for 0 5 seconds just for once when receiving the LOCK signal within 0 5 seconds after c...

Page 619: ...tput is ON for 0 5 seconds when receiving the remote control lock signal 2 The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal T2 0 5 sec T3 0 5 sec T4 40 ms T5 0 5 sec T6 1 0 sec T2 T4 T5 T5 T5 T6 Door LOCK UNLOCK by Remote Control Key Door button Panic button TX SIGNAL LOCK NO SIGNAL DOOR LOCK RELAY ON OFF DOOR UNLOCK RELAY ON OFF HORN RELAY ON OFF ...

Page 620: ...hen the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door 7 The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this function or the key is cycled IGN1 OFF even when there is no LOCK ...

Page 621: ...he output continues on for remaining period 4 The function is erased when turning off the IGN switch Auto Door Unlock Crash Unlock T1 200 ms T2 40 ms T3 5 sec T2 T1 T3 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is co...

Page 622: ...utput is OFF when receiving any signal from the remote control key during PANIC warning 3 Followings are theft deterrent warnings 1 The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft deterrent 2 The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning PANIC output is OFF 3 The PANIC w...

Page 623: ...tion key is in the ignition switch the door unlock switch is turned ON or the door lock switch is unlocked it cancels the armed mode and activates the normal mode 4 When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving UNLOCK signal it outputs LOCK and then activates armed mode RELOCK operation Also at this moment the system outputs haz...

Page 624: ...N 40 8710 T1 0 5 sec T2 1 0 sec T3 50 ms T4 1 0 sec T5 30 sec T1 T3 T2 T4 T5 Tx SIGNAL LOCK NO SIGNAL UNLOCK ENTRANCE DOOR SW OPEN CLOSE ENTRANCE DOOR LOCK SW LOCK UNLOCK DOOR LOCK RELAY ON OFF Dr DOOR UNLOCK RELAY ON OFF HAZARD RELAY ON OFF HORN ON OFF OPERATION ARMED MODE OTHERS ...

Page 625: ...s with the interval of 1 second 6 Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation 2 Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activated in armed mode the warning is canceled immed...

Page 626: ... the emergency warning lamp blinks Same operations with warning in armed mode RELOCK Operation It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key the system outputs LOCK signal and activates the armed mode Installed Removed Normal Armed Armed Ready Armed Warning Warning Completion RELOCK Ready Norma...

Page 627: ...s into the armed mode when pressing this button for 0 1 0 5 seconds 2 Door unlock long press 1 The door is unlocked and it gets out of the armed mode when pressing this button for 0 5 1 0 seconds 2 The front room lamp comes on for 30 seconds when receiving door unlock signal by the remote control key while the front room lamp coupled switch is pressed Panic button 1 Panic function 1 The theft dete...

Page 628: ...Lock 1 All doors are locked when briefly pressing the door LOCK switch on remote control key less than 0 5 seconds 2 The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 50 ms 0 5 0 1 seconds 0 5 0 1 seconds...

Page 629: ...k message from the remote control key 3 The hazard warning lamps blink once only when all the doors unlocked Door Unlock PANIC 1 This function operates when pressing the PANIC switch on the remote control key for less than 0 5 seconds 2 The horn sounds for 27 seconds when receiving the PANIC message from the remote control key DOOR UNLOCK DOOR UNLOCK Chattering time 0 1 seconds 0 1 0 1 sec 27 sec ...

Page 630: ...is not opened within 30 seconds after unlocking the door with remote control key the system outputs LOCK signal and activates the armed mode Relock function Door Unlock Auto Door Lock 0 5 seconds 0 1 second Max 30 seconds 0 3 seconds Auto Door Unlock DOOR UNLOCK SIGNAL OFF ON DOOR LOCK SWITCH UNLOCK LOCK ...

Page 631: ...s not moved to lock position when the system out puts auto door lock signal while the ignition switch is in ON position and the vehicle speed is over 50 km h Door lock knob is not moved to unlock position after receiving the output from collision sensor The WIPER P POS signal is not detected when the wiper relay is activated The vehicle speed over 3 km h is detected at the speed signal area while ...

Page 632: ...rol key is saved as history error When the seat belt switch circuit is OPEN HIGH in KEY OUT ARMED MODE the system recognizes it as FAIL and saves it as History error Normal Close GND When the sensor value is recognized in KEY OUT ARMED MODE the system saves it as History error When the seat belt switch circuit maintains OPEN HIGH in KEY OUT ARMED MODE while the vehicle speed is over 50 km h the sy...

Page 633: ...ICS REKES STICS STICS KYRON SM 2005 09 49 8710 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 6 ELECTRIC WIRING DIAGRAMS Power Ground Chime Bell Buzzer Warning Lamp Brake Seat Belt DR Open ...

Page 634: ...RKSTICS REKES STICS STICS KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 50 8710 Central Door Lock Circuit ...

Page 635: ... EFFECTIVE DATE AFFECTED VIN RKSTICS REKES STICS STICS KYRON SM 2005 09 51 8710 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Tail Lamp Hazard Power Window ...

Page 636: ...RKSTICS REKES STICS STICS KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 52 8710 Windshield Heated Glass Defogger ...

Page 637: ...CTIVE DATE AFFECTED VIN RKSTICS REKES STICS STICS KYRON SM 2005 09 53 8710 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Panic Auto Light Rain Sensing Room Lamp ...

Page 638: ...RKSTICS REKES STICS STICS KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 54 8710 FRT Wiper Washer RR Washer ...

Page 639: ...E A T A CRUISE E L Removal and Installation Preceding Works 1 Disconnect the negative battery cable 2 Remove the lower panel in front of driver s seat For details refer to BODY section 1 Disconnect the connectors from STICS unit and remove the RKSTICS antenna 1 STICS connector 2 STICS antenna 3 Chime buzzer connector 4 PAS buzzer connector 5 Door lock unlock relay connector ...

Page 640: ...YRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 56 8710 2 Unscrew two mounting bolts 10 mm 2EA and remove the STICS unit 3 Separate the STICS unit STICS Unit RK STICS antenna Chime bell RK STICS PAS buzzer Door lock relay ...

Page 641: ...2 1 Overview 2 2 Basic functions of immobilizer key REKES function 3 3 Other functions in system 4 4 Replacement of electronic head part excluding key plate 6 5 REKES operation logic 7 6 Dual REKES coding 10 7 Immobilizer coding and removal of immobilizer unit 12 ...

Page 642: ...obilizer system prevents the vehicle theft by allowing only the authorized key to start the engine The transponder inside the key communicates with the im mobilizer installed in the key box and the system per mits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Battery Transponder IMMO...

Page 643: ...ANIC button 2 Door and tailgate unlock press and hold All doors and tailgate are unlocked and the theft deterrent mode is deactivated The front room lamp and the center room lamp come on for 30 seconds The lamps go off immediately when the LOCK sig nal is sent from the remote control key room lamp coupled function PANIC function with ignition key in Theft deterrent horn sounds approx 27 seconds Th...

Page 644: ...le theft by allowing only the authorized key to start the engine The transponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU 4 3 2 In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contac...

Page 645: ... the challenge message to the immobilizer unit to verify whether the key is valid Only when the two signals are identical it recog nizes the key as the authorized one and transmits the positive message to the ECU The ECU starts the engine Immobilizer and Warning Lamp 1 6 7 Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be starte...

Page 646: ...c Head Part of the Immobilizer When 1 The transponder immobilizer key is broken or damaged 2 The immobilizer system is not properly functioning Key plate Key electronic head assembly Screws 2EA Rubber cover Remove the rubber cover on the back of the key assembly Remove two screws to uncover the key plate Install the new electronic head assembly on the key plate ...

Page 647: ...ds all doors are locked 2 The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key If the vehicle is locked while all doors including tailgate and engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice Chattering time 0 5 sec 0 1 0 5 sec 0 1 0 5 sec 0 1 0 5 sec 0 1 Door Lock Door Close Hood Close ...

Page 648: ... seconds all doors are unlocked 2 When receiving the DOOR UNLOCK message from the remote control key the door unlock relay is turned on for 0 5 seconds 3 The hazard warning lamps blink once only when the doors are successfully unlocked PRESS DOOR UNLOCK SWITCH DOOR UNLOCK OUTPUT DOOR LOCK SWITCH SENSING HAZARD LAMP Chattering time 0 1 sec 0 1 Door Unlock UNLOCK LOCK OFF ON ON OFF ON OFF ...

Page 649: ...E A T A CRUISE E L Remote PANIC With ignition key in 1 When briefly pressing the PANIC switch on the remote control key for less than 0 5 seconds the PANIC function is activated 2 When receiving the PANIC message from the remote control key the horn sounds for 27 seconds PRESS PANIC SWITCH DOOR LOCK SIWTCH HORN T1 27 sec 27 sec 0 1 sec 0 5 sec T1 UNLOCK LOCK ON OFF ...

Page 650: ...s with REKES function only have one REKES remote control key and vehicles with immobilizer system have two keys with remote control function Therefore there is a need to code two immobilizer keys 1 After connecting the scanner and selecting KYRON then select DUAL REKES REKES REMOCON CODING KYRON DUAL REKES PROCESSING THE CODING Press the remocon button About 0 5 1 5 second 2 To start to code press...

Page 651: ...control key once for 0 5 1 5 sec You can hear a beep sound 6 The below screen is displayed when the sec ond key coding is completed To exit REKES key coding press ENTER 7 Back to return the main screen when you have finished coding 8 After exiting the SCAN 100 and disconnecting it from the diagnostic connector perform the function tests for the remote control keys If they do not work repeat the ab...

Page 652: ...se message The immobilizer unit indicator blinks with 0 5 Hz of interval to inform that the immobilizer unit is not programmed i e newly replaced In this case the immobilizer coding should be performed Removal of Immobilizer Unit When Replacing the ECU Preceding Works Remove the battery negative cable 3 Remove the connector from the key switch and disconnect the immobilizer unit 1 Remove the lower...

Page 653: ...ECTION KYRON IMMOBILIZER Immobilizer Coding IMMOBILIZER CODING KYRON IMMOBILIZER WARNING If you start immobilizer coding procedure value of coded key is cleared Are you sure Yes No Continued 1 ECU 2 TCU 3 ABS ESP 4 AIR BAG 5 TCCU 6 IMMOBILIZER FUNCTION SELECTION KYRON IMMOBILIZER 1 READ FINGERPRINT 2 IDENTIFICATION 3 CODING 6 3 TEST PASSWORD KYRON IMMOBILIZER ENTER TESTER PASSWORD YES 1 1 4 3 4 11...

Page 654: ...t time 27 seconds Press ENTER Continued IMMOBILIZER CODING KYRON IMMOBILIZER ENTER TESTER PASSWORD Turn OFF ignition key Press ENTER 114 OK ENTER 11434 FAIL INPUT USER ID KYRON IMMOBILIZER 1 1 4 ENTER USER ID Range 0 255 IMMOBILIZER CODING KYRON IMMOBILIZER CODING FAIL Turn OFF ignition key After Check the IMMO System Retry Coding Procedure Turn ON ignition key Press ENTER ...

Page 655: ...N IMMOBILIZER CODING END Turn OFF ignition key and then Turn ON ignition key Press ENTER IMMOBILIZER CODING KYRON IMMOBILIZER Input code to first key Please wait 05 Seconds 1st Key Coding OK ESC All Key Coding OK IMMOBILIZER CODING KYRON IMMOBILIZER Are you sure exit Yes No ENTER IMMOBILIZER CODING KYRON IMMOBILIZER Turn OFF ignition key Remove key and insert 2nd key and then Turn ON ignition key ...

Page 656: ...MEMO ...

Page 657: ...TH MEMORY 7410 TABLE OF CONTENTS SPWM Seat Position With Memory UNIT 3 1 Overview 3 2 Components 4 3 Operations 5 4 Input output of SPWM unit 8 5 Control and operating conditions 9 6 Removal and installation of seat 15 ...

Page 658: ......

Page 659: ...d in the computer Even if someone have moved your seat and outside rearview mirrors the memory positions will be recalled automatically by pressing the position button 1 Adjusting the power seat s position with the seat adjusting switch 2 Adjusting the angle of the outside rearview mirrors OSRVM 3 Seat memory positions for 3 persons 4 Folding Unfolding the outside rearview mirrors Location Bottom ...

Page 660: ...FFECTED VIN 4 7410 LH outside rearview mirror RH outside rearview mirror Outside rearview mirror folding switch Seat memory switch SPWM Unit 2 COMPONENTS Seat adjusting switch Reclining motor sensor Rear cushion motor sensor Sliding motor sensor Front cushion motor sensor ...

Page 661: ...the mirrors press again Mirror Selection Switch L Driver side mirror R Passenger side mirror Aiming Switch Select the driver side mirror L or pas senger side mirror R with the mirror selection switch And then adjust the selected mirror up down left or right by pressing the corresponding edges of the switch to get the direct rearview 3 OPERATIONS Outside Rearview Mirror Control Seat Position Contro...

Page 662: ...on the button will come on 4 Within 5 seconds press the buttons or you want to set The indicator on the set button blinks 3 times SET button STOP button Position buttons 1 2 3 Driver s Seat Position Memory Function The 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 s...

Page 663: ... recall is completed the buzzer sounds twice If failed the buzzer sounds three times Operating Memory Settings The position memory recall is canceled if operating the seat or the outside rearview mirrors during its operation In the vehicle equipped with automatic transmission the position memory recall is not available if the parking brake is released and the gear shift lever is not in P position ...

Page 664: ...motor RH outside mirror Up Down adjustment motor LH outside mirror Up Down adjustment motor LH outside rearview mirror folding unfolding motor RH outside mirror Left Right adjustment motor LH outside mirror Left Right adjustment motor The changes of each motor are always monitored by the sensor in the motor Power seat control switch In the vehicle equipped with automatic transmission the position ...

Page 665: ...essing SET button 2 When adjusting the seat or outside rearview mirror positions during the memory recall operation 3 When turning off the ignition switch 4 When pressing the STOP button 5 When the memory setting is completed 4 The memory recall is not available when the vehicle speed is over 3 km h or the gear shift lever is not in P position with the parking brake released 5 The memory set can b...

Page 666: ...urning off the ignition switch 2 When the gear shift lever is not in P position with the parking brake released 3 When the parking brake is released only for the vehicle equipped with manual transmission 4 When the vehicle speed is over 3 km h 5 When pressing the STOP button during the memory recall operation 6 When adjusting the seat or outside rearview mirrors during the memory recall operation ...

Page 667: ...hen reversing the control motor the motor starts to rotate in the opposite direction 100 msec after the forward driving is completed 4 The motor doesn t operate if the difference between the stored position and the current position is out of the specified range 1 Sliding 12 edges 6 pulses 2 Cushion height 6 edges 3 pulses 3 Reclining 100 mV Seat sliding relay Seatback reclining relay Seat cushion ...

Page 668: ... recall 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 system detects the value changes from the position sensor This is called the Release of automatic control stop Once the relay is turned on it will not be turned off within 60 ms 1 Rated voltage DC 12 V 2 Operating voltag...

Page 669: ...it is open or the motor sensor failure occurred When an error is detected any memory set or recall operations are prohibited but the manual operation is possible When the sensor input changes by a manual operation this error is cleared Outside Rearview Mirror OSRVM Mirror Position Control 1 The position sensor senses the changes of motors in the mirrors 2 The mirror position is stored by the memor...

Page 670: ... mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignition switch 4 To prevent the outside rearview mirrors from stopping during its operation the mirror operating time is extended 13 seconds when pressing the switch again T1 T3 T3 T1 T2 T T T T1 T1 13 3 sec T2 30 6 sec T3 1 sec 0 1 sec IGN POWER RELAY SIDE REAR VIEW MIRROR FOLDING SWITCH FOLD UNFOLD ON OFF ON OFF ...

Page 671: ...r Seat 1 Slide the seat all the way to the rear and remove the seal rail mounting bolts LH RH 14 mm 1EA Installation Notice 2 Slide the seat to the front stop and remove the seat rear mounting bolts LH RH 14 mm 1EA Installation Notice 3 Pull up the seat and disconnect the harness connector Remove the seat assembly Release the hook to disconnect the connector Main connector Connector on seat Tighte...

Page 672: ...TION WITH MEMORY KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 7410 4 Unscrew the screws arrows and remove the protective cover 5 Disconnect the harness connector and remove the SPWM unit SPWM unit ...

Page 673: ...CLUSTER 8010 TABLE OF CONTENTS INSTRUMENT CLUSTER 2 1 Descriptions of indicator display 2 2 Warning indicator panel 10 3 Removal and installation of meter cluster 18 4 Electrical wiring diagrams 21 ...

Page 674: ...ht 16 4WD HIGH indicator 17 Battery charge warning light 18 Air bag warning light 19 HDC indicator 20 Immobilizer indicator 21 Water separator warning light 22 Seat belt reminder driver s seat 23 4WD LOW indicator 24 4WD CHECK warning light 25 Auto shift indicator for automatic transmission 26 ODOmeter Trip odometer 27 ABS warning light 28 EBD warning light 29 Engine hood open warning light 30 Glo...

Page 675: ...USTER KYRON SM 2005 09 3 8010 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Configuration Front View Rear View Main Connector Sub Connector No 1 No 10 No 11 No 20 No 1 No 10 No 11 No 20 ...

Page 676: ...t 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 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 16 CAN Low 17 CAN High 18 AGND Fuel 19 MGND...

Page 677: ...eter indicates engine speed in revolutions per minute Multiply 1 000 to the current number then it will be the current number of engine revolutions Under the normal engine operating temperature the proper idling speed is 700 800 rpm The red zone danger rpm range starts from 4 500 rpm 1 Connect the tachometer for tune up test and start the engine 2 Eliminate the hysteresis by tapping the tachometer...

Page 678: ...ere 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 field due to lack of measuring conditions such as test equipment and preciseness 1 Check the allowable toleran...

Page 679: ...alue 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 changes by fuel level in normal conditions Therefore the differences...

Page 680: ...if the resistance is out of specified range Resistance value by coolant temperature 20 C 2449W 5 50 C 826W 5 80 C 321W 5 100 C 12W 5 Coolant Temperature Gauge When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal operation Also check the wiring harnesses and connectors for proper connection Indicating ...

Page 681: ...S ROOF S E A T A CRUISE E L 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 converted and the meter resets to 0 0 km in Trip A and Trip B TRIP A TRIP B ODO Displaying range 0 0 999 9 km Displaying range 0 999999 km Displaying range 0 0 999 9 km ...

Page 682: ...on key is communicating with the engine control unit during en gine starting for approx 0 5 seconds ESP Warning Light HDC Warning Light Immobilizer Indicator When the red HDC indicator is on the HDC function does not work 4WD HIGH indicator When shifting the driving mode from 4L to 4H this indicator blinks until the shifting operation is completed After completion of the mode change to 4H the indi...

Page 683: ...aintain minimum driving con ditions and to prevent the system from being damaged In this mode the engine driving force may be decreased or the engine may stall Engine Oil Pressure Warning Light This warning light comes on when the ignition is switched on and should go out when the engine is started If the light comes on while driving it indicates that the oil pres sure is dangerously low Low Fuel ...

Page 684: ...inking ON Not available Stand by In operation System overheat HDC switch OFF HDC system error HDC switch ON The HDC switch is turned ON but HDC system is in stand by mode because the operating requirements are not met HDC system is operating The HDC switch is turned ON and the operating requirements are met HDC is operating with operating sound High brake system temperature over 350 C Alternate bl...

Page 685: ... Switch Resuming the ESP System by Using the ESP OFF Switch ESP Warning Lamp ESP operation including TCS ON OFF ON OFF 500 ms 500 ms ESP warning lamp Min 4 times When the ESP switch is pressed 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 the instrument panel ...

Page 686: ...x 3 5 seconds ESP operation HI LO ON OFF ESP operation including TCS ESP warning lamp ON OFF 150 ms 150 ms 150 ms 150 ms 350 ms PUSH RELEASE PUSH RELEASE Disabled range When turning the ignition switch off while the ESP system is activated the ESP system will be resumed when ignition switch is turned on again When the vehicle is controlled by ESP system during driving the ESP OFF switch does not o...

Page 687: ... NO NO NO OK NO NO NO NO NO NO OK Note 1 NO NO OK NO NO NO NO NO NO NO NO NO OK OK NO NO NO NO OK OK NO ON OFF OFF ON ON ON ON OFF OFF ON Push Release 10 sec 3 5 sec Cancellation of ESP OFF mode Turning the ESP warning lamp off ESP operation HI LO ON OFF ESP function including TCS ESP warning lamp ON OFF Return to switch signal Reset to normal condition Initial start for 1 8 sec Normal mode ESP fa...

Page 688: ...r positions The instrument cluster sends the signal to the engine ECU The engine ECU receives the N switch signal the vehicle speed the clutch operating conditions and the engine coolant temperature and raises the engine speed by 100 200 rpm This helps the vehicle start smoothly during gear shifting The vehicle with the manual transmission doesn t have a independent device or switch that detects t...

Page 689: ...nstallation This sensor is to signal the vehicle speed to 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 Vehicle Speed Input to Non ABS Equipped Vehicle DSL Engin...

Page 690: ... BY EFFECTIVE DATE AFFECTED VIN 18 8010 3 REMOVAL AND INSTALLATION OF METER CLUSTER Preceding Works Disconnect the negative battery cable Location Cluster Center Fascia Panel Assembly LH RH Cluster Outside Mirror Switch Bezel Assembly ...

Page 691: ...ree mounting screws on the hazard switch bezel assembly Removal and Installation 2 Remove four instrument panel mounting screws 3 Disconnect the outside mirror switch bezel connector and remove the meter cluster panel assembly Be careful not to damage the another components during removal procedures NOTICE Remove the bottom of the center fascia panel first For details refer to Removal and Installa...

Page 692: ...KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 20 8010 4 Unscrew four cluster mounting screws 5 Disconnect the connectors from the back of meter cluster and remove the cluster from the instrument panel ...

Page 693: ...LUSTER KYRON SM 2005 09 21 8010 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 4 ELECTRICAL WIRING DIAGRAMS Gauge speed RPM fuel temp Warning Lamp fuel fuel filter ABS ESP brake HDC 4WD ...

Page 694: ...CLUSTER KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 22 8010 Warning Lamp batt charge oil hood door eng check air bag ssps seat belt Turn Signal Fog Lamp Hazard ...

Page 695: ...e 54 3 Power window operations 55 4 Circuit diagram of power window 56 5 Central door lock unlock switch 58 6 Removal and installation of power window switch 64 SEAT POSITION MEMORY SWITCH 72 1 Location and functions 72 2 Switch arrangement 73 3 Exploded view 74 4 Output voltage in each switch position 74 5 Functions and operations 75 6 Removal and installation of seat position memory switch 77 7 ...

Page 696: ...riving dis tance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO Tailgate Glass and Out side Rearview Mirror Heated Glass Switch Press this switch to turn on the tailgate and out side rearview mirror defogger It will operate for about 12 minutes Windshield Heated Glass Switch Press this switch to turn on the windshield heated glass It will operate for about 12 minutes Driver ...

Page 697: ...e lever for more than 0 6 seconds Three wiping cycles with washer spray 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 will be sprayed again and the wiper will automatically operate 3 times Auto light position Audio Remote Control Switch POWER MODE SEEK X X X X X X X X X X...

Page 698: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 8510 1 LOCATION The center fascia switch consists of hazard switch bezel assembly T C control switch and seat warmer switch Front View Rear View Center Fascia Assembly CENTER FASCIA BEZEL SWITCH ASSEMBLY ...

Page 699: ... S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L TRIP switch HDC switch Windshield heated glass switch Tailgate glass and out side rearview mirror heated glass switch Hazard switch 2 SWITCH ARRANGEMENT T C Control Switch Driver s Seat Warmer Switch Passenger s Seat Warmer Switch ...

Page 700: ...en the switch is pressed again within 10 minutes after completion of its first operation cycle 5 The indicators in the switch come on when in use Unit 0 0 999 9 km TRIP A ODO Unit 0 0 999 9 km TRIP B Unit 0 999999 km This switch is designed to defrost and defog on windshield 1 Press this switch to turn on the windshield heated glass It will operate for about 12 minutes 2 Press the switch again to ...

Page 701: ...ng mode changes to 4 H mode then goes off after completion of mode change Choose a proper mode according to the road conditions 4WD HIGH 4WD LOW This warning light comes on when the 4WD system is defective 4WD CHECK This indicator blinks during mode changes to 4 L mode then goes off after completion of mode change T C Control Switch Driver s Seat Warmer Switch Passenger s Seat Warmer Switch Headli...

Page 702: ... 4 SWITCHES IN HAZARD BEZEL SWITCH ASSEMBLY ABS ESP HECU 9 HDC Switch 4 5 1 2 HDC switch is a Push Self Return type switch and connected to ABS ESP HECU terminal This switch has an illumination lamp connected to the tail lamp circuit HDC Switch ON OFF 1 B 2 GND 3 IND 4 ILL 5 ILL Overview ...

Page 703: ...er 1 8 seconds OFF ON OFF OFF Blinking ON Not available Stand by In operation System overheat HDC switch OFF HDC system error HDC switch ON The HDC switch is turned ON but HDC system is in stand by mode because the operating requirements are not met HDC system is operating The HDC switch is turned ON and the operating requirements are met HDC is operating with operating sound High brake system tem...

Page 704: ...turned ON 2 Gearshift lever position Forward Reverse Manual transmission operates in the 1st gear or reverse gear position does not operate in neutral position Automatic transmission operates in any position except P parking or N neutral positions 3 When not depressing the accelerator pedal or brake pedal 4 The vehicle speed is above 7 km h in Automatic transmission 4H mode and and The vehicles wi...

Page 705: ...or brake pedal HDC system is changed to stand by mode When depressing the accelerator pedal again HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by operating the accelerator pedal 5 Vehicle position control function in ESP and HBA function are not in operation The HDC is the device to improve the engine brake effect during downhill driving on a st...

Page 706: ... 4 or or or or or Vehicle with the manual transmission Sensing at the neutral switch Vehicle with the automatic transmission Sensing at the selector lever unit NOTICE 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 NOTICE When depressing the ...

Page 707: ...h Self Return type switch 1 The outside rearview mirror tailgate glass defogger operates for approx 12 minutes when pressing this switch while the ignition switch is turned on 2 It stops when pressing the switch again during its operation 3 If pressing this switch again within 10 minutes after completion of first operation it will operate for about 6 minutes 4 It stops when the ignition switch is ...

Page 708: ... AFFECTED VIN 14 8510 IGN2 SW ALT L Tailgate glass Outside rearview mirror heated glass switch Defogger relay ON OFF HIGH LOW ON OFF ON OFF ALT L 9 V 1 V Key ON ALT ON T1 T1 T1 T1 T2 T3 Timing Chart T1 12 min T2 within 10 min T3 6 min ON IGN2 OFF IGN2 Key ON or ALT OFF ...

Page 709: ...eld defogger operates for approx 12 minutes when pressing this switch while the ignition switch is turned on 2 It stops when pressing the switch again during its operation 3 If pressing this switch again within 10 minutes after completion of first operation it will operate for about 6 minutes 4 It stops when the ignition switch is turned to OFF Windshield Heated Glass Switch T LP REPLAY STICS RR D...

Page 710: ... BY EFFECTIVE DATE AFFECTED VIN 16 8510 IGN2 SW ALT L Windshield defogger SW Defogger Relay ON OFF HIGH LOW ON OFF ON OFF ALT L 9 V 1 V Key ON ALT ON T1 T1 T1 T2 T3 T1 Timing Chart T1 12 min T2 within 10 min T3 6 min ON IGN2 OFF IGN2 Key ON or ALT OFF ...

Page 711: ...switch TRIP Switch Overview To choose a desired driving distance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO TRIP A B display will be initialized to 0 km when the distance of an individual trip exceeds 999 9 km If you press and hold the reset button for more than one sec ond in TRIP A or TRIP B mode the trip ODO meter re sets to zero Unit 0 0 999 9 km TRIP A ODO Unit 0 0 ...

Page 712: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 8510 Hazard switch is connected to the turn signal lamp circuit Hazard Switch Overview ...

Page 713: ...s Doing so will result in damages to the drive train Driving in a 4 wheel mode on a normal paved surface will cause unwanted noises premature wear of tires or increased fuel consumption CAUTIONS To shift from 4L into another mode or vice versa stop the vehicle and depress the brake pedal before any shift If the 4WD CHECK warning light stays on have the 4WD system checked When cornering a curved ro...

Page 714: ...ature to the specified level The is no control switch and unit to control the temperature of the seat surface temperature Seat Warmer Switch Overview Do not place anything sharp on the seat When cleaning the seats do not use organic solvents such as benzene or thinner Do not use this function when the engine is not running The battery could be discharged CAUTIONS The temperature of seat surface sh...

Page 715: ...M S ROOF S E A T A CRUISE E L 6 REMOVAL AND INSTALLATION OF HAZARD BEZEL SWITCH ASSEMBLY Preceding Works Disconnect the negative battery cable Location Tailgate glass outside rearview mirror heated glass switch Hazard warning switch TRIP switch HDC switch T C control switch Driver s seat warmer switch Passenger s seat warmer switch Windshield heated glass switch ...

Page 716: ...D BY EFFECTIVE DATE AFFECTED VIN 22 8510 Removal and Installation 1 Remove the RH panel from the center fascia panel and unscrew three screws from the center fascia panel 2 Disconnect the switch connectors and remove the center fascia panel assembly ...

Page 717: ... SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the hazard switch bezel assembly and miscellaneous switch assembly from the removed center fascia panel Front View Rear View Remove Three Mounting Screws Remove Four Mounting Screws ...

Page 718: ...ANGED BY EFFECTIVE DATE AFFECTED VIN 24 8510 4 Remove each switch from the hazard switch bezel assembly 1 Remove the round cover and switches 2 Remove the hazard switch mounting bracket and remove the hazard switch Front View Rear View Side View ...

Page 719: ...M 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Front View Side View Rear View Driver s Seat Warmer Switch T C Control Switch Passenger s Seat Warmer Switch 5 Remove each switch from the miscellaneous switch assembly ...

Page 720: ... 26 8510 Center Fascia Panel Tailgate glass outside rearview mirror heated glass switch TRIP switch HDC switch Windshield heated glass switch Digital clock T C control switch Driver s seat warmer switch Passenger s seat warmer switch Hazard warning switch Headlight leveling switch ...

Page 721: ...W M S ROOF S E A T A CRUISE E L OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY Front View of Outside Rearview Mirror Bezel Panel Rear fog lamp switch 1 LOCATION Outside rearview mirror switch bezel assembly consists of outside rearview mirror folding switch ESP OFF switch and rear fog lamp switch regional option Rear View of Outside Rearview Mirror Bezel Panel ...

Page 722: ...CHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 28 8510 2 SWITCH ARRANGEMENT ESP OFF Switch Outside Rearview Mirror Folding Switch Outside Rearview Mirror Angle Adjusting Switch ...

Page 723: ...n type switch The outside rearview mirrors folding unfolding function is not available when the vehicle speed is over 3 km h You can fold and unfold the mirros for 30 seconds after ignition OFF Do not fold or unfold the outside rearview mirrors manually It may cause a malfunction of the mirror folding system To fold the outside rearview mirrors press the switch To unfold the mirrors press it again...

Page 724: ...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 T1 T3 T1 T2 T T T T1 T1 13 3 sec T2 30 6 sec T3 1 Sec 0 1 sec IGN SW P W TIME RELAY FOLDING SW FOLDING UNFOLDING ON OFF ON OFF ON OFF T3 Timing Chart ...

Page 725: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Electrical Wiring Diagrams ...

Page 726: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 32 8510 ESP OFF switch is Self return type switch ESP OFF switch ESP OFF Switch Overview ...

Page 727: ...m including ABD function is turned off And the ABS system is still operated The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch is pushed for over approximately 150 ms while the ESP system is not operating The detailed operation procedures are as follows 1 The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms 2 The ...

Page 728: ...ontrol When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds the ESP unit determines it as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESP OFF switch returns to no...

Page 729: ...trol is performed to compen sate the vehicle stability posture during ESP operation NOTICE ESP Warning Lamp Operation Depending on System Conditions NO NO NO OK NO NO NO OK NO Vehicle yaw control ABS W L Warning Lamp Controls Initial start for 1 8 sec NO Normal mode BLINKS WHEN ESP OPERATION ESP fault ABS fault System fault Low batt voltage High battery voltage High brake pad temp ESP OFF mode Ent...

Page 730: ... BY EFFECTIVE DATE AFFECTED VIN 36 8510 4 REMOVALAND INSTALLATION Preceding Works Disconnect the negative battery cable Location Outside rearview mirror folding switch Outside rearview mirror angle adjusting switch Rear fog lamp switch ESP OFF switch ...

Page 731: ...R L A M P S P W M S ROOF S E A T A CRUISE E L Removal and Installation 1 Remove the center fascia panel and unscrew four screws on the meter cluster fascia panel 2 Disconnect the connector from the outside rearview mirror switch bezel assembly and remove the meter cluster fascia panel To make the operation easier move down the steering wheel NOTE ...

Page 732: ...ICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 38 8510 3 Remove the switch assembly from the removed meter cluster fascia panel Front View Rear View 4 Remove the round cover on the switch assembly Round cover ...

Page 733: ... S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Switch Assembly ESP OFF Switch Outside Rearview Mirror Folding Switch Outside Rearview Mirror Adjusting Switch 5 Remove each switch from the outside rearview mirror switch bezel assembly Remove the switch bracket ...

Page 734: ... CHANGED BY EFFECTIVE DATE AFFECTED VIN 40 8510 Round cover Outside rearview mirror adjusting switch bracket Outside rearview mirror adjusting switch Fog lamp switch Outside rearview mirror folding switch ESP switch Meter Cluster Fascia Panel ...

Page 735: ...e Room Lamp Center Room Lamp OVERHEAD CONSOLE SWITCH 1 LOCATION Driver s spot switch The driver s room lamp comes on if you depress the spot switch A Sunroof switch Passenger s spot switch The passenger s room lamp comes on if you depress the spot switch B Main room lamp switch Front center room lamps are turned on when pressing in this switch They are turned off when pressing in this switch again...

Page 736: ...ED BY EFFECTIVE DATE AFFECTED VIN 42 8510 2 COMPONENTS Sun roof switch Interior light switch Overhead console case Main room lamp switch Front Room Lamp Overhead Console Lamp Center Room Lamp and Luggage Room Lamp Center Room Lamp Luggage Room Lamp ...

Page 737: ... S ROOF S E A T A CRUISE E L Front room lamp switches in overhead console Push ON OFF type Sunroof switch Rotary self return type Passenger s spot lamp switch Push ON OFF type Driver s spot lamp switch Push ON OFF type Main room lamp switch Push ON OFF type Front room lamp connector Sunroof switch connector Overview 3 SWITCHES IN OVERHEAD CONSOLE SWITCH ASSEMBLY ...

Page 738: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 44 8510 Sunroof Switch ...

Page 739: ... KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Passenger s spot lamp switch Push ON OFF type Driver s spot lamp switch Push ON OFF type Main room lamp switch Push ON OFF type 1 2 3 4 Front Room Lamp ...

Page 740: ...tely after turning on the ignition key during decaying operation 5 The front room lamp comes on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed 6 The front rear room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output 7 When a door is opened during its extended period the ...

Page 741: ...D BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Electrical Wiring Diagram of Room Lamp ...

Page 742: ...ection with the sunroof open To partially close the sunroof rotate and hold the sunroof switch until it reaches at the desired position Sunroof Tilting Operation Tilt up To tilt up the sunroof rotate the sunroof switch counter clockwise CLOSE direction with the sunroof fully closed Tilt down To tilt down the sunroof rotate the sunroof switch clock wise OPEN direction with the sunroof tilted up Sun...

Page 743: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Circuit Diagram of Sunroof ...

Page 744: ...fer to the LAMP section NOTE 4 REMOVAL AND INSTALLATION OF OVERHEAD CONSOLE SWITCH Preceding Works Disconnect the negative battery cable 1 Open the sunglasses box and unscrew the mounting screws 2 EA Mounting screw 2 Remove the overhead console switch assembly and disconnect the connector Mounting screw ...

Page 745: ...ES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the front room lamp switch from the removed overhead console switch assembly 4 Unscrew three mounting screws and remove the sunroof switch ...

Page 746: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 52 8510 Components Sunroof switch Room lamp main switch Lamp Lamp ...

Page 747: ...d or the Lock switch on the remote control key is pressed theft deterrent mode is activated during the delaying period the delaying time is immediately canceled power window relay is deactivated Window lock switch If this switch is pressed only the main switch of driver s door side is operated Sub and RR is not operated by pressing in the main switch Passenger s Door Window Switch Rear LH door Win...

Page 748: ...ector Rated Current Maximum Current 10 A operating voltage 0 4 A operating voltage 10 A operating voltage Power window switch motor operation Door lock switch actuator operation Window lock switch motor operation 20 A restricted current 0 7 A actuator voltage 20 A restricted current Switch Assembly Front View Side View Rear View Connector ...

Page 749: ...er Window Auto down When the front of the switch is lightly pressed the window will be lowered while the switch is pressed When pressed to its end the window will open automatically until it is fully open If you want to stop the window while automatic lowering lightly press the switch again or pull up the switch Power window versions in this vehicle Auto Down Auto Down Up The circuit diagram shows...

Page 750: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 56 8510 4 CIRCUIT DIAGRAM OF POWER WINDOW ...

Page 751: ... The power window relay output is ON for 30 seconds for T1 when turning off the IGN 1 switch The power window relay output is OFF when opening the driver s door or the passenger s door The power window relay is turned OFF when receiving the remote control key lock signal armed mode during its extended operation period of 30 seconds T1 30 sec T2 OFF during T1 output T1 T2 Time Lag Power Window Cont...

Page 752: ...ions This vehicle has five door lock unlock actuators including tailgate actuator The doors can be opened separately However the door lock switch on driver s door armrest locks unlocks all doors with STICS control This is a same control type with Auto door lock function that locks the doors when the vehicle speed exceeds 50 km h Door Lock Unlock Relay ...

Page 753: ...river s or passenger s door lock switch to unlock position 3 LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other functions 4 All door lock signals are UNLOCK for 0 5 second just for once when receiving the LOCK signal within 0 5 second after closing the driver s or passenger s door with the ignition key removed Door Lock Unlock by Door Lock Switch Door LOC...

Page 754: ...on on the central door lock switch However the door lock system outputs UNLOCK signal when the front doors are locked and vice versa 2 The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored CENTRAL LOCK SW MONITOR ING LOCK RELAY UNLOCK RELAY ON OFF LOCK UNLOCK ON OFF ON OFF T1 0 5 sec T2 0 5 sec T2 T1 Door Lock Unlock by Central Door Lock Switch ...

Page 755: ...outputs LOCK for 0 5 second when receiving LOCK signal from the remote control key 2 The door lock system outputs UNLOCK signal for 0 5 second when receiving UNLOCK signal from the remote control key TX signal LOCK RELAY UNLOCK RELAY HORN RELAY HAZARD RELAY LOCK NO SIGNAL ESCORT ON OFF ON OFF ON OFF ON OFF T2 0 5 sec T3 0 5 sec T4 40 ms T5 0 5 sec T6 1 0 sec T2 T4 T5 T5 T5 T6 Door LOCK UNLOCK by R...

Page 756: ...and accelerates again to over 50 km h Nonetheless the central door lock function works properly 6 When the system receives UNLOCK signal from a door switch it outputs five LOCK signals If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals for the door 7 The door lock system outputs UNLOCK automatically if the LOCK output conditions ar...

Page 757: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Electrical Wiring Diagram ...

Page 758: ...Y EFFECTIVE DATE AFFECTED VIN 64 8510 6 REMOVAL AND INSTALLATION OF POWER WINDOW SWITCH Preceding Works Disconnect the negative battery cable Location Driver s Door Power Windows Switch Passenger s Door Power Windows Switch Rear Door Window Switch LH RH ...

Page 759: ...I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Front Door Driver s 1 Remove the driver s door trim Location Inner door handle assembly Power Window Switch Assembly Door trim armrest Be careful not to damage the door trim For more information refer to the Body section NOTE ...

Page 760: ... SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 66 8510 2 Unscrew ten mounting screws on the inner door handle of the door trim 3 Remove the inner door handle and the memory seat switch assembly Switch Assembly Door Trim Armrest ...

Page 761: ...DEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 4 Remove the switch from the memory seat switch assembly Unscrew two mounting screws and remove the switch Front View Side View Connector ...

Page 762: ...ssenger s 1 Remove the passenger s door trim 2 Unscrew the mounting screws and remove the inner door handle and the memory seat switch assembly from the passenger s door trim Door trim armrest Power window switch Be careful not to damage the door trim For more information refer to the Body section NOTE ...

Page 763: ...TED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the switch from the power window switch assembly Connector Front View Side View ...

Page 764: ...S KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 70 8510 Rear Door Power Window Switch 1 Separate the power window switch assembly with a special tool 2 Disconnect the switch connector and remove the switch assembly ...

Page 765: ...FFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the switch Connector Front View Side View ...

Page 766: ... one of position buttons or for approx 1 5 seconds At this moment the buzzer sounds once 2 The driver s seat and the outside rearview mirrors start to move The memory function stops during its op eration when driving off the vehicle 3 Wait until they stop moving The buzzer sounds twice 1 Place the selector lever in P automatic transmission or N manual transmission position and apply the parking br...

Page 767: ...NSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 SWITCH ARRANGEMENT The driver s seat position memory switch is installed in door trim and its connector 4 pins is connected to the SPWM Seat Position With Memory unit Driver s Seat Memory Switch ...

Page 768: ...ON The memory switch connector receives the position switch signal at the pin no 1 and the resistance value and output voltage in each switch differs from others The table below shows the output voltage for each switch and the supply voltage is 5 V Output Voltage Function SET STOP Position 1 Position 2 Position 3 Output voltage 0 100 mv 0 100 mv 0 12 1 36 mv 2 12 2 59 mv 3 4 4 15 mv 1 2 3 4 5 6 7 ...

Page 769: ...ting recalling is completed 9 The buzzer sounds three times when an error is found from the sensor during the memory recall operation Seat Position Memory Operation 1 To store the seat position and the outside rearview mirror position press the SET button and within 5 seconds press one of position switches The memory setting is available up to 3 different drivers 2 The memory set mode is only avai...

Page 770: ...f the following conditions is established the memory recall function is deactivated 1 When turning off the ignition switch 2 When the gear shift lever is not in P position with the parking brake released 3 When the parking brake is released only for the vehicle equipped with manual transmission 4 When the vehicle speed is over 3 km h 5 When pressing the STOP button during the memory recall operati...

Page 771: ...STER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 6 REMOVALAND INSTALLATION OF SEAT POSITION MEMORYSWITCH Preceding Works Disconnect the negative battery cable 1 Remove the driver s door trim Location Memory seat switch Power window switch Speaker Memory Seat Switch For details refer to the Body section NOTE ...

Page 772: ...ES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 78 8510 2 Remove the memory seat switch from the door trim Switch Arrangement PCB assembly Memory switch button Memory switch box Memory switch cover 4 pin Connector ...

Page 773: ...TIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 7 ELECTRICAL DIAGRAM OF POWER SEAT OUTSIDE REARVIEW MIRROR ...

Page 774: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 80 8510 ...

Page 775: ...s and hold Automatic searching for a station In CD DVD player Cassette tape mode Press briefly Replay next previous track Press and hold Move forward backward in current tract SEEK X X X X X X X X X X SEEK Increases or decreases the volume Stops audio output from audio system To resume the audio output press the button again MUTE Turns on and off the audio system POWER Changes the audio mode in or...

Page 776: ...NENTS The remote audio control switch is installed on the the steering wheel Its rated voltage is 5 V and has three connectors Switch PCB Connector and cable Switch PCB 35 36 43 34 33 32 31 1 2 3 4 5 6 1 2 3 4 Main Connector Pin No 31 32 33 Output voltage Audio signal Audio ground Tail lamp power ...

Page 777: ...510 CHANGED BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 CIRCUIT DIAGRAM ...

Page 778: ...TRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 84 8510 4 REMOVALAND INSTALLATION Preceding Works Disconnect the negative battery cable 1 Remove the airbag module assembly from the steering wheel ...

Page 779: ...CHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Unscrew mounting screws at both sides of the removed airbag module and remove the audio remote control switch ...

Page 780: ...tion switch pay particular attention not to damage the air bag spring clock installed on the multifunction switch Mounted View Front auto washer and wiper 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 will be sprayed again and the wiper will automati cally operate 3 times MULTIFUNCTI...

Page 781: ...e ambient illumina tion intensity to determine the timing for turning the headlamps and tail lamps on or off automatically when the light switch is set to AUTO integrated with rhe rain sensor AUTO Light Switch Tail lamp ON Position tail license plate fog and instrument panel lights are illuminated All lights are off Automatic light ON Headlamps and tail lamps automatically turn on or off based upo...

Page 782: ...l return to the OFF position when released Operates automatically ac cording to the vehicle speed or amount of rain Front Automatic Wiping Speed Control Switch Fast Fast interval Slow Slow interval HI Continuous wipe slow operation Front Wiper Switch MIST OFF AUTO LO Passing To flash the high beam pull the lever towards the steering wheel and release it The le ver will return to the normal positio...

Page 783: ...raes Rear Wiper Stops Rear Washer and Wiper Switch When the switch is fully turned washer fluid will be sprayed onto the rear win dow glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer When the wiper switch is in the AUTO position this sensor detects the amount of rain turns on the wiper and controls the intermitte...

Page 784: ...ATE AFFECTED VIN 90 8510 29 46 44 45 48 47 30 3 OPERATING RANGE 29 Air bag 30 Air bag 43 Sound switch 37 42 Auto cruise 31 33 Audio remote control 44 48 Steering wheel angular sensor Airbag clock spring Audio remote control Auto cruise Steering wheel angular sensor ...

Page 785: ...lamp switch 6 HS 1 Headlamp switch 7 AUTO AUTO light 8 E Light fog hazard warning switch ground 9 TB Flasher unit power 10 TL Turn signal LH lamp switch 11 TR Turn signal RH lamp switch 12 FOG Front fog lamp switch 13 HA Hazard switch 14 LO Low wiper speed 15 HI High wiper speed 16 S Wiper stop 17 AUTO W Intermittent wiper 18 INT T Intermittent wiper 19 INT E Intermittent wiper ground 20 W Front w...

Page 786: ...module and steering wheel Air bag Module Assembly Lift up the hook when disconnecting the air bag contact coil connector A Steering Wheel Assembly Put an installation mark on the steering wheel column shaft and nut when removing the steering wheel Place the steering wheel to the straight forward direction Be careful not to drop or shock the air bag module during removal procedures NOTICE ...

Page 787: ...ment lower panel inner bracket and lower undercover For details refer to the Body section Instrument lower panel Inner bracket For installation align the steering wheel to the installation mark and tighten the nut to the speci fied tightening torque 3 Unscrew four screws from the steering column cover and remove the upper and lower covers 4 Unscrew four screws and remove the air bag contact coil a...

Page 788: ...ng wheel sensor and the multifunction switch 4 EA at this moment disconnect the connectors Multifunction switch Turn signal wiper switch Steering wheel angular sensor 6 Remove the steering wheel angular sensor from the re moved multifunction switch assembly Light switch Steering wheel angular sensor connector Multifunction switch connector Turn signal wiper switch ...

Page 789: ...95 8510 CHANGED BY EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L MEMO ...

Page 790: ...efer to the Switch section Disconnect the connector Remove the panel from bottom Rated voltage DC 12 V Operating voltage DC 8 V DC 16 V Time difference 2 sec day room temp Current consumption Max 150 mA with IGN ON Max 2 5 mA with IGN OFF Display type VFD Brightness 100 with Tail lamp OFF 40 with Tail lamp ON Blinking cycle of Colon Once per second Digital Clock DIGITAL CLOCK ...

Page 791: ...ICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Disconnect the digital clock connector 3 Unscrew three mounting screws and remove the digital clock from the center fascia panel Digital Clock ...

Page 792: ...ICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 98 8510 Preceding Works Disconnect the negative battery cable 1 Remove the center console cover Remove the panel from bottom CIGARETTE LIGHTER Cigarette Lighter ...

Page 793: ...ED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Disconnect the cigarette lighter connector 3 Remove the cigarette lighter from the cover ...

Page 794: ...nector 3 Remove the power outlet from the bracket 1 Remove the power outlet bracket from the center console passenger side Front Power Outlet 1 Cap 2 Cap cover 3 Socket 4 Installation holder 5 Insulator 6 terminal 7 terminal 8 Connector Rated voltage over DC 12 V Max operating current 10 A Resistance over 5 MΩ POWER OUTLET ...

Page 795: ... S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Unscrew eight screws and remove the power out let mounting bracket 3 Remove the power outlet from the bracket 1 Remove the rear lower quarter panel RH and dis connect the power outlet connector Rear Power Outlet ...

Page 796: ...SWITCHES ELECTRICDEVICES KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 102 8510 Electrical Wiring Diagram of Cigarette and Power Outlet ...

Page 797: ...ICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 1 LOCATION HORN INCLUDING THEFT WARNING HORN Horn Assembly Horn Horn Connector Connector Tone adjusting screw Theft Deterrent Horn Horn Connector ...

Page 798: ...IN 104 8510 2 ELECTRICAL WIRING DIAGRAM OF HORN Location of horns One at each side in engine compartment Location of theft deterrent horn Under the battery tray in engine compartment The theft deterrent horn is controlled by STICS in armed mode regardless of horn relay operation ...

Page 799: ...heft Deterrent Mode Definitions in theft deterrent mode 1 Door OPEN CLOSE Door OPEN Any of door switches engine hood front doors rear doors tailgate output OPEN signal Door CLOSE All door switches engine hood front doors rear doors tailgate output CLOSE signal 2 Door LOCK UNLOCK Door LOCK Any of door lock switches front doors rear doors tailgate output LOCK signal Door UNLOCK All lock switches fro...

Page 800: ...y is in the ignition switch or the door lock switch is unlocked cancels the armed mode and activates the normal mode However in these cases if closing the door the theft deterrent horn outputs once and the hazard warning flasher outputs twice and then activates armed mode 4 When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving UNLOCK si...

Page 801: ...the interval of 1 second 5 Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC ESCORT during warning operation 2 Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activated in armed mode the warning is canceled immed...

Page 802: ... when receiving the PANIC signal from the remote control key in Armed Ready Armed Warning Completion Relock Ready mode maintaining the theft deterrent mode 4 This function operates only in armed mode TX SIGNAL REMOTE CONTROL KEY SIGNAL THEFT DETERRENT MODE HORN PANIC NO SIGNAL WARNING OTHERS ON OFF T1 27 sec T2 0 5 sec T3 1 0 sec T3 T2 T1 T1 7 Operations when removing and installing the battery If...

Page 803: ... EFFECTIVE DATE AFFECTED VIN SWITCHES ELECTRICDEVICES KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Electrical Wiring Diagram of Theft Warning Horn ...

Page 804: ... cable 1 Disconnect the horn connector and unscrew the mounting bolt 10 mm to remove the horn assembly Horn Tone adjusting screw Connector Theft Deterrent Horn Assembly Preceding Works Disconnect the battery negative cable 1 Disconnect the theft deterrent horn connector and un screw the mounting bolt 10 mm to remove the theft warning horn assembly Theft Warning Horn Connector ...

Page 805: ...AV SYSTEM 8932 8930 TABLE OF CONTENTS AV SYSTEM 2 1 AV head unit 2 2 AV system configuration 3 3 Head unit 6 4 Tuner and DSP amplifier 13 5 Subwoofer 15 6 Removal and installation of AV system 16 ...

Page 806: ...8932 1 AV HEAD UNIT DVD Cassette player 10 speakers center speaker woofer speakers tweeter speakers AV SYSTEM DVD Cassette Radio Cassette tape slot DVD title insert slot 6 5 inch TFT LCD 1 AV head unit 2 Tuner 3 DSP amplifier 4 DVD 6 DISC changer 5 Subwoofer MUTE button ...

Page 807: ... Front tweeter speaker AV System DVD Head Unit DVD Changer Steering wheel remote control switch Subwoofer with built in amplifier Rear speaker Rear tweeter speaker Radio antenna module TV antenna module Front speaker Front tweeter speaker Front center speaker AV Head Unit DVD RADIO and TAPE TV 2 CD RADIO Tape CD slot DSP Amplifier and Tuner Audio System 6 Speakers 2 AV SYSTEM CONFIGURATION DVD cha...

Page 808: ... LCD monitor Tuner 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 AM FM radio antenna AMP The heated wire and radio antenna is in tegrated in the tailgate glass The antenna transmits AM FM ...

Page 809: ...built in DSP function that digitalizes sound to divide and control It amplifies sound goes to each speaker and has function of allowing dynamic and vivid sound Subwoofer without built in AMP Woofer is installed at the bottom of passenger s seat It enforces mid low sounds Front speaker LH Tweeter speaker FL Front speaker RH Tweeter speaker FR Rear speaker RH Tweeter speaker RR Rear speaker LH Tweet...

Page 810: ...D UNIT DVD slot Display when turning on the monitor Power ON OFF Volume control AV replay AV reset screen Replay mode selection briefly press Current replay mode press and hold Next channel radio or TV or next track audio or video The monitor moves to parking position when turning the ignition switch to OFF position It moves to the preset position when turning the ignition switch to ON position ag...

Page 811: ...ACK UP 3 VIDEO GND 4 VIDEO SIGNAL 5 GND 6 BACK UP 7 R V VIDEO 8 R V GND 1 BACK UP 2 BACK UP 3 VIDEO GND 4 VIDEO signal 5 GND 6 7 RESET 8 SPDIF GND 9 SPDIF signal 10 CAN GND 11 CAN HI 12 CAN LO 13 DVDC ON 1 MUTE 2 NAVI ON OFF 3 NAVI Voice GND 4 NAVI voice 5 GND 6 7 RESET 8 SPDIF GND 9 SPDIF signal 10 CAN GND 11 CAN HI 12 CAN LO 13 AMP ON 1 CAN HI 2 3 Illumination 4 ACC 5 BACK UP 6 7 Speed pulse 8 R...

Page 812: ...AV SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 8 8932 Tuner DSP amplifier DVD changer GPS antenna connector Head Unit Wiring Connector ...

Page 813: ...region code If region code is different the disc cannot be played This system cannot play the disc if the region code is other than 2 3 or 6 Region Code 2 Middle East 3 General Area 6 China PBC Play back control compatible video CD This system can play PBC compatible video CD Typical audio and video CDs can be played and PBC compatible video CD uses recorded PBC menu on the disc to play the CD int...

Page 814: ... key Full touch DiversityAntenna with high reception performance Automatic station selection Automatic station selection Station memory 8 channels in each band AM1 AM2 FM1 FM2 Automatic replay Audio CD DVD title Playback control supported Sub woofer speakers Install 6 discs in the magazine Automatic replay Audio CD DVD title DSP function Equalizer function Functions ofAV Unit ...

Page 815: ...ter speakers Screen setting brightness colors gamma contrast Aspect ratio setting 16 9 4 3 ZOOM1 ZOOM2 Initial screen setting of DVD title sound caption etc Turning OFF the screen however audio system still operates Turning OFF ON the button operating sound Beep sound Turning OFF ON the speakers Turning OFF ON the PBC function Turning OFF ON the driving restriction Moves to replay mode out from SE...

Page 816: ...TADIUM THEATER CHURCH CLUB Press OFF button to cancel the DSP function 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 Adjusting the sound according to the seated position Press BAL POS button in SET ADJ screen and select a seat position dr...

Page 817: ...CTIVE DATE AFFECTED VIN AV SYSTEM KYRON SM 2005 09 13 8932 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 4 TUNER AND DSPAMPLIFIER Front View Side View Rear View ...

Page 818: ...5 BACK UP 6 BACK UP 7 SPEAKER RL 8 SPEAKER FL 9 SPEAKER FR 10 SPEAKER RR 11 SPEAKER WOOFER 1 12 SPEAKER WOOFER 2 13 GND 14 GND 15 SPEAKER CENTER 16 SPEAKER CENTER 17 SPEAKER RL 18 SPEAKER FL ANT ON CAN LO Radio antenna module 1 ACC ON 2 B 3 VIDEO GND 4 VIDEO SIG 5 CHASSIS GND 6 B BACKUP 7 RV VIDEO 8 RV GND Tuner wiring Rearview camera not applied 4 3 2 1 8 7 6 5 12 11 10 9 13 7 6 3 1 5 4 2 8 CAN W...

Page 819: ... VIN AV SYSTEM KYRON SM 2005 09 15 8932 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 5 SUBWOOFER Passenger s Seat 1 Subwoofer_1 2 Subwoofer_1 3 Subwoofer_2 4 Subwoofer_2 1 2 3 4 ...

Page 820: ...32 6 REMOVALAND INSTALLATION OF AV SYSTEM 2 Disconnect the head unit harness connector and the fiber optic cable Preceding Work 1 Remove the center panel 2 Remove the center fascia panel 1 Unscrew four mounting screws from the AV head unit and AC control panel AV Head Unit ...

Page 821: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN AV SYSTEM KYRON SM 2005 09 17 8932 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the AV head unit ...

Page 822: ...D VIN 18 8932 Preceding Work Remove the negative battery cable 1 Remove the service cover from the right lower quar ter panel in the luggage compartment 2 Remove the OVM tool box 3 Unscrew eight mounting nuts from the tuner amplifier deck assembly TunerAssembly ...

Page 823: ...E L 4 Disconnect the harness connectors and the fiber optic cable from the tuner amplifier deck assembly 1 Fiber optic cable and connectors for DSP amplifier 2 Radio antenna cable TV antenna cables and connectors Fiber optic cable Radio antenna cable Use the pliers as shown in figure when disconnecting the TV antenna cables NOTICE Connectors TV antenna cables When removed ...

Page 824: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN 20 8932 5 Unscrew the mounting screws from the removed tuner amplifier deck assembly and remove the tuner assembly Match the colors when inserting TV antenna cables into the connections NOTE ...

Page 825: ... from AV head unit Unscrew six mounting bolts 10 mm from the amplifier DSPAmplifier Check if the fiber optic cable is defective If the red lamp comes on when the ignition switch is in ON position the system receives the normal input signal Preceding Work Disconnect the negative battery cable 1 Disconnect the connectors and the fiber optic cable from the AV head unit Unscrew the mounting bolts and ...

Page 826: ...M 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 22 8932 Preceding Work Disconnect the negative battery cable 1 Remove the glove box lamp and release the locking device to lower the glove box DVD Changer DVD changer box ...

Page 827: ... S ROOF S E A T A CRUISE E L 2 Remove the side instrument panel in passenger compartment and unscrew the mounting screws for lower instrument panel 3 Unscrew the inner and outer mounting screws from the glove box and remove the lower instrument panel 4 Open the DVD changer cover Unscrew the mounting screws and remove the inner cover and outer cover ...

Page 828: ...HANGED BY EFFECTIVE DATE AFFECTED VIN 24 8932 5 Remove the DVD changer cover 7 Disconnect the fiber optic cable from the DVD changer through the opening of lower instrument panel 6 Unscrew the mounting screws from the DVD changer ...

Page 829: ... S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 9 Disconnect the harness connector and pull out the DVD changer with case 8 Slide out the DVD changer and unscrew the mounting screws from the DVD changer case 10 Separate the case from the DVD changer ...

Page 830: ...AV SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 26 8932 DVD Changer Fiber optic cable terminal Connector Front view ...

Page 831: ... S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Speaker 2 Unscrew the mounting screws and disconnect the harness connector to remove the center speaker Components Front Center Speaker Speaker assembly Speaker cover Preceding Work Disconnect the negative battery cable 1 Remove the center speaker cover ...

Page 832: ...TED VIN 28 8932 Preceding Work Disconnect the negative battery cable and remove the passenger s seat 1 Disconnect the harness connector and unscrew the mounting nuts to remove the sub woofer speaker Components Volume control lever Connection Sun Woofer Speaker ...

Page 833: ...ROOF S E A T A CRUISE E L 2 Unscrew four mounting screws and disconnect the harness connector to remove the speakers from the front and rear doors Front Rear Door Speakers Front door speaker Rear door speaker 40W 2Ω 40W 2Ω Preceding Work Disconnect the negative battery cable and remove the door trim 1 Disconnect the harness connector from the speaker ...

Page 834: ...VE DATE AFFECTED VIN 30 8932 Preceding Work Disconnect the negative battery cable and remove the door trim For details refer to Body section 1 Unscrew the mounting screws 2 EA from the removed door trim and remove the speaker Door Tweeter Speaker ...

Page 835: ...na connection at tuner Radio antenna connection at tuner TV Antenna Module LH RH RadioAntenna Module Radio antenna module TV antenna module TV antenna module Preceding Works 1 Remove the luggage room lamp assembly 2 Remove the third row and fourth row seats 3 Remove the rear quarter upper and lower trims 4 Remove the rear headlining Preceding Work Remove the rear quarter up per panel ...

Page 836: ...MEMO ...

Page 837: ... 7830 TABLE OF CONTENTS WIPER AND WASHER SYSTEM 2 1 System layout of wiper and washer with rain sensor 4 2 Wiper washer related function and specification 6 3 Wiper and washer system related circuit 11 4 Removal and installation 12 ...

Page 838: ...nsor unit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity To control the system the sensed values of rain sen sor and auto light sensor are sent to pin no 63 in STICS unit 3 Rear washer fluid supply system There is no separate washer fluid reservoir for the rear washer system in this vehicle The rear washer system uses the front washer...

Page 839: ...icle The inside of nozzle is de signed to utilize the fluidic movement This is 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 It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzl...

Page 840: ...ed and the wiper will automatically operate 4 times Then the fluid will be sprayed again and the wiper will automatically op erate 3 times The rain sensor unit is integrated into the auto light sensor It sends the amount of rain drops to STICS Front nozzle The washer nozzles are in stalled at both sides of engine hood The spraying pattern is specially designed to improve the spraying performance W...

Page 841: ...her hose mounting There is no separate washer fluid reservoir for the rear washer system in this vehicle The rear washer sys tem uses the front washer fluid 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 as sembling the vehicle the rear washer hose is fixed on headlining with silicon...

Page 842: ...while washer fluid is sprayed one more and the wiper operates 3 times Wiper and washer fluid for rear wind shield operate simultaneously Only wiper operates Wiping stops Washer fluid for rear windshield operates once Wiping speed gets faster when placing the pointer at the HI positon Wiping stops When turning up the switch the wiper operates once When releasing the switch the pointers return back ...

Page 843: ...is turned on three times immediately after turning off the washer switch Wiper MIST and Front Washer Coupled Wiper KEY IN IGN2 SW WASHER SW WIPER MOTOR PARKING WIPER LOW RELAY ON OFF ON OFF ON OFF ON OFF T1 0 3 T2 0 1 0 59 sec T2 T1 KEY IN IGN2 SW ON T1 0 3 sec T2 over 0 6 sec T3 one wiper cycle T1 T2 T3 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch for 0 1 0 59 sec...

Page 844: ...N the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off 2 It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation Rear Washer Motor Control T1 within 0 3 sec T2 0 1 0 59 sec T3 over 0 6 sec T4 3 cycles T5 pause T1 T1 T5 ...

Page 845: ...F the washer motor output is activated for 1 second If the system recognizes this output the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second Then the wiper relay output is deactivated after 3 cycles T1 over 100 ms T2 1 0 0 1 sec T3 within 0 3 sec T4 4 cycles T5 3 cycles T6 0 5 0 1 sec T1 T2 T2 T5 T4 T3 T6 KEY IN IGN2 SW ON OFF INT SW AUTO AUTO ...

Page 846: ...sher operation stops and the auto INT operation is activated 1 The rear washer switch input is overridden during the front washer operation 2 The rear washer switch input is overridden during the auto washer and wiper AFW operation 3 The front washer switch input is overridden during the rear washer operation 4 The auto washer switch input is overridden during the rear washer operation 5 The front...

Page 847: ...TIVE DATE AFFECTED VIN WIPER WASHERSYSTEM KYRON SM 2005 09 11 7810 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L STICS 3 WIPER AND WASHER SYSTEM RELATED CIRCUIT ...

Page 848: ... Preceding Work Disconnect the negative battery cable 1 Disconnect the mounting nut from the wiper blade assembly and then unscrew the mounting nut At this moment perform the work with the engine hood removed or opened 2 Close the engine hood and then remove the wiper blade asembly Wiper blade assembly Driver side Passenger side ...

Page 849: ... I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Remove the cowl mounting molding 4 Remove the cowl mounting clip and then disconnect the cowl from the left driver side 5 Disconnect the wiper motor connector 1 and front windshield heated wire connector 2 connected to the wiper link assembly Passenger side cowl Driver side cowl ...

Page 850: ... 7810 7 Unscrew the mounting nut 10 mm 1EA and bolts 8 mm 3EA from the removed wiper linkage assembly and then remove the wiper motor Mark the adjustment mark before unscrewing the wiper motor cen ter mounting nut 6 Unscrew the mounting nut 10 mm 3EA from the wiper link assembly ...

Page 851: ...0 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Layout of Front Wiper Assembly Wiper Motor Assembly Linkage aseembly Passenger seat cowl Driver seat cowl Wiper motor Wiper blade Passenger side Wiper blade driver side Connector ...

Page 852: ...onnection of negative battery cable 1 Disconnect the mounting screws from the each tailgate trim part 1 Remove the tailgate upper trim 3 Disconnect the mounting clip underside the tailgate 4 Upper mounting screw on the tailgate lower trim 5 Lower mounting screw on the tailgate lower trim 2 Remove the inner tailgate handle ...

Page 853: ...YSTEM KYRON SM 2005 09 17 7810 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Disconnect the mounting screw and then remove trim and vinyl cover from the tailgate underside Mounting Piece Position ...

Page 854: ... DATE AFFECTED VIN 18 7810 3 Close the tailgate and then remove the wiper blade assembly 4 Remove the wiper blade and then unscrew the wiper motor cap and the mounting nut 17 mm 1EA Open the cap Unscrew the nut 10 mm 1EA Disconnect the cap Disconnect the nut ...

Page 855: ...I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 5 Open the tailgate unscrew the connector and mounting bolts 10 mm 2EA and then remove the wiper motor Rear Wiper Assembly Passenger seat wiper blade assembly Mounting nut Rear wiper motor and linkage assembly Spacer ring tailgate wiper Splasher ring tailgate wiper Front Rear Inside ...

Page 856: ... AFFECTED VIN 20 7810 Reservoir Tank and Nozzle Assembly Reservoir Tank 1 Remove the front wheel house cover 2 Remove the washer motor from the reservoir tank and then drain the washer fluid Preceding Work 1 Disconnect the battery negative cable 2 Remove the tire ...

Page 857: ...ank Be careful not to contact the washer fluid or foreign materials into the motor and connector after disconnecting 4 Disconnect the washer hose connecting the reservoir tank and nozzle from the reservoir tank wheel house Unscrew the washer reservoir tank mounting bolt and then remove it Be careful not to damage when disconnecting Connection Hose on the Wheel House Side Upper Mounting Bolt Front ...

Page 858: ... EFFECTIVE DATE AFFECTED VIN 22 7810 Nozzle and Hose 2 Remove the nozzle by pressing the right left nozzle located at the engine hood as shown in the figure Front Side 1 Open the engine hood and then disconnect the hose Nozzle Side Connection Point ...

Page 859: ... S P W M S ROOF S E A T A CRUISE E L 2 Close the tailgate and then remove the nozzle with a flat blade screwdriver or special tool Preceding Work 1 Remove the tailgate spoiler 2 Remove the tailgate upper trim 1 Open the tailgate and then disconnect the nozzle hose from the check valve Be careful not to damage the body and the nozzle NOTICE Rear Side ...

Page 860: ...MEMO ...

Page 861: ... overview 2 2 Rain sensor operation 4 3 Rain sensor related circuit 5 4 Functions and specifications of rain sensing wiper 6 5 Operation mode of rain sensing wiper system 11 6 Functions and checks of rain sensor 12 7 Diagnosis procedures 14 8 Trouble shooting 15 9 Electrical wiring diagram 18 TABLE OF CONTENTS ...

Page 862: ...detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor refer to the below picture AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto speed control A position that can control sensitivity against rains on the windshield and tra...

Page 863: ...asher MIST AUTO then sends the information to the rain sensor Wiper relay HI Wiper relay LO Front washer relay Engine compart ment fuse box STICS Rear washer relay 1 Rain detected headlamp If it rains heavy which requires the highest INT speed the headlamps are turned on automatically 2 Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain th...

Page 864: ...its infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor Followings are the components and functions of the rain sensor unit Rain Sensor Unit Including Cover Emitter Lens The LED emits the infra red rays is ...

Page 865: ...are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain ...

Page 866: ...ycle 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 Rain Detected signal T1 1 cycle T1 T1 T1 4 FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING WIPER Power up Remi...

Page 867: ... 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 2 The operation data is sent to the rain sensor even during the washer coupled wiper operation KEY IN IGN2 ON OFF INT AUTO SW AUTO OFF WASHER SW ON OFF WIPER P POS ON OFF WIPER LOW RELAY...

Page 868: ...per 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 T1 1 cycle T1 T1 T1 Auto Light Control 1 Only when the auto light switch is in AUTO position control the tail lamp and headlamp by communicating with the rain sensor while the ignition key is in ON position...

Page 869: ... key is in ON position and the INT switch is in ON position The wiper motor runs only when the rain sensor requires WIPER PARKING SENSITIVITY RKSTICS to RAIN SENSOR IGN Operation GND Stop 2 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 ig...

Page 870: ... is in ON position and the INT switch is in ON position 2 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 SENSITIVITY RAIN SENSOR to RKSTICS WIPER LOW RELAY SENSITIVITY RAIN SENSOR to RKSTIC...

Page 871: ...nsitivity against rains on windshield Auto delay auto speed control Medium sensitivity against rains on windshield Auto delay auto speed control Medium high sensitivity against rains on windshield Auto delay auto speed control High sensitivity against rains on windshield The wiper motor rotates continuously in low speed of approx 45 rev minute at B 13 5V in the normal battery voltage The rain sens...

Page 872: ... the wiper operates up to 5 minutes after rain stops 3 If this function does not occur check No 2 terminal on the rain sensor If any defective cannot be found check the wiper relay LOW for defective Instant Wipe Function When the variable resistance knob on the multifunction wiper switch is turned by each 1 stage from low sensitivity S mark to high sensitivity F mark the wiper operates one cycle A...

Page 873: ...he highest value of FAST stage 5 4 Check the wiper blade for wear If the wiper blade cannot wipe the glass uniformly and clearly the irregular operations could be occurred And the wiper blade should be replaced with new one with same specifications Self Diagnosis Position the wiper switch to AUTO position and rotate the variable resistance knob from FAST toward SLOW by one step At this moment chec...

Page 874: ...AGNOSIS PROCEDURES 1 Check the glass and coupler for proper installation 2 Check the power up function 3 Check the instant wipe function 4 Check the washer coupled wiper function 5 Check the high speed 6 Find the causes for irregular operations abrupt operations 7 Check the system with self diagnosis function ...

Page 875: ...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 Symptom 3 The wiper operates 3 or 4 times at high speed abruptly Symptom 2 It rains but the system does not work in the AUTO position 1 Check whether the multifunction wiper switch is in the AUTO position 2 ...

Page 876: ...the rain sensor cover by inserting a small flat blade screwdriver into service holes at both sides refer to picture 2 Disconnect the connector from the rain sensor unit located at the front windshield glass and then lift up the rain sensor unit to disconnect from the glass Otherwise the cover or rain sensor components could be damaged NOTICE Service hole ...

Page 877: ...T SENSOR KYRON SM 2005 09 17 8610 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Components of the Rain Sensor Unit Emitter lens Receiver lens Auto light sensor PCB Assembly and Emitter Lens Housing and Receiver Lens ...

Page 878: ...RAIN SENSOR UNIT WITH AUTO RIGHT SENSOR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 8610 9 ELECTRICAL WIRING DIAGRAM ...

Page 879: ...D SYSTEM PAS 2 1 System configuration 2 2 Component specifications 4 3 Alarm interval 5 4 Troubleshooting of sensor 5 5 Cautions on parking aid system 6 6 Removal and installation of parking aid 7 7 Circuit diagram 12 TABLE OF CONTENTS ...

Page 880: ...r bumper 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 PARKING AID SYSTEM PAS STICS PAS piezoelectric buzzer PAS buzzer ...

Page 881: ...ID SYSTEM KYRON SM 2005 09 3 8790 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Left Right Center Sensor Location Center sensor Right sensor Left sensor Connector Center sensor Parking Aid Unit ...

Page 882: ...NENT SPECIFICATIONS The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval and detects the reflected signals from obstacles while the gear selector lever is in R position The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches This supplemen tary system is to secure the safety distanc...

Page 883: ...ensor will be diagnosed once If found any failure due to open circuit to sensor or communication error warning buzzer sounds for 3 seconds and the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Warning beeps When failed also when diagnosing the unit 1 2 3 L C R sensor Remark Interval msec Stage 81 120 cm ...

Page 884: ...2 Cotton sponge clothes snow that absorb ultrasonic waves 3 Obstacles lower than the bumper ex drain ditch or mud puddle 2 Not defective but improperly working 1 When the sensing portion is frozen operates normally after thawed 2 When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned 3 When receiving other ultrasonic signals metal sound or air braking n...

Page 885: ...L A M P S P W M S ROOF S E A T A CRUISE E L 6 REMOVALAND INSTALLATION OF PARKING AID Parking Aid Sensor Preceding Work Disconnect the negative battery cable and remove the spare tire 1 Disconnect the harness connector and then remove the center sensor by turning the mounting cover Sensor assembly Connector Center PAS Sensor Center PAS sensor ...

Page 886: ...D VIN 8 8790 Preceding Work Disconnect of negative battery cable 1 Disconnect the center connector and then remove the cover by turning it RH LH PAS Sensor RH sensor LH sensor 2 Remove the RH LH sensor mounting cover and spring and then remove the sensor from the bumper ...

Page 887: ... SYSTEM KYRON SM 2005 09 9 8790 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Connector Components of PAS Sensor PAS sensor PAS sensor upper mounting cover Spring PAS sensor lower mounting cover ...

Page 888: ... AFFECTED VIN 10 8790 Precautions When Installing LH RH Sensors Fit The Sensor Into The Mounting Hole When Extended 1 Align the sensor lower cover with the sensor groove 2 Insert the sensor upper cover into the sensor groove When Compressed Align Wigh the Groove ...

Page 889: ... W M S ROOF S E A T A CRUISE E L PAS Unit Preceding Work 1 Disconnection of negative battery cable 2 Removal of rear lower quarter panel and seat belt Forremovalandinstallation refertotheBODYsection 1 Disconnect the connector and mounting bolts 10 mm 2EA and then remove the PAS unit Disconnection of connector Removal of mounting bolt Connector Connector ...

Page 890: ...PARKING AID SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 12 8790 7 CIRCUIT DIAGRAM ...

Page 891: ...ions of interior units and sensors 2 2 Switches units and sensors in engine compartment 4 3 Interior switches 6 4 Audio video system 8 5 Electric components and layout 10 6 Fuses and relays 12 7 Interior fuse box 15 8 Diagnostic connector 18 9 Electrical wiring diagrams 20 ...

Page 892: ...TS AND SENSORS Steering Wheel Angular Sensor Immobilizer TV antenna amplifier TCCU and TCU Driver Seat Memory Switch RK STICS Buzzer for PAS Under Instrument Panel ELECTRIC SYSTEM LAYOUT PAS Unit TCU TCCU Steering wheel angular sensor Curtain air bag module Sun sensor Chime bell Door lock relay Immobilizer ...

Page 893: ... ROOF S E A T A CRUISE E L Interior Temperature and Humidity Sensor Air Bag ECU Engine ECU and SSPS Unit Curtain Air Bag Sensor Sub woofer TV antenna amplifier DVD changer TV tuner Rain Sensing Unit Including Auto Lignt and ECM Sensor Cluster Sun Roof Unit and Motor Sun roof unit Sun roof motor DSP amp SSPS unit under the engine ECU Curtain air bag module ...

Page 894: ...FECTED VIN 4 8000 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT Horn RH FFH Assembly Receiver Drier and Triple Pressure Switch AQS Sensor and FFH Ambient Temperature Sensor FFH ambient temperature sensor AQS sensor ambient temperature sensor integrated type ...

Page 895: ...SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L ESP Pressure Sensor Primary Secondary Hood Contact Switch Horn LH Fuse and Relay Box Theft Deterrent Horn Under the Battery IWE Vacuum Solenoid Valve 4WD on battery tray ABS ESP HECU ...

Page 896: ... on Outside Rearview Mirror Adjusting Switch Remote Control Switch on the Steering Wheel Seat Position Memory Switch Driver s Door Audio remote control switch Audio remote control switch Outside rearview mirror folding switch ESP OFF switch Outside rearview mirror adjusting switch Driver s Power Window Main Switch ...

Page 897: ...P W M S ROOF S E A T A CRUISE E L Sun Roof Switch Passenger s Power Window Switch Bezel Assembly on Hazard Switch Room lamp main switch Sun roof switch Outside rearview mirror and rear glass heated switch HDC switch TRIP switch Hazard switch Front defogger switch Center Fascia Switch 4WD switch Driver seat warmer switch Passenger seat warmer switch ...

Page 898: ...fier integrated type AV head unit Front speaker RH DVD changer Tweeter speaker DVD tape Front speaker LH AV System Center speaker Audio remote control switches DVD changer AV Head Unit Sub Woofer Tweeter speaker LH Center speaker 1 6 INDASH CD TAPE RADIO 2 CD RADIO Other Audio Head Unit 6 Indash changer Tape CD slot ...

Page 899: ...CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L TV antenna amplifier RH Rear speaker RH Tuner Amp Tweeter speaker TV antenna amplifier LH 6 DVD changer AV System Rear speaker LH Location Inside of panel above glove box DSP integrated amplifier Tuner Tweeter speaker LH Radio antenna amplifier ...

Page 900: ...ELECTRIC SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 10 8000 5 ELECTRIC COMPONENTS AND LAYOUT Wiring Harness Arrangement ...

Page 901: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC SYSTEM KYRON SM 2005 09 11 8000 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Components Locator ...

Page 902: ...ELAYS There are three fuse and relay boxes in this vehicle one at each side of instrument panel and one in engine compartment The designation and capacity of relays and fuses is shown on the fuse and relay box cover Fuse and Relay Box in Engine Compartment Fuses and Relays Connector Arrangement ...

Page 903: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC SYSTEM KYRON SM 2005 09 13 8000 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L ...

Page 904: ...00 Removal and Installation 1 Disconnect the negative battery cable open the fuse and relay box cover in engine compartment and unscrew the mounting nuts 2 Lift the fuse and relay box assembly and disconnect connectors behind the assembly 3 Remove the fuse and relay box assembly ...

Page 905: ...ATE AFFECTED VIN ELECTRIC SYSTEM KYRON SM 2005 09 15 8000 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 7 INTERIOR FUSE BOX Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 906: ...ELECTRIC SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 8000 Designation and Capacity Driver Side ...

Page 907: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC SYSTEM KYRON SM 2005 09 17 8000 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Passenger Side ...

Page 908: ...etween Scan 100 and Diagnostic Connector CAN module CAN module connecting cable 8 DIAGNOSTIC CONNECTOR Scan 100 Diagnostic connector Additional cable for CAN module CAN module Additional Devices of Scan 100 Diagnosis EAS EPB Only Connection of Scan 100 Including CAN Module and Additional Cable ...

Page 909: ...ed under the instrument panel and consists of 16 pins The REKES key coding should be performed with Scan 100 Functions of Terminal Pin no 1 Pin no 2 Pin no 3 Pin no 4 Pin no 5 Pin no 6 Pin no 7 Pin no 8 Pin no 9 Pin no 10 Pin no 11 Pin no 12 Pin no 13 Pin no 14 Pin no 15 Pin no 16 FFH diagnosis FFH forced driving Ground Signal ground CAN HIGH Engine ECU ABS ESP Air bag TGS lever position unit TCU ...

Page 910: ...ELECTRIC SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 20 8000 9 ELECTRICAL WIRING DIAGRAMS ...

Page 911: ...6 2 Aiming and adjustment of front lamp 8 3 Removal and installation of headlamps 11 REAR COMBINATION LAMP 18 1 Composition of rear combination lamp 18 2 Removal and installation of rear combination lamp 20 INTERIOR LAMPS 28 1 Composition of interior lamps 28 2 Removal and installation of interior lamps 30 TABLE OF CONTENTS ...

Page 912: ...am one at each side 12V 55W Turn Signal Lamp Stop Lamp Assembly Fog lamp angle adjustment Fog Lamp Assembly LAMPS T Stop Lamp General LH 1 12V 27W 8W EU LH 1 12V P21W 5W Position lamp and Turn Signal Lamp General one at each side 12V 28W 8W EU one at each side 12V P21W Fog Lamp General one at each side 12V 27W EU one at each side 12V H27W Turn Signal Lamp General one at each side 12V 27W EU one at...

Page 913: ...mp Assembly High Mounted Stop Lamp Assembly Side Repeater Assembly General one at each side 12V 5W EU one at each side 12V W5W Reversing Lamp General one at each side 12V 16W Tail Lamp General one at each side 12V 27W 8W EU one at each side 12V P21W 5W General one at each side 12V 5W EU one at each side 12V W5W Rear Fog Lamp General one at each side 12V P21W Tail Lamp Reversing Lamp Rear Fog Lamp ...

Page 914: ...12V 5W one at each door Center room lamp coupled operation with door Luggage room lamp Lamp OFF Center room lamp Lamp ON Luggage room lamp coupled operation with tailgate Toward tailgate Toward dirver side Center Room Lamp Luggage Room Lamp When this switch is pushed to wards the tailgate the lamp comes on when the tailgate is open If the switch is pushed to the opposite direction the lamp will go...

Page 915: ...tion key during decaying operation 5 The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed 6 The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remote con...

Page 916: ...AFFECTED VIN 6 8310 1 COMPOSITIONS OF FRONT LAMPS Headlamp Assembly Lamp Lamp cap High beam bulb Low beam bulb General Positon lamp and turn signal lamp bulb Connector Fog lamp bulb Connector Lamp and case FRONT LAMPS Front Fog Lamp EU Position lamp ...

Page 917: ...005 09 7 8310 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Connection Connector When Installing Positon lamp and turn signal lamp connector Headlamp connector Connector Lamp Lamp cover Side Repeater ...

Page 918: ... Beam No 3 adjustment hole Up and Down No 4 adjustment hole Left and Right HeadlampAiming Adjust the headlamp aiming while turning the aiming screws up down left right in turn with a screwdriver Headlamp aiming requirements 1 parking on a flat surface 2 specified tire pressure 3 one passenger driver 75 kg 4 spare tire and OVM tools loaded unlade all other loads Low Beam 1 Left 2 Right Low Beam A U...

Page 919: ...creen 2 m 1 5 m in front of the headlamps in vertical by 3 m away and align the center lines of the vehicle and the screen Aiming Procedures When Using a Screen 단위 mm LOW BEAM 36 차량의 중심선 헤드램프 벌브 수직 헤드램프 벌브 수평선 헤드램프 촛점 수평선 A A 1342 지면 단위 mm HIGH BEAM LH RH 45 90 90 90 85 촛점 허용범위 촛점 허용범위 A A 1078 30 지면 Center line of vehicle and screen Ground Unit mm Allowable focusing area Allowable focusing area G...

Page 920: ...per Front fog lamp aiming up down can be adjusted by the control knob installed on the fog lamp Fog Lamp Aiming Adjustment The lamp aiming moves down and the light faces downward when the knob is turned counterclockwise The lamp aiming moves up and the light faces upward when the knob is turned clockwise Up Down Down Up ...

Page 921: ... Turn signal lamp Position lamp Low beam High beam 2 Remove the headlamp lower cover from the upper front bumper and unscrew the headlamp lower mounting nut 10 mm 3 REMOVAL AND INSTALLATION OF HEADLAMPS Preceding Work Disconnect the negative battery cable 1 Open the engine hood and unscrew two headlamp up per mounting bolts 10 mm Be careful not to damage the headlamp cover when removing it in orde...

Page 922: ...to damage the headlamp assembly when removing it Low beam Turn signal lamp and Position lamp High beam Turn signal lamp and Position lamp General Low beam High beam Headlamp Assembly If the lamp cover rubber ring is damaged while installing replace it with new one NOTICE Position lamp EU ...

Page 923: ...E R L A M P S P W M S ROOF S E A T A CRUISE E L Replacement of Headlamp Bulb 1 Remove the headlamp dust cover 2 Disconnect the high low beam connectors from the headlamp assembly 3 Remove the clamps Low Beam Side High Beam Side Low Beam Side High Beam Side To make the bulb replacement easier remove the headlamp assembly NOTE ...

Page 924: ...gnal lamp bulb should be removed after removing the headlamp assembly Low Beam Side High Beam Side Use only specified bulb for replacement Do not touch the bulb with bare hands when it is hot You may get burnt NOTICE Use only specified bulb for replacement Do not touch the bulb with bare hands when it is hot You may get burnt NOTICE ...

Page 925: ... P S P W M S ROOF S E A T A CRUISE E L Fog Lamp Assembly Preceding Work Disconnect the negative battery cable 2 Disconnect the connector and unscrew four mounting screws to remove the front fog lamp assembly Fog lamp bulb and connector Lamp and case Front View Rear View 1 Remove the front wheel house and then remove the horn assembly ...

Page 926: ...f Fog Lamp Bulb Disconnect the fog lamp connector located on the front bumper Side Repeater Preceding Work Disconnection of negative battery cable 2 Disconnect the connector and remove the lamp Connector Lamp 12V 5W Side repeater cover Rear Front 1 Push out the side repeater assembly ...

Page 927: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN LAMP KYRON SM 2005 09 17 8310 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L MEMO ...

Page 928: ...ATE AFFECTED VIN 18 8310 Turn Signal Lamp Stop Lamp Assembly License Plate Lamp Assembly REAR COMBINATION LAMP 1 COMPOSITION OF REAR COMBINATION LAMP Bulb holder connector Turn signal lamp valve Stop lamp bulb Combination lamp Lamp Bulb Connector ...

Page 929: ... 8310 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L High Mounted Stop Lamp Tail Lamp Back up Lamp Assembly Bulb tail lamp Bulb Passenger Back up lamp Driver RR Fog Lamp Bulb holder Connector Combination lamp ...

Page 930: ...NSTALLATION OF REAR COMBINATION LAMP Turn Signal Lamp Stop Lamp Preceding Work Disconnect the negative battery cable 1 Open the tailgate and unscrew two mounting screws to remove the rear combination lamp assembly 2 Disconnect the connector and remove the rear combination lamp assembly ...

Page 931: ...2005 09 21 8310 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 3 Open the bulb holders connectors by turning them counterclockwise and remove the bulbs Use only specified bulb for replacement NOTICE ...

Page 932: ...mp Back up Lamp RR Fog Lamp Preceding Work Disconnect the negative battery cable 1 Open the tailgate and remove the bolt cover Then unscrew three mounting nuts 10 mm and remove the rear combination lamp assembly tail lamp back up lamp RR fog lamp 2 Disconnect the connector and remove the rear combination lamp assembly Use only specified bulb for replacement NOTICE ...

Page 933: ... E R L A M P S P W M S ROOF S E A T A CRUISE E L License Plate LampAssembly Preceding Work Disconnect the negative battery cable 1 Remove the upper and lower trim of the tailgate Disconnect the connectors and unscrew eight mounting nuts 10 mm to remove the rear garnish assembly Tailgate Rear Garnish Assembly Inside Outside ...

Page 934: ... AFFECTED VIN 24 8310 Tailgate garnish Connector Lamp 2 Disconnect the bulb and bulb cable from the removed rear garnish assembly and then remove the lamp by pressing A section of the lamp Disconnect the Bulb Connector Remove the Lamp Exploded View ...

Page 935: ...L A M P S P W M S ROOF S E A T A CRUISE E L Replacement of Bulb 1 Pry off the license plate lamp with a flat bladed screwdriver 2 Remove the bulb from the removed license plate lamp 3 Install the bulbs into the license plate lamp Make sure the location and LOCK direction are correct Use only specified bulb for replacement NOTICE ...

Page 936: ...ery cable 1 Open the tailgate remove the upper trim and then disconnect the high mounted stop lamp connector 2 Disconnect the rear washer nozzle hose In the vehicle with tailgate air spoiler the LED type high mounted stop lamp is integrated in the tailgate air spoiler It should be replaced with the tailgate upper garnish assembly NOTE ...

Page 937: ...gate upper garnish assembly from the removed air spoiler Cap nut 5 Replace the tailgate upper garnish assembly with new one In the vehicle with tailgate air spoiler the LED type high mounted stop lamp is integrated in the tailgate air spoiler It should be replaced with the tailgate upper garnish assembly In the vehicle without tailgate air spoiler the bulb type high mounted stop lamp is used It ca...

Page 938: ...DATE AFFECTED VIN 28 8310 1 COMPOSITION OF INTERIOR LAMPS Front room lamp bulb Front room lamp cover Sunglasses box Lamp lens Front view Rear view Bulb luguage room INTERIOR LAMPS Front Room Lamp Assembly Interior Room Luggage Room Lamp Assembly ...

Page 939: ...FECTIVE DATE AFFECTED VIN LAMP KYRON SM 2005 09 29 8310 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Glove Box Lamp Assembly Door Courtesy Lamp Assembly Bulb ...

Page 940: ...310 2 REMOVAL AND INSTALLATION OF INTERIOR LAMPS Front Room Lamp Preceding Work Disconnect the negative battery cable 1 Open the sunglasses box and remove two front room lamp assembly mounting screws 2 Disconnect the connector and remove the front room lamp assembly ...

Page 941: ... V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 2 Carefully remove the bulb from the lamp and replace it with new one 1 Remove the front room lamp cover Replacement of the Front Room Lamp Bulb Use only specified bulb for replacement NOTICE The tab can be damaged when removing the room lamp abnormally NOTICE ...

Page 942: ... battery cable 1 Remove the lamp cover 2 Unscrew the lamp mounting screws luggage room lamp and nuts center room lamp 3 Disconnect the connector and remove the lamp assembly Center Luggage Room Lamp Slot Slot Center room lamp Luggage room lamp Use the slot around the cover when replacing the lamp bulb NOTICE ...

Page 943: ... M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Replacement of Bulb 1 Remove the lamp cover and then carefully remove the bulb Replace it with new one Center Room Luggage Room Lamp Assembly Center room lamp Luggage room lamp Use only specified bulb for replacement NOTICE ...

Page 944: ... 1 from the door trim and remove the bulb 2 Replace the bulb with new one Preceding Work Disconnect the negative battery cable 1 Open the glove box and remove the lamp cover by pressing both sides of the lamp as shown in the figure 2 Disconnect the connector and remove the lamp assembly Replace the bulb with new one 12V 5W 12V 5W Location Toward tailgate use the slot around the lens when replacing...

Page 945: ...UNROOF SYSTEM 7340 SUNROOF ASSEMBLY 2 1 Components and locations 2 2 Operation and function 3 3 Trouble diagnosis 6 4 Removal and installation of sunroof assembly 7 5 Circuit diagram 21 TABLE OF CONTENTS ...

Page 946: ...SUNROOF SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 2 7340 1 COMPONENTS AND LOCATIONS Sunroof Motor SUNROOF ASSEMBLY Sunroof Control Unit SCU Sunroof Switch Sunroof Assembly ...

Page 947: ...nroof Tilting Operation Tilt up To tilt up the sunroof rotate the sunroof switch counter clockwise CLOSE direction with the sunroof fully closed Tilt down To tilt down the sunroof rotate the sunroof switch clock wise OPEN direction with the sunroof tilted up Sunroof Sliding Operation Open To fully open the sunroof briefly rotate the sunroof switch clockwise OPEN direction with the sunroof closed T...

Page 948: ... operated by rotating the motor operat ing hole on the sunroof motor with a proper tool Circuit Diagram Power supply conditioner Supply voltage monitor Tilt Logic input Slide Controller assembly Motor drive B Motor drive A Puls input Close position Sensing Motor HALL I C MICROSWITCH Motor Connector SCU SCU Main Connector ...

Page 949: ... sunroof opening and tilting level is significantly low 4 The sunroof does not operate properly when operating the sunroof switch 3 0 point reset of sunroof 1 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 2 Check if the sunroof is fully closed Tilt the s...

Page 950: ...tion Improper operation of motor Caught side cover by dislocation of sun shade Interference between drain hose and vehicle body Interference between vehicle body and roof panel Gap and clearance between roof panel and glass Check and correct drain hose condition Readjust glass location Readjust glass location Check and replace repair Replace it Reinstall sun shade and side cover Replace damaged pa...

Page 951: ... Seal glass panel Side cover outer Side cover inner Frame assembly Sunroof control unit Sunroof motor Tube cable guide Seal drive tube Drive tube Frame assembly Drain channel Sunshade assembly Ventilation roof Wind deflector Pin Main lever LH Drain lever Slider LH Drain lever LH Drain channel support Panel curve on Rivet roll Breed nail Drain channel support bar RH Return spring Drain channel supp...

Page 952: ...ATE AFFECTED VIN 8 7340 Wind Deflector 1 Fully open the sunroof 2 Unhook the wind deflector side locks at both sides 3 Unhook the wind deflector bottom locks as shown in figure A With Sunroof Opened Wind deflector Work only when the sunroof is open NOTICE ...

Page 953: ... P W M S ROOF S E A T A CRUISE E L Glass Panel Assembly Inside Cover of Glass Panel Assembly 1 Remove the inner side covers at both sides by pushing them rearward 2 Remove the three mounting bolts TORX bolts of the glass panel with a special wrench 25 T 3 Remove the glass panel Work only when the sunroof is tilted up NOTICE Tightening torque 5 Nm ...

Page 954: ... inside cover 1 Cut off the locks on the outside cover with a cutter and remove the outside cover 2 Insert the locks of the new outside cover into the mount ing holes 3 Push down the outside cover to install into the roof panel and lock it to the sunroof system with a pliers Outside Cover of Glass Panel Sunroof mechanism ...

Page 955: ...ORX bolts T25 at both sides At this moment the logo on the glass panel should face the rear side of the vehicle 2 Completely close the sunroof using the sunroof switch 3 Adjust the following items with the specified value and tighten the bolts Gap Between Front and Rear Glass Panel Gap Distance from roof panel to glass 1 Front gap 1 0 mm 2 Rear gap 0 1 mm Front Rear Front Rear To prevent the wind ...

Page 956: ...iving the installation gap should be maintained the ratio of 4 6 front rear when installation Measure the interference between roof and glass panel while moving the glass panel Gap between roof and glass panel should be approx 5 mm If this gap is too small the glass panel may be scratched or the interferencing noise may sound After Assembly 6 4 Rear Gap Front Gap 6 4 Front Rear Gap between roof an...

Page 957: ... S E A T A CRUISE E L Drain Channel Preceding Work Removal of glass panel 1 Remove the two mounting bolts TORX bolt at both sides on the drain channel with the glass panel removed 2 Unhook the locks A and remove the drain channel 3 When installing Hook the locks B of the drain channel Drain channel Tightening torque 1 2 Nm Drain channel With Sunroof Tilted up ...

Page 958: ...Panel Preceding Work Removal of glass panel and drain channel 1 Move the sun shade panel forward and remove the slide blocks of the sun shade panel from the guide rail with a flat bladed screwdriver as shown in the figure 2 Remove the sun shade panel from the sunroof With Sunroof Tilted up ...

Page 959: ...ly close the sunroof with sunroof switch 2 Remove the sun visor passenger s hand grip A pillar headlining B pillar headlining to deflect the front section of the headlining Be careful not to damage the headlining SCUAssembly 1 Disconnect the connector from the sunroof control unit 2 Unscrew the mounting screw and remove the SCU assembly Sunroof control unit Sunroof motor With Sunroof Fully Closed ...

Page 960: ...embly 1 Disconnect the connector from the SCU 2 Unscrew the three mounting bolts 25T with a special wrench and remove the motor assembly Work only when the sunroof is closed NOTICE To make the motor positioning easier do not operate the motor even for the testing before installation NOTICE ...

Page 961: ...e Removal and installation procedures of drain hoses Release the clamps and remove hoses However the fastener at rear side of rear hose should be removed Front Hose Rear Hose Rear Drain Hose Remove headlining and rear trim Front Drain Hose Remove only Apillar sun visor sunroof molding and front section of headlining When installing be careful not to kink damage and twist the hose NOTICE Not allowe...

Page 962: ...SUNROOF SYSTEM KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 18 7340 Fastener location of rear drain hose Note The rear drain hose can be removed after releasing the fasteners ...

Page 963: ...SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Sunroof Assembly Preceding Work Removal of headlining 1 Disconnect the front and rear drain hoses with the sunroof closed 2 Unscrew the two bracket mounting bolts 10 mm at both sides ...

Page 964: ...ON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 20 7340 3 Unscrew the mounting bolts 10 mm at both sides Installation Notice 4 Remove the sunroof assembly from the vehicle Sunroof Assembly Tightening torque 6 10 Nm ...

Page 965: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN SUNROOF SYSTEM KYRON SM 2005 09 21 7340 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 5 CIRCUIT DIAGRAM ...

Page 966: ...MEMO ...

Page 967: ...SEMBLY 3 1 Seat mounting points 3 2 Composition of seat 4 3 Removal and installation of seat 11 4 Seat heating 17 5 Seat arrangement 17 SEAT BELT 18 1 Seat belt locations 18 2 Removal and installation of seat belt 20 TABLE OF CONTENTS ...

Page 968: ......

Page 969: ... S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 1 SEAT MOUNTING POINTS Front Seat Second Row Seat Third Row Seat Mounting bolts SEAT ASSEMBLY Tightening torque 35 55 Nm Tightening torque 35 55 Nm Tightening torque 35 55 Nm Tightening torque 35 55 Nm ...

Page 970: ...r Rear SPWM Seat Position With Memory Unit Reclining lever Seat cushion angle adjusting lever front Sliding lever Seat cushion angle adjusting lever rear Seat height control switch Lumbar support lever Sliding rail Sliding rail Sliding motor Reclining Motor Seat Cushion Motor Front Seat cushion up down bar rear Seat cushion up down bar front ...

Page 971: ...FFECTED VIN SEAT SEAT BELT KYRON SM 2005 09 5 7410 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L SPWM unit Location of Seat Position With Memory Unit Bottom of Driver Seat ...

Page 972: ...BELT KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 6 7410 Reclining Motor Sliding rail Sliding rail Sliding motor Front Seat Passenger Seat Reclining lever Sliding lever No seat height control function ...

Page 973: ... 7410 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Switches and Functions of Driver Seat Functions 1 Seat Sliding Adjustment 2 SeatCushionHeightAdjustment 3 Seat CushionAngleAdjustment 4 Seatback RecliningAdjustment ...

Page 974: ...es and Functions of Passenger Seat 1 Headrest Height Adjustment To raise the headrest pull it up without press ing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down 2 Seatback Reclining Adjustment 3 Seat Sliding Adjustment ...

Page 975: ... Seat 1 Headrest Height Adjustment 2 Seatback Reclining Adjustment To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever To raise the headrest pull it up without pressing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down Full Flatting the Second Row Seat ...

Page 976: ...Third Row Seat 1 Headrest Height Adjustment 2 Full flat lever for third row seat To raise the headrest pull it up without pressing the release button To lower the headrest press the release button A on top of seatback and push the headrest down Unfolding Folding of Third Row Seat ...

Page 977: ... seat rearward as far as possible and unscrew the two front mounting bolts 14 mm at both sides Installation Notice 2 Move the seat forward as far as possible and unscrew the two rear mounting bolts 14 mm at both sides Installation Notice 3 Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly Disconnect the connector Main connector Connector seat side ...

Page 978: ... unscrew the two front mounting bolts 14 mm at both sides Installation Notice 2 Move the seat forward as far as possible and unscrew the two rear mounting bolts 14 mm at both sides Installation Notice 3 Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly Tightening torque 35 55 Nm Tightening torque 35 55 Nm ...

Page 979: ...Slide the front seats forward and remove the four front mounting nuts 14 mm of the second row seat Installation Notice 2 Lay down the seatback of the second row seat and remove the eight rear mounting nuts 14 mm Insert a wrench between seatback and cushion to remove the mounting bolts with arrow mark 3 Remove the second row seat from the vehicle Tightening torque 35 55 Nm Tightening torque 35 55 N...

Page 980: ...VE DATE AFFECTED VIN 14 7410 Third Row Seat 1 Unscrew the six mounting bolts 10 mm and remove the storage box from the luggage compartment 2 Unscrew the mounting bolts and remove the third row seat Tightening torque 35 55 Nm Tightening torque 35 55 Nm ...

Page 981: ... C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Power Seat Switch Preceding Work Disconnect the negative battery cable 1 Slide the front seat forward and unscrew the mounting screws of seat side cover 2 Disconnect the switch connector and remove the seat side cover ...

Page 982: ...AT SEAT BELT KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 16 7410 3 Remove the power seat switch cover and unscrew the two mounting screws to remove the switch Composition of Power Seat Switch ...

Page 983: ...S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L Press the button to warm the seat and press it again to stop the operation The indicator on the switch comes on during operation 4 SEAT HEATING 5 SEAT ARRANGEMENT Driver s Seat Heating Switch Passenger s Seat Heating Switch ...

Page 984: ...indow 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 Seat Belt 2 point type SEAT BELT Seat Belt 3 point type Seat Belt 3 point type ...

Page 985: ...Belt 3 Point Type Seat belt Pre tensioner Seat belt O ring Seat belt anchor Seat belt O ring Seat belt Seat belt anchor Bracket Seat Belt 2 Point Type 2 point type seat belt is installed only in the center seat of second row seat Buckle of 3 point type seat belt Buckle of 2 point type seat belt Seat Belt in Second Row Seat Seat Belt Window Side in Third Row Seat Seat Melt in Front Seats ...

Page 986: ...eat Belt Preceding Work Removal of front seat 1 Remove the seat belt D ring cover 1 Press both sides of button 1 and push the bot tom of D ring cover arrow to release the upper hook 2 2 Raise the arrow section and remove the D ring cover In order not to damage the O ring cover be sure to observe the following procedures NOTICE ...

Page 987: ...4 Unscrew the seat belt upper mounting bolt from the height adjuster 5 Carefully lower the seat belt and unscrew the mounting screws and bolts to remove the seat belt 2 Open the bolt cap and unscrew the seat belt anchor bolt 3 Remove the B pillar lower and disconnect the pretensioner connector Tightening torque 35 55 Nm Tightening torque 35 55 Nm Bolt cap Tightening torque 35 55 Nm ...

Page 988: ...the mounting bolts and remove the height adjuster Seat belt Seat belt mounting bolt 35 55 Nm Height adjuster D ring Seat belt anchor bolt 35 55 Nm 6 Unscrew the mounting screws and remove the B pillar upper Composition of Front Seat Belt Tightening torque 35 55 Nm Tightening torque 35 55 Nm ...

Page 989: ... un screw the guide pin screw and mount ing bolts to remove the seat belt Rear Seat Belt Preceding Work Removal of second row seat and third row seat 1 Open the bolt cap and unscrew the up per mounting bolt 2 Unscrew the lower anchor bolt of the rear seat belt Tightening torque 35 55 Nm Tightening torque 35 55 Nm Tightening torque 35 55 Nm Seat belt O ring bracket Anchor bolt D ring D ring Tighten...

Page 990: ...eat Tightening torque 35 55 Nm Buckle for 3 point type seat belt in second row seat Buckle for 2 point type seat belt in second row seat Center seat belt Buckle for 3 point type seat belt in second row seat Seat belt latch Buckle Cover Reel Type Buckles and Center Seat Belt Fixed Type Buckle Front Seat Buckle mounting bolt 35 55 Nm ...

Page 991: ...AUTO CRUISE SYSTEM TABLE OF CONTENTS AUTO CRUISE ASSEMBLY 2 1 Cruise control system 2 2 Curise control switch 2 3 Removal and installation of cruise control switch 2 4 Electrical wiring diagrams 3 ...

Page 992: ...nt cluster The cruise control system is capable of monitoring internal software and hardware faults as well as external faults in the connectors and wire harness If a fault is detected creise control is stopped immediately and the program logic and hardware logic independently prevent the cruise control from opening the throttle The cruise control will function in temperatures ranging from 40 C 40...

Page 993: ...Y EFFECTIVE DATE AFFECTED VIN AUTO CRUISE SYSTEM KYRON SM 2005 09 R SENSOR P A S S T I C S I M M O CLUSTER S W A V W I P E R L A M P S P W M S ROOF S E A T A CRUISE E L 4 ELECTRICAL WIRING DIAGRAMS Diesel Gasoline ...

Page 994: ...MEMO ...

Page 995: ...l and installation of rear quarter trim and pillar 12 HEADLINING ASSEMBLY 14 1 Removal and installation of headlining 14 CENTER CONSOLE A T DELUXE MODEL 18 1 Removal and installation of center console A T 18 CENTER CONSOLE MANUAL TRANSMISSION 20 1 Removal and installation of center console M T 20 OUTSIDE REARVIEW MIRROR 22 1 Removal and installation of outside rearview mirror 22 INSIDE REARVIEW MI...

Page 996: ... 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 7730 2 1 LOCATIONS C Pillar Trim Door Trim Driver Side Door Center Console A T Deluxe Type INTERIOR TRIM B Pillar Trim Upper Lower Rear Quarter Panel Instrument Panel Assembly ...

Page 997: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYINTERIOR KYRON SM 2005 09 3 7730 I N T E X T R E P A I R Headlining Assembly Door Trim Passenger Side Door Rear Doors A Pillar Trim Sun Visor Hand Grip ...

Page 998: ...nd remove the undercover and bracket Fuel Lid Opening Lever Hood Release Lever 1 REMOVAL AND INSTALLATION OF INSTRUMENT PANEL Preceding Work Disconnect the negative battery cable Step 1 1 Insert a flat blade screwdriver into the groove A and pry off the instrument side cover Parking brake release lever Parking brake release lever Slot Guide bracket Guide groove Cable Insert tab Parking brake pedal...

Page 999: ...w mir ror switch bezel Refer to Switch section 7 Remove the DVD changer and passenger side lower instrument panel Refer to AV System section 9 Remove the steering wheel assembly steering angle sensor air bag air bag contact coil multifunction switch Center Speaker 5 Unscrewthreemountingscrewsandremovetheleftside panel from the center fascia panel and AV head unit 4 Remove the right side panel from...

Page 1000: ... center bolt in the instrument panel 3 Unscrew the mounting nuts and screws from the fuse relay box and side instrument panel at driver side 4 Remove the parking brake lever bracket and fuse relay box assembly 5 Unscrew the meter cluster mounting nuts and lower instrument panel mounting bolts Parking Brake Lever Bracket Driver Side Fuse Relay Box ...

Page 1001: ... the mounting nuts and screws from the fuse relay box and side instrument panel at passenger side 8 Unscrew the mounting nuts from the DVD changer in passenger side instrument panel 11 Remove the instrument panel assembly 10 Disconnect the GPS antenna connector GPS Antena 6 Remove the center speaker from the instrument panel Refer to AV System section ...

Page 1002: ...ument panel frame 5 Disconnect the A C main A cable and the sensor cluster B connector and the frame mounting bolt center side 2 Unscrew the mounting bolts from the driver side steering column bracket 3 Disconnect the main wiring connector A and air bag connector B 4 Disconnect the center wiring connector and unscrew the mounting bolt A B ...

Page 1003: ...nd cable C and air bag ground cable D then release the clamp E from console box 8 Unscrew the center mounting bolts at both sides in the instrument panel frame 9 Disconnect the main wiring the optical cable and the SSPS connector etc on the pas senger side 7 Unscrew the mounting bolts A B from the passenger side instrument panel frame and air conditioner module ...

Page 1004: ...BODYINTERIOR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 7730 10 10 Remove the instrument panel frame Instrument Panel and Panel Frame Assembly ...

Page 1005: ...0 I N T E X T R E P A I R 1 REMOVAL AND INSTALLATION OF SUN VISOR Unscrew the screws and disconnect the vanity mirror lamp connector Remove the sun visor and sun visor hook Mounting Screws 3 Vanity Mirror Lamp Connector Passenger side Driver side Sun Visor Components SUN VISOR ...

Page 1006: ...ate Side A Upper Bolt D Pillar Side 1 REMOVAL AND INSTALLATION OF REAR QUARTER TRIM AND PILLAR Preceding Works Disconnect the negative battery cable and remove the seats For seat belt refer to Seat and Seat Belt section Remove the seat belt and D pillar before removing the rear quarter trim Disconnect the power outlet connector before removing the passenger side rear quarter trim Rear Quarter Trim...

Page 1007: ...d remove the lower B pillar Be careful not to damage the pillars and fasteners D Pillar B Pillar Assembly A Pillar Assembly Remove the seat belt and unscrew the mount ing screws to remove the C pillar C Pillar Remove the door weather strip and unscrew the mounting screws to remove the A pillar A Pillar Unscrew the upper screw and remove the up per B pillar ...

Page 1008: ...in the figure below Refer to Body and Lamp sections Rear washer fluid hose Rear washer fluid hose Sunroof unit connector Room lamp connector Luggage room lamp connector Front room lamp connector Headlining Rear washer fluid hose Roof wiring connector Room lamps Sunroof Hand grip D pillar C pillar A pillar Hand grip Sun visor Sun visor Inside rearview mirror Pillars B pillar upper HEADLINING ASSEMB...

Page 1009: ... T E X T R E P A I R 2 Disconnect the connectors and washer fluid hoses from the headlining and remove the fasteners Use only designated special tool when removing the fasteners Fastener Sunroof Unit Connector Rear Washer Fluid Hose Rear Washer Fluid Hose and Roof Wiring Connector ...

Page 1010: ...Y EFFECTIVE DATE AFFECTED VIN 7730 16 2 Disconnect the rear washer fluid hose nozzle side 3 Remove the roof wiring connector A and rear washer fluid hose B in driver side 1 Remove the sunroof molding and disconnect the sunroof unit connector ...

Page 1011: ...GED BY EFFECTIVE DATE AFFECTED VIN BODYINTERIOR KYRON SM 2005 09 17 7730 I N T E X T R E P A I R 4 Pull out the fasteners rear 4 front 2 luggage compartment 4 at each side and remove the headlining assembly ...

Page 1012: ...cover and storage box 2 Disconnect the cigarette lighter connector and remove the console fascia cover 1 REMOVAL AND INSTALLATION OF CENTER CONSOLE A T 1 Place the gear selector lever to D position and remove the lever knob Move the gear selector lever to N position To remove the lever knob pull up the knob after turning the fastener Fastener ...

Page 1013: ...T E X T R E P A I R 4 Unscrew two mounting screws from the center storage box 5 Remove the screw caps and unscrew the mount ing screws at both sides of center console 6 Remove the storage box cover and disconnect two mounting bolts 10 mm in center console 7 Remove the center console ...

Page 1014: ...er knob by turning it counterclockwise 2 Remove the rear duct adapter A and center console cover B 4 Unscrew two mounting screws in center storage box 3 Remove the storage box in center console B Center Console Assembly 1 REMOVAL AND INSTALLATION OF CENTER CONSOLE M T CENTER CONSOLE MANUAL TRANSMISSION A ...

Page 1015: ... the mounting screws at both sides of center console 6 Remove the storage box cover and unscrew the mounting bolts in center console 8 Disconnect the cigarette lighter connector and remove the center console assembly 7 Slacken the equalizer adjusting nut so that the parking brake lever can be raised all the way ...

Page 1016: ...cover and disconnect the outside rearview mirror connector Outside Rearview Mirror Switch Assembly Outside Rearview Mirror Assembly For removal installation of switch refer to Switch section Components 1 REMOVAL AND INSTALLATION OF OUTSIDE REARVIEW MIRROR UP Right Down Left OUTSIDE REARVIEW MIRROR ...

Page 1017: ...R E P A I R 3 Unscrew five mounting bolts 10 mm and remove the outside rearview mirror 2 Remove the door trim and then remove the inner cover of outside rearview mirror Unscrew the mounting screws with dotted circle and remove the door trim from lower side For details refer to Door section ...

Page 1018: ... AFFECTED VIN 7730 24 1 Pryofftheroommirrorcoverwithaflatbladescrewdriver 2 Disconnect the harness connector and remove the inside rearview mirror Inside Rearview Mirror INSIDE REARVIEW MIRROR ECM sensor 1 REMOVAL AND INSTALLATION OF INSIDE REARVIEW MIRROR ...

Page 1019: ... 4610 4620 FENDER 26 1 Removal and installation of fender 26 FRONT DOOR 28 1 Removal and installation of front door 28 2 Removal and installation of front door trim 29 3 Components of front door opening system 30 4 Front window regulator 31 REAR DOOR 33 1 Removal and installation of rear door 33 2 Removal and installation of rear door trim 34 3 Components of rear door opening system 35 4 Rear wind...

Page 1020: ...TIVE DATE AFFECTED VIN 2 5110 1 FRONT Sunroof Engine Hood Front bumper Headlamp assembly Fog lamp Front bumper garnish Front bumper grille Energy absorber Front bumper Cover Front end member lower Front Fender Front Door Front Section BODY EXTERIOR ...

Page 1021: ...IN BODYEXTERIOR KYRON SM 2005 09 3 5110 I N T E X T R E P A I R 2 REAR Energy absorber Rear bumper fascia Parking aid sensor wiring Parking aid sensors Impact beam Rear Door Rear Air Spoiler Tailgate Roof Fashion Rail Rear Bumper Assembly ...

Page 1022: ...N SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 4 5110 1 CONSTRUCTION Front Bumper Fascia assembly Front bumper Energy absorber Front bumper Cover Front end member lower Bolt Screw Grommet Screw Screw Scrivet BUMPER ...

Page 1023: ...OR KYRON SM 2005 09 5 5110 I N T E X T R E P A I R Fascia assembly Rear bumper Screw Energy absorber Rear bumper Bracket Rear bumper upper Grommet Screw Screw Scrivet Bolt Cover Rear bumper guide Grommet Screw Screw Rear Bumper Lamp assembly Reflector ...

Page 1024: ... bolts around headlamps 4 Remove the scrivets from the upper cover 2 Unscrew the center mounting bolts 10 mm 3 Unscrew the lower mounting bolts 10 mm Bolt Bolt Bolt 2 REMOVAL AND INSTALLATION OF BUMPER Front Bumper Preceding Work Disconnect the negative battery cable and remove the headlamps and fog lamps ...

Page 1025: ...he mounting screws from the wheelhouse and remove the front bumper assembly Screws Upper Side 6 Install the front bumper in the reverse order of removal Front bumper Headlamp assembly Fog lamp Front bumper garnish Front bumper grille Energy absorber Front bumper Cover Front end member lower Fasteners Lower Side ...

Page 1026: ... bumper arrow Unscrew the mounting screw from the rear bumper arrow 2 Remove the scrivets from the rear bumper 3 Unscrew the mounting screws from the wheelhouse 4 Unscrew the lower mounting screws from the bumper Rear Bumper Preceding Work Disconnect the negative battery cable and remove the rear combination lamps 1 2 ...

Page 1027: ...9 5110 I N T E X T R E P A I R 5 Disconnect the parking aid sensor connector 6 Unscrew the lower mounting bolts from the bumper Rear bumper fascia Energy absorber Energy absorber Parking aid sensor Left Right Center 7 Remove the rear bumper fascia and the energy absorber ...

Page 1028: ... Carefully remove the rear bumper beam assembly Do not remove the lower bolt Do not remove the upper bolt A Disconnect the rear main wiring parking aid sensor connector At this moment the side fastener for the connector should be removed Rear Bumper Beam Bolts LH Rear Bumper Beam Bolts RH 9 Install the rear bumper beam assembly in the reverse order of removal Tightening Torque 42 62 Nm Tightening ...

Page 1029: ...N Hood panel Hood hinge Bolt Hood hinge Hood insulator Fastener Hood insulator pad Hood latch Hood lifter Rear seal Hood rear Seal Hood front sub Seal Hood front Bracket Hood lifter mounting Screw Hood guide bumper Overslam bumper Trunk lid Hood latch release cable Clip Screw Hood latch release handle HOOD ASSEMBLY ...

Page 1030: ... Hood 1 Disconnect the washer fluid nozzle from the engine hood 2 Unscrew the two shock absorber mounting bolts 10 mm from the engine hood 3 Slacken the mounting bolts on the hood hinge Do not remove the bolts 4 Carefully remove the engine hood Pay particular attention to avoid vehicle damage and personal injury Alignment mark Make an alignment mark on the hood and hinge for installation NOTICE ...

Page 1031: ...orber and remove the hood shock absorber 1 Up Down Left Right Slacken the hood hinge mounting bolts and adjust the hood position until it is placed to the desired location 2 Hood height To adjust the height of hood front end turn the overslam bumper Hood ShockAbsorber Hood Adjustment The hood may drop due to its weight Make sure to support it with a safety device CAUTION ...

Page 1032: ...BODYEXTERIOR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 14 5110 Hood Insulation Pad 1 Remove the fasteners and remove the insulation pad ...

Page 1033: ...ing Work Remove the front bumper assembly including headlamp 1 Remove the lower instrument panel in front of driver s seat and disconnect the hood release lever cable 2 Unscrew the three hood latch bolts 10 mm disconnect the hood release cable and remove the hood latch 3 Remove the hood cable from the vehicle Hood release lever ...

Page 1034: ...Preceding Work Remove the headlining assembly Unscrew the front and rear mounting nuts 10 mm and remove the roof fashion rail The front mounting nut is located behind the hand grip bracket ROOF FASHION RAIL To prevent water leaks apply the liquid sealant to the bolt thread when install ing the roof fashion rail CAUTION ...

Page 1035: ... strip Tailgate latch assembly Striker Screw Shim Door striker Tailgate handle outside Nut Nut Tailgate actuator rod Tailgate handle inside Cap Tailgate handle inside Tailgate lifter Ball stud Body side guide Tailgate side guide Bolt Tailgate overslam bumper Tailgate overslam bumper center 1 TAILGATE ASSEMBLY TAILGATE ...

Page 1036: ...DATE AFFECTED VIN 18 5110 Removal and Installation of Tailgate Assembly Operating Mechanism Tailgate handle outside Tailgate handle and rod inside Safety crank assembly Latch assembly Actuator Actuator Construction Inside View Construction Outside View ...

Page 1037: ...YRON SM 2005 09 19 5110 I N T E X T R E P A I R 1 Unscrew the scrivets and remove the upper trim from the tailgate 3 Remove the scrivets 4 Remove the fasteners and then remove the lower trim 2 Remove the inside handle Tailgate Trim Locations of Fasteners ...

Page 1038: ...ork Remove the upper and lower trims from the tailgate 1 Disconnect the main wiring connector A ground B heated wire C and heated wire ground D Remove the wiring harness 2 Disconnect the rear washer nozzle hose 3 Disconnect the stop lamp connector from the rear air spoiler TailgateAssembly ...

Page 1039: ... 4 Disconnect the ground A and heated wire cable B from the tailgate 5 Release the fixing clips and remove both shock absorbers 6 Unscrew the two hinge bolts 10 mm and re move the tailgate assembly Pay particular attention to avoid vehicle dam age and personal injury CAUTION Tightening torque 15 26 Nm ...

Page 1040: ...IVE DATE AFFECTED VIN 22 5110 Actuator Disconnect the actuator rod and connector and remove the actuator assembly Latch 1 Disconnect the connecting rod in tailgate 2 Remove the latch assembly Tailgate Latch andActuator Preceding Work Remove the trim ...

Page 1041: ... N T E X T R E P A I R 1 Unscrew four mounting nuts 10 mm and three cap nuts 10 mm from the rear air spoiler 2 Remove the upper trim and disconnect the high mounted stop lamp 3 Disconnect the rear washer nozzle hose 4 Remove the rear air spoiler from the tailgate REAR AIR SPOILER ...

Page 1042: ...ip Door garnish mounting Garnish assembly Rear door Clip Door garnish mounting Garnish assembly Front side seal Clip Side seal molding mounting Clip Side seal molding mounting lower Screw Clip Side seal molding mounting Clip Side seal molding mounting lower Screw Grommet Screw Screw Garnish assembly Rear side seal Clip Door garnish mounting Screw Fender panel SIDE SEAL MOLDING ...

Page 1043: ...9 25 5110 I N T E X T R E P A I R All side moldings can be removed installed with a similar procedure 3 Carefully remove the side molding seal 1 Unscrewthemountingscrewinwheelhouse 2 Unscrew four mounting screws from the front rear side seal moldings Side Seal Molding ...

Page 1044: ...g Work Disconnect the negative battery cable and remove the headlamps front bumper and cowl 1 Remove the tires and wheelhouse cover 3 Remove the insulator sponge in fender 2 Remove the quadrant cover 4 Disconnect the side repeater connec tor and remove the lamp assembly FENDER Be careful not to damage the fasteners CAUTION ...

Page 1045: ...I R 7 Unscrew the mounting bolt on the fender near the headlamp 6 Unscrew the lower mounting bolts in fender 9 Unscrew the upper bolts from the fender 10 Remove the fender from the vehicle 8 Unscrew the bolts and screws from the fender wheelhouse 5 Unscrew the quadrant cover bolts A and cowl bolt B ...

Page 1046: ...ain wiring harness cover and disconnect the door main connector 3 Unscrew the upper and lower hinge bolts and remove the door assembly 1 REMOVAL AND INSTALLATION OF FRONT DOOR Upper Door Mounting Bracket Lower Door Mounting Bracket FRONT DOOR Tightening torque 16 30 Nm Tightening torque 16 30 Nm Tightening torque 20 31 Nm Disconnect the Door Wiring Harness ...

Page 1047: ...r courtesy lamp connector B door tweeter speaker memory seat position switch connector C and power window switch D from the removed door trim Remove the components as in order shown in figure below 3 Separate the bottom of door trim and pull it up to remove Locations of Fasteners Tightening torque 4 6 Nm Front 1 Unscrew seven mounting screws from the door trim refer to figure below ...

Page 1048: ...ting Cable assembly Front door inside handle Cable holder Screw Door striker mounting Overslam bumper Front door outside handle assembly Bolt Flange Front door checker assembly Clip Door actuator rod Inside handle assembly front door Nut Rod Front door outside handle Door striker shim Door striker Nut Front door outside handle Cable assembly Front door safety lock knob ...

Page 1049: ...mbly Window guide rail Window motor Driver Side Window and Regulator Passenger Side Window and Regulator 4 FRONT WINDOW REGULATOR Dual Rail with Regulator 1 The dual rail with regulator is installed to this vehicle Its advantages are as below 1 Smooth operation 2 Safety operation 3 Preventing the glass pinch 4 Preventing the glass tilting 5 Reduced the length of glass run 6 Increased durability of...

Page 1050: ... mounting bracket can be seen Unscrew the nuts from the window mounting bracket and remove the window 2 Disconnect the window motor connector and unscrew the mounting bolts from the window regulator 3 Remove the window regulator from the door Driver Side Window Motor Driver Side Passenger Side Removal and Installation of Window Regulator Passenger Side Window Motor ...

Page 1051: ...door main connector 2 Unscrew the mounting bolts from the door check link vehicle side 3 Unscrew the upper and lower hinge bolts and remove the door assembly Disconnect the Door Wiring Harness 1 REMOVAL AND INSTALLATION OF REAR DOOR Upper Door Mounting Bracket Lower Door Mounting Bracket REAR DOOR Tightening torque 20 31 Nm Tightening torque 16 30 Nm Tightening torque 16 30 Nm ...

Page 1052: ...fer to the figure below Installation Notice 3 Remove the door handle cable A and the door tweeter speaker B as in order shown in figure below 2 Separate the power window switch con nector and disconnect the connector Remove the door trim 2 REMOVAL AND INSTALLATION OF REAR DOOR TRIM Locations of fasteners Tightening torque 4 6 Nm ...

Page 1053: ... Door latch and cable assembly Bolt Cable assembly Rear door safety lock knob Rod Rear door outside handle Rear door outside handle Door striker shim Door striker Cable holder Nut Overslam bumper Label Child safety lock Rear door checker assembly Bolt Flange Rear door outside handle assembly Cable assembly Rear door inside handle Screw bolt ...

Page 1054: ... window regulator from the door 1 Lower the window Unscrew the mounting screw and bolts from and remove the guide channel and windshield dam 2 Disconnect the motor connector and un screw the mounting screws from the win dow guide to remove the rear window Mounting screw 4 REAR WINDOW REGULATOR Preceding Work Disconnect the negative battery cable ...

Page 1055: ...EFFECTIVE DATE AFFECTED VIN BODYEXTERIOR KYRON SM 2005 09 37 5110 I N T E X T R E P A I R Components Window mounting bracket Guide rail Window cable Guide channel Fixed glass assembly Window assembly Window motor ...

Page 1056: ...he tires and place the safety jack under the fuel tank 2 Drain all fuel 2 Disconnect the fuel supply hose C and air breather hose D Kyron does not have service hole from passen ger compartment to fuel tank So fuel tank must be disassembled for fuel sender related job NOTICE 1 REMOVAL AND INSTALLATION OF FUEL TANK FOR REMOVING REAR LEFT UPPER ARM AND LOWER ARM FUEL TANK ...

Page 1057: ... BODYEXTERIOR KYRON SM 2005 09 39 5110 I N T E X T R E P A I R 4 Seal the fuel hose opening and carefully lower the fuel tank Fuel Tank Assembly 3 Remove the two bolts 14 mm from the fuel tank and unscrew the fuel tank bracket bolt F 14 mm ...

Page 1058: ...D VIN 40 5110 1 Remove the butterfly nut from the spare tire carrier and loosen the lock bolt until the hook is released Always install the safety stand under the vehicle body before starting this operation NOTICE 1 REMOVAL AND INSTALLATION OF SPARE TIRE SPARE TIRE ...

Page 1059: ...D VIN BODYEXTERIOR KYRON SM 2005 09 41 5110 I N T E X T R E P A I R 2 Remove the spare tire by pulling down the carrier 3 Install in the reverse order of removal 4 The spare tire carrier can be removed by pulling out the lock pin arrow ...

Page 1060: ...MEMO ...

Page 1061: ...BODY REPAIR 4610 4620 TABLE OF CONTENTS BODY REPAIR 3 1 Dimensions 3 2 Jack up points 4 3 Design changes for improving NVH performance 6 4 Frame 10 5 Body repair 21 ...

Page 1062: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 3 5110 I N T E X T R E P A I R 1 DIMENSIONS Unit mm only for the vehicle with roof fashion rail BODY REPAIR ...

Page 1063: ...4 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 2 JACK UP POINTS IRS Lifting Point Dotted Circles ...

Page 1064: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 5 5110 I N T E X T R E P A I R 5 Link System Lifting Point Dotted Circles ...

Page 1065: ...ANGES FOR IMPROVING NVH PERFORMANCE Dual Type 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 Deadening sheet ...

Page 1066: ... and Rear Floor Applied BPR 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 to protect the passengers in case of side collision Door impact beam reinforcement to reinforce the door impact beam ...

Page 1067: ... the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise Insulation pad Foaming pad Foaming pad Foaming pad Anti vibration pads 6 positions The foaming pads are applied to the symmetry surface of the vehicle Thus totally 6 foaming pad are applied to the vehicle body ...

Page 1068: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 9 5110 I N T E X T R E P A I R Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 1069: ...o 2 Bracket body mounting No 1 Bracket 2 way connector mounting Bracket front coil spring Bracket front coil spring Bracket front upper arm Bracket front upper arm Bracket front upper arm Bracket clutch and brake tube Bracket assembly front lower arm rear Bracket assembly radiator Bracket assembly radiator Cross member T M Bracket T M cross member Bracket spare tire stopper Hanger exhaust pipe fro...

Page 1070: ...Frame assembly chassis Bracket sub frame mounting rear Beam assembly impact rear bumper rear Cross member assembly No 6 Cross member assembly No 2 Beam assembly impact front bumper Bolt Cross member assembly No 3 Bracket rear lower link Bracket thrust link Bracket sub frame mounting front Bolt Bracket step bar frame rear Bracket sub frame mounting rear ...

Page 1071: ...12 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Frame Dimensions 5 Link Suspension Frame Unit mm ...

Page 1072: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 13 5110 I N T E X T R E P A I R Unit mm ...

Page 1073: ...14 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Sectional Drawing Unit mm ...

Page 1074: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 15 5110 I N T E X T R E P A I R Unit mm ...

Page 1075: ...16 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 IRS Suspension Frame Unit mm ...

Page 1076: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 17 5110 I N T E X T R E P A I R Unit mm ...

Page 1077: ...18 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Unit mm Sectional Drawing ...

Page 1078: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 19 5110 I N T E X T R E P A I R Unit mm ...

Page 1079: ...er plain body mounting Insulator body lower Washer plain body mounting Washer tube assembly body No 3 Insulator body No 4 upper Washer tube assembly body No 5 Insulator body No 5 upper Washer tube assembly body No 4 Bolt Bolt Bolt Body No 3 mounting Body No 4 mounting Body No 5 mounting Body No 1 mounting Body No 2 mounting Body No 3 mounting Body No 4 mounting Body No 5 mounting Tightening torque...

Page 1080: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 21 5110 I N T E X T R E P A I R 5 BODY REPAIR White Body Without sunroof With sunroof ...

Page 1081: ...22 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Body Dimensions Side Structure Complete Unit mm ...

Page 1082: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 23 5110 I N T E X T R E P A I R Engine Compartment Unit mm ...

Page 1083: ...24 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Unit mm Front End ...

Page 1084: ...CHANGED BY EFFECTIVE DATE AFFECTED VIN BODYREPAIR KYRON SM 2005 09 25 5110 I N T E X T R E P A I R Unit mm Windshield Glass Mounting Panel ...

Page 1085: ...26 BODYREPAIR KYRON SM 2005 09 CHANGED BY EFFECTIVE DATE AFFECTED VIN 5110 Tailgate Unit mm ...

Page 1086: ... mm Difference between headlamp and hood below 1 5 mm Seal should not be protruded and rolled Difference between both sides below 1 mm Closely adhered against windshield no coming off Especially any coming off between cowl grille end and windshield glass end is not permissible Seal should not be protruded and rolled Difference between both fenders below 1 mm Difference below 1 mm Permissible Gap A...

Page 1087: ...Permissible Gap 4 5 0 5 mm Permissible Gap 4 0 1 0 mm Permissible Gap 0 mm Permissible Gap 2 8 0 5 mm Permissible Gap 2 0 1 0 mm Permissible Gap Approx 8 7 1 0 mm Permissible Gap Approx 6 mm Difference between both sides below 1 5 mm Difference below 1 mm Permissible Gap 4 0 1 0 mm Difference below 1 mm ...

Page 1088: ...unting Nut assembly door outside handle mounting Bolt flange Checker assembly front door Inside handle assembly front door Nut Door outside handle rod Door striker Cable assembly front door inside handle Cable assembly front door safety lock knob Clip door actuator rod Clip door outside rod Screw door striker mounting Door striker shim Overslam bumper Panel assembly front door Hinge assembly front...

Page 1089: ...door trim Bezel front door center Lens door courtesy lamp Cap door trim center Clip Cap front door trim Bracket front door pull handle mounting Screw Screw Grommet Trim assembly front door Bulb Holder assembly bulb Cap front door trim Regulator front door power window Bolt Glass run front door window Motor assembly power window front ...

Page 1090: ...older Nut Overslam bumper Rear door checker assembly Handle assembly rear door outside Screw Panel assembly rear door Bolt Hinge assembly rear door upper Hinge assembly rear door lower Bolt Bolt flange Door striker Bolt Cable assembly rear door inside handle Label child safety Cable assembly rear door safety lock knob Door outside handle rod Door striker shim Rear Door ...

Page 1091: ...r window Rear power window motor Glass run rear door window Trim assembly rear door Screw Weather strip rear door trim Cap rear door trim Clip Cap door trim center Bezel rear door center Bracket rear door pull handle mounting Grommet Screw Nut Bolt serrated Bolt Panel assembly armrest rear door trim ...

Page 1092: ...lgate Panel assembly tailgate Hinge assembly tailgate Nut Nut Trim assembly tailgate lower Cover tailgate lower Clip Nut Strap assembly tailgate lower Screw Grommet screw Screw Sill trim tailgate Bracket tailgate lower Screw Trim assembly tailgate upper Clip trim mounting Screw rivet Bracket strap mounting Cover strap Tailgate ...

Page 1093: ... shim Handle assembly tailgate outside Nut Crank assembly tailgate safety lock Nut Rod tailgate actuator Handle tailgate inner Cap tailgate inside handle Lifter assembly tailgate Ball stud Bumper assembly guide body side Bumper assembly guide tailgate side Bolt Tailgate overslam bumper Tailgate molding Bumper assembly tailgate overslam center ...

Page 1094: ... hinge Hood insulator Fastener hood insulator pad Hood latch assembly Lifter assembly hood Sill assembly hood rear Sill assembly hood front sub Sill assembly hood front Bracket lifter mounting Screw Bumper hood guide Bumper trunk lid overslam Cable assembly hood latch release Clip Screw Handle assembly hood latch release Screw Engine Hood ...

Page 1095: ... Panel assembly front apron Bracket fender mounting Panel assembly front end inner Panel front end Member assembly front end upper Member assembly front end center Bolt Member assembly headlamp upper Panel Assembly Front End Panel assembly front apron Bolt Pad fender mounting sealing Panel assembly cowl side inner Bracket fender mounting Panel fender Member assembly headlamp upper Bolt ...

Page 1096: ...r assembly body mounting No 2 Member assembly front seat mounting rear Bracket third row seat front mounting Bracket parking cable guide Bracket parking cable pivot Bracket TCU TCCU mounting Bracket center support Panel assembly side sill inner Member assembly front seat mounting front Member assembly front seat mounting Bracket third row seat front mounting Bracket third row seat front mounting B...

Page 1097: ...er Cross member assembly rear floor No 4 upper Member assembly rear floor Cross member assembly rear floor No 4 lower Cross member assembly rear floor No 3 Cross member assembly rear floor No 2 Cross member assembly rear floor No 1 Panel container Panel assembly back outer Extension assembly rear floor corner Extension rear floor side Extension rear floor side Extension assembly rear floor corner ...

Page 1098: ...Rail assembly roof front Rail roof center No 1 Rail roof center No 2 Rail roof center No 3 Rail assembly roof rear Panel roof Reinforcement assembly sunroof Rail roof center No 2 Rail roof center No 3 Rail assembly roof rear Rail assembly roof front Roof Panel with Sunroof Roof Panel without Sunroof Roof Panel ...

Page 1099: ...nting lower Housing assembly fuel filler Panel assembly quarter inner Reinforcement D pillar outer upper Reinforcement assembly quarter inner rear upper Pillar assembly D outer Panel assembly wheelhouse rear Pillar assembly A B inner Bracket fender mounting lower Bracket fender mounting rear upper Reinforcement assembly C pillar inner ...

Page 1100: ...gine mounting rear Heat shield insulator Bolt Bolt Cross member assembly T M mounting Insulator engine mounting rear Insulator engine mounting front Bolt Bolt Washer Insulator engine mounting front Engine Insulator Mounting Tightening torque 62 93 Nm Tightening torque 22 28 Nm Engine Mounting Bracket Transmission Side ...

Page 1101: ...rber rear bumper Bracket rear bumper upper Grommet screw Screw Scrivet Bolt Cover rear bumper guide Grommet screw Screw Fascia assembly front bumper Energy absorber front bumper Cover front end member lower Bolt Bolt Grommet screw Screw Scrivet Lamp assembly reflex reflector Front Bumper Rear Bumper Excluding PAS Bumper ...

Page 1102: ...A I R Glass Glass assembly windshield Plate inside rearview mirror base Molding assembly windshield Glass front door drop Glass rear door drop Grommet door glass mounting Bolt door glass mounting Glass rear door fixed Glass assembly quarter Nut side glass mounting Glass assembly tailgate tinted ...

Page 1103: ...GED BY EFFECTIVE DATE AFFECTED VIN 5110 Key Set Blank key Key set Blank key Immobilizer key Bulb Immobilizer unit Ignition key box Transponder Key hall illumination Driver s door Passenger s door Ignition lock and cylinder mounting bolt ...

Page 1104: ...ew Cover assembly rear wheelhouse Molding assembly roof without roof fashion rail Molding assembly roof No 1 Molding assembly roof No 3 Molding assembly roof No 4 Rail assembly fashion Garnish assembly tailgate upper Nut Cover upper Nut Nut Hex flange cap Tape door tooling hall sealing Plug tailgate tooling hall Spoiler assembly Garnish assembly tailgate With roof fashion rail Molding assembly roo...

Page 1105: ...g Garnish assembly rear door Clip door garnish mounting Garnish assembly front side sill Clip side sill molding mounting Screw Clip side sill molding mounting Grommet screw Screw Garnish assembly rear side sill Screw Screw backside from bumper fascia Grille radiator Screw Others II Clip side sill molding mounting lower Clip side sill molding mounting lower Clip door garnish mounting ...

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