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SSANGYONG KYRON 2007.04, Manual

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SSANGYONG KYRON 2007.04 Manual Download Page 642

05-3

M/T

KYRON 2007.04

3170-01

1. OVERVIEW AND CHARACTERISTICS OF MANUAL 
    TRANSMISSION

1) SYSTEM COMPONENTS

Inside

Front View

(1) Features

All gears use the helical type and high strength materials.

1.

The helical type gear prevents the axial gear missing and provides less noise.

-

The semi-remote control type gear shift mechanism is used to prevent incorrect shifting.
To improve the shifting performance, 3-piece double cone is used for 1/2 shift.
The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double 
engagement, the independent interlock devices are installed.

2.
3.
4.

The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type 
according to the vehicle model.

5.

TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement 
and to provide silent gear engagement.

-

Summary of Contents for KYRON 2007.04

Page 1: ...GENERAL INFORMATION 0000 00 GENERAL INFORMATION GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 3 ...

Page 2: ......

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

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

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

Page 6: ......

Page 7: ...10 08 CONNECTOR GROUND WIRING 8201 00 WIRING HARNESS COMPONENTS LOCATION CONNECTOR GROUND 8210 00 W H ENGINE ROOM 8210 02 W H MAIN 8210 03 W H FLOOR 8210 09 W H ROOF 8210 10 W H TAIL GATE 8210 06 W H DRIVER DOOR 8210 07 W H PASSENGER DOOR 8210 08 W H RR DOOR 3 11 12 13 15 15 16 16 17 ...

Page 8: ......

Page 9: ...0 3 CONNECTOR GROUND KYRON 2007 03 8201 00 WIRING HARNESS 8201 00 WIRING HARNESS COMPONENTS LOCATION 1 WIRING HARNESS 2 COMPONENTS LOCATION ...

Page 10: ...0 4 KYRON 2007 03 8201 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 11: ...0 5 CONNECTOR GROUND KYRON 2007 03 8201 00 GROUND SPLICE PACK ...

Page 12: ...0 6 KYRON 2007 03 8201 00 CONNECTOR GROUND 4 SPLICE PACK CIRCUIT S101 S201 S202 CAN S203 GND S204 ILL S205 GND ...

Page 13: ...0 7 CONNECTOR GROUND KYRON 2007 03 8201 00 S206 S301 CAN S302 S303 ...

Page 14: ...0 8 KYRON 2007 03 8201 00 CONNECTOR GROUND WIRNING CONNECTOR MODE CONNECTOR 5 CONNECTOR WIRNING CONNECTOR WIRNING CONNECTOR ...

Page 15: ...0 9 CONNECTOR GROUND KYRON 2007 03 8201 00 UNIT CONNECTOR SENSOR CONNECTOR LAMP CONNECTOR SWITCH CONNECTOR ...

Page 16: ...0 10 KYRON 2007 03 8201 00 CONNECTOR GROUND ETC ...

Page 17: ...ON FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 8410 04 I P LH FUSE RELAY BOX 8401 06 I P RH FUSE RELAY BOX ELECTRICITY DIVIDE 8210 02 ENGINE ROOM FUSE RELAY BOX CIRCUIT 8410 04 I P LH FUSE RELAY BOX CIRCUIT 8410 06 I P RH FUSE RELAY BOX CIRCUIT 3 5 6 7 12 16 ...

Page 18: ......

Page 19: ...0 3 POWER DISTRIBUTION KYRON 2007 03 8410 02 FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 1 UPPER 2 LOW 3 ENGINE ROOM FUSE RELAY BOX ...

Page 20: ...0 4 KYRON 2007 03 8410 02 POWER DISTRIBUTION 4 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 5 ENGINE ROOM FUSE BOX CONNECTOR NUMBER ...

Page 21: ...0 5 POWER DISTRIBUTION KYRON 2007 03 8410 04 8410 04 I P LH FUSE RELAY BOX 1 I P LH FUSE RELAY BOX 2 POWER SUPPLY ...

Page 22: ...0 6 KYRON 2007 03 8410 06 POWER DISTRIBUTION 8410 06 I P RH FUSE RELAY BOX 1 I P RH FUSE RELAY BOX ...

Page 23: ...TS This sensor is installed at the front bottom of engine compartment This changes the air source mode by detecting the air pollution and the ambient temperature Manual air conditioner FATCFATC Ambient temperature sensor It changes sun load coming through front windshield into current to input to FATC controller Type Air Conditioner Controller FATC Manual air conditioner ...

Page 24: ...t Side Bloor Unit Side Condenser Installed in front of vehicle and condenses vapor refrigerant into low temperature and high pressure liquid refrigerant Receiver Drier LH Engine ECU Passenger Footstep Coolant Temperature Sensor On Engine Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condi...

Page 25: ...01 4 KYRON 2007 04 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM COMPONENTS Locations of Vents Air Duct ...

Page 26: ...ONT AIR CONDITIONER MODULE WIRING LAYOUT Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Active incar sensor interior temperature sensor and humidity sensor Main wire connector Intake sensor Mode door actuator Air mix door actuator ...

Page 27: ...erature Sensor Air Source Door Actuator Air Conditioner Filter Mode Door Actuator Intake Sensor Power Transistor Blower Motor A C Controller Unit Interior Temperature Sensor Interior Humidity Sensor Power transistor Blower motor Interior temperature and humidity sensor ...

Page 28: ...01 7 AIR CONDITIONER KYRON 2007 04 6810 15 3 Components ...

Page 29: ...01 8 KYRON 2007 04 6810 15 AIR CONDITIONER 4 PTC HEATER AND FFH HEATER LAYOUT 1 PTC HEATER ASSEMBLY LAYOUT 2 FFH HEATER ASSEMBLY LAYOUT ...

Page 30: ...007 04 6810 15 Ambient temperature sensor The ambient temperature sensor is installed in the front area of the engine compartment to detect the ambient temperature Ambient temperature sensor Connector 5 AMBIENT TEMPERATURE SENSOR ...

Page 31: ... and changes it into current and then sends the signal to FATC controller Inspection Remove the sun sensor and measure the current between terminals under sunlight Measure the current again under shade It is in normal conditions if the measured value is less than the measured value under sunlight Turn the ignition switch to ON position Measure the voltage to the sun sensor from FATC connector appr...

Page 32: ...sensor that detects interior temperature 1 Location 2 Functions Incar temperature sensor This sensor is a negative temperature coefficient NTC thermistor and detects the interior temperature with air coming from sensor hole and then sends the voltage value according to the changed resistance to FATC controller Active incar sensor interior temperature sensor ...

Page 33: ... to refrigerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below 20 C Coolant temperature over 115 C For approx 4 seconds after starting the engine When engine speed is below 650 rpm When eng...

Page 34: ...on if the resistance is extremely high or low replace the sensor If the measured value is out of the specified range replace the water temperature sensor If the measured value is within the specified range check as below Turn the ignition switch to ON position and measure the voltage to water temperature sensor from the FATC controller connector standard approx 2 V at 25 C If the voltage value can...

Page 35: ... fan control signal from FATC Air conditioner power transistor 1 Inspection If the power transistor defect code DTC 6 appears check as below Turn the ignition switch to ON position Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6 The specified voltage value in each stage If the voltage is out of specified value check the circuit for open If the circuit is ...

Page 36: ...d adjusts the mode door for VENT FOOT and DEF mode to change the air flow directions according to FATC controller Under the FATC controller AUTO mode it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed Mode door actuator ...

Page 37: ...een terminal No 1 and 2 on the connector Check whether the output voltages ON approx 12 V off 0 V If the voltage value is out of the specified value replace the Intake Sensor If the circuit is in normal condition check as below Turn the ignition switch to ON position and turn on the air conditioner by pressing the A C button And measure the voltage between terminal A12 and A11 on the FATC controll...

Page 38: ...temperature and ambient temperature while PTC is operated by the coolant temperature intake air temperature FFH system consists of independent fuel lines and fuel pump coolant circuit and coolant circulation pump electrical glow plug and exhaust system It also provides the diagnostic function FFH system cannot be operated or stopped by driver s intention The FFH system is automatically operated by...

Page 39: ...racket assembly 8 Ambient temperature switch 14 Tube clip mounting 3 FFH bracket assembly 9 FFH fuel pump 15 Tube clip mounting 4 FFH water pump bracket 10 Fuel pump bracket 16 Intake hose 5 FFH NO 3 inlet hose 11 Fuel pipe NO 1 17 Clamp 6 FFH NO 2 inlet hose 12 Fuel pipe NO 2 18 FFH NO 1 inlet hose 2 FFH LAYOUT 1 Components ...

Page 40: ...01 19 AIR CONDITIONER KYRON 2007 04 6810 15 2 Exploded View ...

Page 41: ...01 20 KYRON 2007 04 6810 15 AIR CONDITIONER ...

Page 42: ...ipe 14 Flame sensor 15 Bush for flame sensor graphite 16 Control and overheating sensor with cable 17 O ring 18 Surface sensor with cable 19 Controller connector 14 pin connector waterproof 20 Pressure spring for surface sensor 21 Pressure spring for control and overheating sensor 22 O ring 23 Coolant hose inlet 24 Coolant hose outlet 25 Tooth ring 2x 26 Cable harness cover 27 Rubber seal 28 O rin...

Page 43: ...01 22 KYRON 2007 04 6810 15 AIR CONDITIONER 3 SPECIFICATIONS ...

Page 44: ...rature difference when operating FFH FFH is operated again For example if the initial operating temperature was 4 C the ambient temperature at repeat operation should be below 1 C and the coolant temperature should be below 75 C 2 FFH Operations According To the Changes of Coolant Temperature Above graph shows the FFH control process while the FFH is operating The control element is coolant temper...

Page 45: ...ature from radiation and direct contact Before working on the coolant circuit disconnect the negative battery cable and wait until all components have cooled down completely When installing the heater and the water pump note the direction of flow of the coolant circuit Fill the heater and water hoses with coolant before connecting to the coolant circuit When routing the coolant pipes observe a suf...

Page 46: ...01 25 AIR CONDITIONER KYRON 2007 04 6810 15 4 Circuit Diagram ...

Page 47: ...erheated lack of water poorly vented cooling circuit the overheating sensor triggers the fuel supply is interrupted and the heater is switched off The heater is switched off if the lower or upper voltage limit is reached The fuel pump does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted The fan motor speed is monitored continuously If the fan motor does ...

Page 48: ...01 27 AIR CONDITIONER KYRON 2007 04 6810 15 6 Specification Water Pump 7 Characteristic Curve of Water Pump 12 V ...

Page 49: ...01 28 KYRON 2007 04 6810 15 AIR CONDITIONER 8 Function Diagram 9 Switching Diagram According to Temperature Changes ...

Page 50: ...gs and seat belt pretensioners included the air bag unit must be replaced Please do not attempt to delete the failure code with scan 100 because some data about the deployment situation are stored in the unit The air bag related components especially the air bag unit must be stored in a sealed case to prevent any damage Please do not connect a tester to any air bag connector or single item to meas...

Page 51: ...rts when the front air bags deploy The air bag units and their connection wires connectors included the seat belt pretensioners and their connection wires connectors included the entire front air bags and the instrument panel IP Replacement parts when a curtain air bag deploys The new curtain air bag for the deployed side the air bag unit and its connection wires connectors included the collision ...

Page 52: ...ongitudinal collisions and determine whether or not the air bags are deployed The roles of each collision sensor are as below Front G sensors inside the air bag unit Curtain air bag G sensors These are located inside the left and right B pillar panel bottoms When a collision occurs the air bag at the side of collision deploys accordingly Please pay attention to that in the case of the curtain air ...

Page 53: ...e air bag unit and its connection wires connectors included the collision G sensor assembly for the curtain air bag and the trims and roof headlining for the broken parts When an air bag deploys curtain air bags and seat belt pretensioners included the air bag unit must be replaced Please do not attempt to delete the failure code with SCAN 100 because some data about the deployment situation are s...

Page 54: ......

Page 55: ...N 2007 04 8810 03 AIR BAG 2 AIR BAG SYSTEM LOCATIONS AND RELATED LH RH When the curtain air bag LH deploys When the curtain air bag RH deploys BPT Belt Pretensioner Curtain air bag collision G sensor COMPONENTS ...

Page 56: ... SDM The collision G sensor is installed nside this And it sends out signals to deploy the front air bags driver s and passenger s air bags and or the driver s and passenger s seat belt pretensioners or the driver s and passenger s curtain air bag When the front collision G sensor sends out only the air bag deployment signal the signal deploys the two front air bags and activates their seat belt p...

Page 57: ...ION PROCESS The overall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyoung Motors Air Bag System Block Diagram Functions and Roles Included ...

Page 58: ...02 11 AIR BAG KYRON 2007 04 8810 03 ...

Page 59: ...leration sensor inside the air bag unit is activated by the deceleration from vehicle collision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver 1 Components Air bag cover Air bag hou...

Page 60: ...s the driver s one The driver s air bag the passenger s air bag and the seat belt pretensioners on both seats are made to operate together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and i...

Page 61: ...nerator A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B pillar The signal is transmitted to the air bag unit The air bag unit instantly inflates the necessary air bag necessary by sending a high current When the Curtain Air Bag is Installed Terms of the Curtain Air Bag When the Curtain Air Bag Deploys Curtain air bag mounting point N...

Page 62: ...02 15 AIR BAG KYRON 2007 04 8810 03 Tightening torque 8 10 Nm Tightening torque 8 10 Nm Sectimal view a a Sectimal view b b 1 Components a a b b ...

Page 63: ... BPT Belt Pre Tensioner The belt pretensioner retracts the seat belt to tighten or take up slack in the wearer s belt When a collision occurs or when brakes are applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat Curtain air bag G sensor ...

Page 64: ... reel assembly Reel bracket Ring upper stay D ring Bending tongue Tongue stopper Mini anchor D bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D bolt Label D bolt Spacer Bush Mini anchor cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 65: ...02 18 KYRON 2007 04 8810 03 AIR BAG Location of Air Bag 5 Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 66: ...nsor is installed inside each B pillar of the driver s and passenger s seats that is around the pretensioner reel The body panel has guiding holes to ensure its correct installation But incorrect tightening torque may break the sensor or make it insecure As a result the sensor may have inaccurate judgment and have the air bag deployed inaccurately ...

Page 67: ...ires the detonator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for a firing Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag rela...

Page 68: ...when colliding When the ignition key is the ON position the air bag signal is not accepted for the first 7 seconds When the ignition key is the ON position and the vehicle speed is 3 km h or higher 40 ms after receiving the air bag deployment signal the sticks sends out the door UNLOCK signal for 5 seconds Even though the ignition switch is turned off in the middle of the unlock signal being sent ...

Page 69: ...unlock request by other functions is ignored unless the ignition key switch is turned off When another lock or unlock output is requested while the door is being either locked or unlock the new request will be ignored But if an unlock request is made by the air bag signal or the remote control key the request will be accepted When the lock and unlock functions are simultaneously requested the lock...

Page 70: ...bag unit flashes the air bag warning lamp six times by supplying an intermittent ground to the warning lamp circuit After flashing six times the air bag warning lamp will turn off if no more malfunctions have been detected 2 When Turning the Ignition Switch to the ON Position When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for a...

Page 71: ...e Air Bag Unit Receives Any Malfunction Signals from the Other Systems When due to an error from outside the system the intermittent failure signal is received 5 times or less the air bag warning lamp comes on for about 6 seconds and then goes off ...

Page 72: ...02 25 AIR BAG KYRON 2007 04 8810 03 8 AIR BAG ELECTRICAL WIRING DIAGRAM ...

Page 73: ...03 3 SEAT KYRON 2007 04 7410 01 7410 01 SEAT AND SEAT BELT 1 SEAT OVERVIEW 1 FRONT SEAT DRIVER S SEAT Reclining Motor Lumbar support lever ...

Page 74: ...AT SPWM Seat Position With Memory Unit Seat cushion up down bar front Sliding rail Sliding rail Seat cushion up down bar rear Sliding motor 1 SEAT OVERVIEW 1 Front Seat Driver s Seat Seat Cushion Motor Front Seat Cushion Motor Rear ...

Page 75: ...03 5 SEAT KYRON 2007 04 7410 01 Seat cushion angle adjusting lever rear Seat height control switch Seat cushion angle adjusting lever front Reclining lever Sliding lever ...

Page 76: ...03 6 KYRON 2007 04 7410 01 SEAT Location of Seat Position With Memory Unit Bottom of Driver Seat SPWM unit ...

Page 77: ...03 7 SEAT KYRON 2007 04 7410 01 2 Front Seat Passenger Seat Reclining Motor Sliding rail Sliding rail Sliding motor Reclining lever Sliding lever No seat height control function ...

Page 78: ...senger s seat window side seats of second row seat third row seat 2 Point type seat belt center seat of second row seat Pretensioner Installed at front seats The seat belt pretensioner rewinds the seat belt immediately to protect occupant s face and chest when a strong frontal collision occurs ...

Page 79: ...rd Row Seat Seat Melt in Front Seats Bracket Seat belt Seat belt anchor Seat belt Seat belt Oring Seat belt O ring Seat belt anchor Pre tensioner Buckle of 3 point type seat belt Buckle of 2 point type seat belt 2 Seat Belt 2 Point Type point type seat belt is installed only in the center seat of second row seat 2 ...

Page 80: ...7 04 7340 01 1 HAZARD MANUAL OPERATION The sunroof can be operated by rotating the motor operating hole on the sunroof motor with a proper tool 1 Circuit Diagram SCU Main Connector Motor Connector SCU 7340 01 SUNROOF SYSTEM ...

Page 81: ... operate properly when operating the sunroof switch 1 2 3 4 0 point reset of sunroof 3 Close the sunroof with the sunroof switch and keep the position for approx 10 seconds If the 0 point setting is successfully completed the sunroof should be properly opened from this position Check if the sunroof is fully closed Tilt the sunroof with the sunroof switch and keep it at the position for 10 seconds ...

Page 82: ...04 5 SUNROOF KYRON 2007 04 7340 01 3 TROUBLE DIAGNOSIS ...

Page 83: ...04 6 KYRON 2007 04 7340 01 SUNROOF 1 SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Sunroof Switch ...

Page 84: ... switch clockwise OPEN direction with the sunroof closed To partially open the sunroof rotate and hold the sunroof switch until it reaches at the desired position Close To fully close the sunroof briefly rotate the sunroof switch counterclockwise CLOSE direction with the sunroof open To partially close the sunroof rotate and hold the sunroof switch until it reaches at the desired position Tilt up ...

Page 85: ...04 8 KYRON 2007 04 7340 01 SUNROOF 3 SUNROOF CIRCUIT DIAGRAM ...

Page 86: ...NO DATA ...

Page 87: ...NO DATA ...

Page 88: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 89: ......

Page 90: ...0 3 FFH KYRON 2007 04 0000 00 0000 00 FFH 1 FFH ...

Page 91: ...0 4 KYRON 2007 04 0000 00 FFH ...

Page 92: ...0 5 FFH KYRON 2007 04 0000 00 ...

Page 93: ...0 6 KYRON 2007 04 0000 00 FFH ...

Page 94: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 95: ......

Page 96: ...0 3 P TRUNK KYRON 2007 04 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 97: ...0 4 KYRON 2007 04 0000 00 P TRUNK ...

Page 98: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 99: ......

Page 100: ...rminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symptom 3 ...

Page 101: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 102: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 103: ......

Page 104: ...0 3 STICS KYRON 2007 04 0000 00 0000 00 STICS 1 STICS ...

Page 105: ...0 4 KYRON 2007 04 0000 00 STICS ...

Page 106: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 107: ......

Page 108: ...0 3 TC KYRON 2007 04 0000 00 0000 00 TC 1 TC ...

Page 109: ...0 4 KYRON 2007 04 0000 00 TC ...

Page 110: ...0 5 TC KYRON 2007 04 0000 00 ...

Page 111: ...0 6 KYRON 2007 04 0000 00 TC ...

Page 112: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 113: ......

Page 114: ...0 3 TCU KYRON 2007 04 0000 00 0000 00 TCU 1 TCU ...

Page 115: ...0 4 KYRON 2007 04 0000 00 TCU ...

Page 116: ...0 5 TCU KYRON 2007 04 0000 00 ...

Page 117: ...0 6 KYRON 2007 04 0000 00 TCU ...

Page 118: ...0 7 TCU KYRON 2007 04 0000 00 ...

Page 119: ...0 8 KYRON 2007 04 0000 00 TCU ...

Page 120: ...0 9 TCU KYRON 2007 04 0000 00 ...

Page 121: ...0 10 KYRON 2007 04 0000 00 TCU ...

Page 122: ...0 11 TCU KYRON 2007 04 0000 00 ...

Page 123: ...0 12 KYRON 2007 04 0000 00 TCU ...

Page 124: ...0 13 TCU KYRON 2007 04 0000 00 ...

Page 125: ...0 14 KYRON 2007 04 0000 00 TCU ...

Page 126: ...0 15 TCU KYRON 2007 04 0000 00 ...

Page 127: ...0 16 KYRON 2007 04 0000 00 TCU ...

Page 128: ...0 17 TCU KYRON 2007 04 0000 00 ...

Page 129: ...0 18 KYRON 2007 04 0000 00 TCU ...

Page 130: ...0 19 TCU KYRON 2007 04 0000 00 ...

Page 131: ......

Page 132: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 133: ......

Page 134: ...0 3 TGS LEVER KYRON 2007 04 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 135: ...0 4 KYRON 2007 04 0000 00 TGS LEVER ...

Page 136: ...0 5 TGS LEVER KYRON 2007 04 0000 00 ...

Page 137: ...0 6 KYRON 2007 04 0000 00 TGS LEVER ...

Page 138: ...gits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D20DT engine the injector MDP minimum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running However for the D20DT EURO 4 engine it is learned when the vehicle is in motion and the engine is at idle speed 2 Common Rail The orifice is added to the conn...

Page 139: ... rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail ...

Page 140: ......

Page 141: ...ase in I D Common Rail Orifice for Preventing Fuel Pulsation Added 1 COMPONENTS OF FUEL SYSTEM Injector 7 way Injection and C3I Coding C3I Fuel nozzle holes 7 Orifice Orifice for HP pump fuel outlet Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ...

Page 142: ...ming Pump Fuel filter Priming pump Connector Fuel from HP pump Fuel filter HP pump Fuel tank Fuel tank Fuel return port Low pressure fuel supply port Venturi Fuel return port Fuel temperature sensor IMV connector High pressure fuel supply port orifice included IMV valve ...

Page 143: ...02 8 KYRON 2007 04 1881 09 ENGINE FUEL SYSTEM 2 FUEL FLOW OF D20DT EU IV ENGINE ...

Page 144: ...equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Page 145: ...007 04 2321 01 ENGINE INTAKE SYSTEM 2 INTAKE SYSTEM LAYOUT Uncompressed air Compressed air Ambient air Air cleaner VGT Turbo Chargera HFM Sensor ver 6 0 Air coeaner Turbo charger Temperature sensor Pretension graph ...

Page 146: ...ld Intercooler Turbo charger Intake manifold Throttle body Coolant port Compress ed air EGR gas To corresponding cylinders Booster Pressure Sensor Ground Supply power Output voltage Throttle body Normal flap open Engine stopped flap closed Intake duct Intake duct ...

Page 147: ...lly and sends the valve location signal to ECU vacuum modulator control has been deleted EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe EGR cooler E EGR valve To EGR cooler Exhaust manifold E EGR valve Coolant Intake manifold Intake manifold EGR gas From EGR cooler Turbocharger intercooler Intake compressed air Exhaust manifold EGR pipe EGR ...

Page 148: ...ill be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase PCV valve Oil separator PCV valve Oil separator Blow by gas To air duct hos...

Page 149: ...overlapped in normal driving mode These are the cause of oil and carbon accumulated in the intake pipe When the EGR system is operated the particulate material in the exhaust gas is drawn into the intake pipe and the oil not filtered in the PCV oil separator is also drawn into the intake pipe However unless the particulate material or oil are accumulated excessively in the pipe they do not affect ...

Page 150: ...ENGINE COOLING SYSTEM 2112 00 1520 00 ENGINE COOLING SYSTEM COOLING SYSTEM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE WATER PUMP 1 OVERVIEW 3 4 ...

Page 151: ...06 2 KYRON 2007 04 2112 00 ENGINE COOLING SYSTEM ...

Page 152: ...STEM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT EURO4 engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block 1 Cooling System for Engine ...

Page 153: ...t and a belt pulley The impeller is supported by a completely sealed bearing The water pump is serviced as an assembly and therefore cannot be disassembled The capacity of water pump has been increased due to the EGR cooler increased engine power and additional coolant port in the cylinder block For D20DT EURO4 engine For D20DT engine Port to EGR cooler ...

Page 154: ...06 5 ENGINE COOLING SYSTEM KYRON 2007 04 1520 00 1 Structure of Water Pump for D20DT Engine ...

Page 155: ......

Page 156: ...CU pin for D20DT EURO4 engine and D20DT engine are not same For more details refer to the respective section E EGR Electric Exhaust Gas Recirculation Valve It is electrically controlled by the ECU for precise control Old version was controlled by the vacuum modulator Throttle Body It is electrically controlled by ECU as E EGR valve AQGS Advanced Quick Glow System Unit The glow control relay K line...

Page 157: ...07 4 KYRON 2007 04 1491 01 ENGINE ELECTRICAL SYSTEM 2 D20DT EU IV ENGINE S ECU CIRCUIT ...

Page 158: ...ering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usin...

Page 159: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 160: ...10 5 CRUISE CONTROL SYSTEM KYRON 2007 04 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 161: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 162: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 163: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 164: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 165: ...en circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may result i...

Page 166: ...M LAYOUT 6 EXHAUST SYSTEM LAYOUT 7 LUBRICATION SYSTEM LAYOUT 8 COOLING SYSTEM LAYOUT 9 FUEL SYSTEM LAYOUT 10 FUEL SUPPLY SYSTEM 11 CLEANNESS 12 MAINTENANCE AND REPAIR 13 GUIDELINES FOR SERVICE WORK SAFETY 14 DURING SERVICE WORK FOR INSPECTION 15 DURING SERVICE WORK FOR ELECTRIC DEVICES 16 OWNER INSPECTIONS AND SERVICES 17 STANDARD BOLTS SPECIFICATIONS 3 7 11 15 17 19 21 23 25 27 29 35 37 41 43 44 ...

Page 167: ......

Page 168: ...01 3 ENGINE D20DT KYRON 2007 04 0000 00 1 ENGINE ASSEMBLY LAYOUT 1 LH Side View D20DT D27DT 0000 00 ENGINE GENERAL ...

Page 169: ...01 4 KYRON 2007 04 0000 00 ENGINE D20DT 2 RH side view D20DT D27DT ...

Page 170: ...01 5 ENGINE D20DT KYRON 2007 04 0000 00 3 Front view D20DT D27DT ...

Page 171: ...01 6 KYRON 2007 04 0000 00 ENGINE D20DT 4 Fan belt D20DT D27DT ...

Page 172: ...01 7 ENGINE D20DT KYRON 2007 04 0000 00 2 COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ...

Page 173: ...01 8 KYRON 2007 04 0000 00 ENGINE D20DT ...

Page 174: ...01 9 ENGINE D20DT KYRON 2007 04 0000 00 ...

Page 175: ...01 10 KYRON 2007 04 0000 00 ENGINE D20DT ...

Page 176: ...01 11 ENGINE D20DT KYRON 2007 04 0000 00 3 ENGINE CONTROLS LAYOUT 1 Ecu related componets 1 D20DT Engine ...

Page 177: ...01 12 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 178: ...01 13 ENGINE D20DT KYRON 2007 04 0000 00 2 ENGINE AND SENSORS 1 D20DT Engine ...

Page 179: ...01 14 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 180: ...01 15 ENGINE D20DT KYRON 2007 04 0000 00 4 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1 D20DT Engine ...

Page 181: ...01 16 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 182: ...01 17 ENGINE D20DT KYRON 2007 04 0000 00 5 INTAKE SYSTEM LAYOUT 1 D20DT Engine ...

Page 183: ...01 18 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 184: ...01 19 ENGINE D20DT KYRON 2007 04 0000 00 6 EXHAUST SYSTEM LAYOUT 1 D20DT Engine ...

Page 185: ...01 20 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 186: ...01 21 ENGINE D20DT KYRON 2007 04 0000 00 7 LUBRICATION SYSTEM LAYOUT 1 D20DT Engine ...

Page 187: ...01 22 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 188: ...01 23 ENGINE D20DT KYRON 2007 04 0000 00 8 COOLING SYSTEM LAYOUT 1 D20DT Engine ...

Page 189: ...01 24 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 190: ...01 25 ENGINE D20DT KYRON 2007 04 0000 00 9 FUEL SYSTEM LAYOUT 1 D20DT Engine ...

Page 191: ...01 26 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 192: ...ines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissio...

Page 193: ...01 28 KYRON 2007 04 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 194: ... is stucked due to foreign materials injector remains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operati...

Page 195: ...z dust and foreign materials from getting into fuel system Wash your hands and do not wear working gloves Follow the below procedures before starting service works for fuel system 1 2 3 4 If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in DIAGNOSIS section in this manual At this point th...

Page 196: ...s The pipes should be tightened to specified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to ...

Page 197: ...t value by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history fau...

Page 198: ...TEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump c...

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Page 200: ...intenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity eng...

Page 201: ...Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the b...

Page 202: ... by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Howe...

Page 203: ... contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of polar...

Page 204: ...foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly ...

Page 205: ...tween HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance d...

Page 206: ...icle and then support with chassis stand before service work Before service work be sure to isconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 ...

Page 207: ...ease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line be...

Page 208: ...e Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front o...

Page 209: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 210: ...a true oil level reading Engine Coolant Level and Condition Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Windshield Washer Fluid Level Check the washer fluid level in the reservoir Add fluid if necessary 3 At least twice a month Tire And Wheel Inspection and Pressure Check Check the tire for abnormal wear or d...

Page 211: ...e Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Exhaust System Inspection Inspect t...

Page 212: ... hinges and the latches the glove box and the console doors and any folding seat hardware Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the coo...

Page 213: ...01 48 KYRON 2007 04 0000 00 ENGINE D20DT 17 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 214: ...ring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of a...

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Page 216: ... rail 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 1114 01 ENGINE ASSEMBLY 1 MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT 1 D20DT ENGINE The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque ...

Page 217: ...Coolant reservoir 8 Fuel filter 2 FFH device 9 ABS ESP unit 3 Brake fluid reservoir 10 Priming pump 4 Washer fluid reservoir 11 EGR valve 5 Common rail 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 2 D27DT ENGINE ...

Page 218: ...10 Poly grooved belt 11 Cam position sensor 12 EGR valve 13 Power steering pump 14 EGR center pipe 1 TVD Torsional Vibration Damper 2 Air conditioner compressor 3 Power steering pump pulley 4 Idle pulley 5 Water pump pulley 6 Alternator 7 Viscos clutch pulley 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 EGR valve 13 Power steering pump 14 EGR center pipe ...

Page 219: ...ler cap 24 Glow plug 25 Booster pressure sensor 26 PCV valve and oil separator 27 Oil dipstick 28 EGR LH pipe 15 Cylinder head cover 16 Intake manifold 17 Water outlet port 18 Common rail 19 Fuel pressure sensor 20 Fuel pipe 21 Injector 22 Fuel return line 23 Oil filler cap 24 Glow plug 25 Booster pressure sensor 26 PCV valve and oil separator 27 Oil dipstick 28 EGR LH pipe 2 Top View D27DT D20DT ...

Page 220: ...n plug 33 Turbo charger 34 EGR RH pipe 35 PCV valve and oil separator 36 Oil dipstick 37 Exhaust manifold 29 Cylinder head 30 Cylinder block 31 Oil pan 32 Drain plug 33 Turbo charger 34 EGR RH pipe 35 PCV valve and oil separator 36 Oil dipstick 37 Exhaust manifold 3 Right Side View D27DT D20DT ...

Page 221: ...ssure pump 39 Turbo charger booster vacuum modulator Gray 40 EGR valve vacuum modulator 41 EGR valve Black 38 High pressure pump 39 Turbo charger booster vacuum modulator Gray 40 EGR valve vacuum modulator 41 EGR valve Black 4 Left Side View D27DT D20DT ...

Page 222: ...02 9 ENGINE D20DT KYRON 2007 04 1114 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 223: ...02 10 KYRON 2007 04 1114 01 ENGINE D20DT 2 Engine Performance Curve 1 Vehicle with A T Output and Torque D20DT engine D27DT engine ...

Page 224: ...02 11 ENGINE D20DT KYRON 2007 04 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 225: ...02 12 KYRON 2007 04 1114 01 ENGINE D20DT Output and Torque 2 Vehicle with M T D20DT engine D27DT engine ...

Page 226: ...02 13 ENGINE D20DT KYRON 2007 04 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 227: ...02 14 KYRON 2007 04 1114 01 ENGINE D20DT 4 TIGHTENING TORQUE ...

Page 228: ...02 15 ENGINE D20DT KYRON 2007 04 1114 01 ...

Page 229: ...02 16 KYRON 2007 04 1114 01 ENGINE D20DT ...

Page 230: ...d stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining proced...

Page 231: ...in plug water separating operation every 10 000 km 1 2 Priming pump 3 When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 232: ...gets out from the port then turn the drain plug to B direction to tighten it 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to per...

Page 233: ...hrough electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant temperature sen...

Page 234: ...mpletely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure pump t...

Page 235: ...03 8 KYRON 2007 04 1881 01 ENGINE D20DT 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Page 236: ...t excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the cond...

Page 237: ...rials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel filter ...

Page 238: ...stem pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value It is bec...

Page 239: ...rs The fuel injection device is composed of electrical solenoid valve needle and nozzle and controlled by engine ECU The injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel u...

Page 240: ... D20DT KYRON 2007 04 1881 01 6 Fuel filter replacement Fuel filter change interval every 30 000 km Water separation interval every 10 000 km same with engine oil change interval Never reuse the removed fuel filter ...

Page 241: ...03 14 KYRON 2007 04 1881 01 ENGINE D20DT 7 Circuit Diagram ...

Page 242: ...03 15 ENGINE D20DT KYRON 2007 04 1881 01 ...

Page 243: ...03 16 KYRON 2007 04 1881 01 ENGINE D20DT ...

Page 244: ... every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2 Special Tools and Equipment Special Tools and Equipment Application Y99220112B Intake manifold guide pin Installation of intake manifold 2321 01 INTAKE SYSTEM ...

Page 245: ...04 4 KYRON 2007 04 2321 01 ENGINE D20DT 1 ENGINE INTAKE COMPONENTS LOCATOR 1 D20DT Engine Air Cleaner Cover Elemen t Housing Intake Manifold HFM Sensor Intercooler ...

Page 246: ...04 5 ENGINE D20DT KYRON 2007 04 2321 01 2 D27DT Engine Air Cleaner Intake Manifold HFM Sensor Intercooler Cover Element Housing ...

Page 247: ...04 6 KYRON 2007 04 2321 01 ENGINE D20DT 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 248: ...omplaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to rece...

Page 249: ...05 4 KYRON 2007 04 1913 01 ENGINE D20DT D20DT D27DT HUBER EGR System for IDI Engine Including the EGR Valve Potentiometer EGR System for DI Engine ...

Page 250: ...05 5 ENGINE D20DT KYRON 2007 04 1913 01 1 COMPONENTS LOCATOR OF EXHAUST SYSTEM Muffler Exhaust Manifold EGR Valve Turbo Charger Catalytic Converter DOC EGR Pipe Vacuum Modulator 1 D20DT ENGINE ...

Page 251: ...05 6 KYRON 2007 04 1913 01 ENGINE D20DT Turbo Charger EGR Valve Muffler Exhaust Manifold Catalytic Converter DOC EGR Pipe Vacuum Modulator ...

Page 252: ...05 7 ENGINE D20DT KYRON 2007 04 1913 01 2 EXHAUST GAS FLOWS ...

Page 253: ...2 When most trips are less than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km 3 When operating in dusty sandy and salty areas 4 In hilly or moutainous terrain 5 When doing frequent trailer towing Oil Pressure Switch 1 Operating temperature 40 140 2 Operating pressure 0 3 0 55 bar 3 Permissible pressure 10 bar 1533 01 ENGINE LUBRICATION SYSTEM...

Page 254: ...06 4 KYRON 2007 04 1533 01 ENGINE D20DT 1 COMPONENTS OF LUBRICATION SYSTEM 1 D20DT ENGINE Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover ...

Page 255: ...06 5 ENGINE D20DT KYRON 2007 04 1533 01 Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover 2 D27DT Engine ...

Page 256: ...01 ENGINE D20DT Cylinder Head Cylinder Block Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 2 LUBRICATION SYSTEM LAYOUT ...

Page 257: ...07 04 1533 01 1 Opening pressure of by pass valve in oil filter 3 0 4 bar 2 To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head 3 LUBRICATION DIAGRAM ...

Page 258: ...07 3 ENGINE D20DT KYRON 2007 04 9210 05 9210 05 ENGINE COOLING SYSTEM 1 ENGINE COOLING SPECIFICATIONS ...

Page 259: ...07 4 KYRON 2007 04 9210 05 ENGINE D20DT Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING 1 D20DT Engine ...

Page 260: ...07 5 ENGINE D20DT KYRON 2007 04 9210 05 Coolant Reservoir FFH Coolant Temperature Sensor Radiator Water Pump Cooling Fan 2 D27DT Engine ...

Page 261: ... 2 COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 262: ...ws from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley D20DT D27DT Cylinder head Intake manifold Coolant outlet port Cylinder head Coolant outlet port Intake manifold Improved shape and gasket material to prevent coo...

Page 263: ...08 3 ENGINE D20DT KYRON 2007 04 1461 01 1461 01 ENGINE ELECTRIC SYSTEM 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 264: ...DT Fuel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor 1 COMPONENTS OF ELECTRIC IN ENGINE 1 D20DT ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 265: ...YRON 2007 04 1461 01 Coolant Temperature Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 2 EA 2 D27DT ENGINE Booster Pressure Sensor Camshaft Position Sensor Fuel Pressure Sensor Fuel Temperature Sensor ...

Page 266: ... 2007 04 1461 01 ENGINE D20DT 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN 1 D20DT ENGINE Glow Plug Alternator Air Conditioner Compressor Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 267: ...08 7 ENGINE D20DT KYRON 2007 04 1461 01 1 D27DT ENGINE Air Conditioner Compressor Alternator Glow Plug Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 268: ...08 8 KYRON 2007 04 1461 01 ENGINE D20DT 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 269: ...08 9 ENGINE D20DT KYRON 2007 04 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 270: ...491 01 EGINE CONTROL SYSTEM 1 ENGINE ECU AND OTHER COMPONENTS 1 D20DT Engine ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay ...

Page 271: ...N 2007 04 1491 01 ENGINE D20DT ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay 2 D20DT Engine ...

Page 272: ...09 5 ENGINE D20DT KYRON 2007 04 1491 01 3 TOP VIEW 1 D20DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 273: ...09 6 KYRON 2007 04 1491 01 ENGINE D20DT Fuel Pressure Sensor 2 D27DT Engine Booster Pressure Sensor Injectors 5 EA Glow Plugs 5 ...

Page 274: ...09 7 ENGINE D20DT KYRON 2007 04 1491 01 1 D20DT Engine 4 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 275: ...09 8 KYRON 2007 04 1491 01 ENGINE D20DT 2 D27DT Engine Coolant Temperature Sensor Knock Sensors 2 EA Fuel Temperature Sensor Fuel Pressure Regulating Valve Crankshaft Position Sensor ...

Page 276: ...aft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheater auxiliary he...

Page 277: ...ge of ECU is normally 40 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circuit divides current applying time inj...

Page 278: ...lete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined accord...

Page 279: ... advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liable to...

Page 280: ...ade according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a function of ...

Page 281: ...ow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order to m...

Page 282: ... As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel accor...

Page 283: ...the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and chooses...

Page 284: ... emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the f...

Page 285: ...e altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The diffe...

Page 286: ... be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection and t...

Page 287: ...e extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled and the...

Page 288: ...n the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors It i...

Page 289: ...ptimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number 16 di...

Page 290: ...ninum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 291: ......

Page 292: ...g wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using th...

Page 293: ...s or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 294: ...10 5 ENGINE D20DT KYRON 2007 04 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 295: ... reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use t...

Page 296: ... hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is runni...

Page 297: ...er 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DECEL...

Page 298: ...e below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed p...

Page 299: ...ircuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may result in sy...

Page 300: ... STRUCTURE AND COMPARISON 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 3 TIGHTENING TORQUE 4 MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT OERVIEW AND OPERATION PROCESS 1 ENGINE COMPARTMENT 2 SYSTEM IN ENGINE COMPARTMENT 3 7 9 12 21 25 ...

Page 301: ......

Page 302: ...01 3 ENGINE GENERAL KYRON 2007 04 0000 00 0000 00 ENGINE GENERAL 1 STRUCTURE AND COMPARISON D27DT EU IV Engine Front View D27DT EU IV Engine Top View ...

Page 303: ...01 4 KYRON 2007 04 0000 00 ENGINE GENERAL D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Page 304: ...01 5 ENGINE GENERAL KYRON 2007 04 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Page 305: ...01 6 KYRON 2007 04 0000 00 ENGINE GENERAL D27DT Engine General Side View D27DT Engine General Left Side View ...

Page 306: ...01 7 ENGINE GENERAL KYRON 2007 04 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 307: ...01 8 KYRON 2007 04 0000 00 ENGINE GENERAL 2 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 308: ...01 9 ENGINE GENERAL KYRON 2007 04 0000 00 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Page 309: ...01 10 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 310: ...01 11 ENGINE GENERAL KYRON 2007 04 0000 00 ...

Page 311: ...NE GENERAL MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT 4 The shape and size of D27DTP POWER UP are slightly different from those of D27DT engine but the basic configuration of two systems is almost same 1 Engine Assembly ...

Page 312: ...01 13 ENGINE GENERAL KYRON 2007 04 0000 00 2 Major Changes and Summary ...

Page 313: ...01 14 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 314: ...01 15 ENGINE GENERAL KYRON 2007 04 0000 00 ...

Page 315: ...01 16 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 316: ...01 17 ENGINE GENERAL KYRON 2007 04 0000 00 ...

Page 317: ...01 18 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 318: ...01 19 ENGINE GENERAL KYRON 2007 04 0000 00 ...

Page 319: ...01 20 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 320: ...01 21 ENGINE GENERAL KYRON 2007 04 0000 00 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Page 321: ...01 22 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 322: ... compartment fuse box PTC relay box Battery Vacuum modulator for VGT turbo charger 1 2 3 4 5 6 7 8 9 10 11 12 13 FFH Assembly Only for vehicle with FFH Power steering oil tank Engine oil filler cap Fan shroud E EGR Valve High capacity PCV oil separator HFM sensor 6 0 VGT turbo charger Air cleaner housing 2Coolant surge tank ABS ESP HECU Including TPMS function optional Exhaust gas FRT Temp sensor ...

Page 323: ...01 24 KYRON 2007 04 0000 00 ENGINE GENERAL Major Sensors and Components ...

Page 324: ...01 25 ENGINE GENERAL KYRON 2007 04 0000 00 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Page 325: ...01 26 KYRON 2007 04 0000 00 ENGINE GENERAL ...

Page 326: ...01 27 ENGINE GENERAL KYRON 2007 04 0000 00 2 Preheat System ...

Page 327: ...01 28 KYRON 2007 04 0000 00 ENGINE GENERAL 3 Fuel System ...

Page 328: ...01 29 ENGINE GENERAL KYRON 2007 04 0000 00 Fuel Supply System ...

Page 329: ...01 30 KYRON 2007 04 0000 00 ENGINE GENERAL 4 Lubrication System ...

Page 330: ...01 31 ENGINE GENERAL KYRON 2007 04 0000 00 5 Cooling System ...

Page 331: ...01 32 KYRON 2007 04 0000 00 ENGINE GENERAL 6 Intake System ...

Page 332: ...01 33 ENGINE GENERAL KYRON 2007 04 0000 00 7 Exhaust System ...

Page 333: ...currently 7 to the tip of the injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle is leaned only ...

Page 334: ...d to the connection to the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume It is also installed on the connection of the high pressure fuel supply line of the HP pump D27DTP D27DT EU IV D27DT ...

Page 335: ...pump Common rail D27DT Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail The I D and O D of the fuel rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely ...

Page 336: ...02 6 KYRON 2007 04 1881 09 ENGINE FUEL SYSTEM 2 COMPONENTS OF FUEL SYSTEM ...

Page 337: ...02 7 ENGINE FUEL SYSTEM KYRON 2007 04 1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 338: ...ine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Page 339: ...ECU vacuum modulator control has been deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more details refer t...

Page 340: ...NO DATA ...

Page 341: ... FOR EACH ENGINE For the D27DTP POWER UP engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block For the D27DT engine the cooling system uses the fan clutch Cooling System for D27DTP POWER UP Engine ...

Page 342: ...06 4 KYRON 2007 04 1520 01 ENGINE COOLING SYSTEM D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 343: ...NO DATA ...

Page 344: ...ering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usin...

Page 345: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 346: ...08 5 CRUISE CONTROL SYSTEM KYRON 2007 04 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 347: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 348: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 349: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 350: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 351: ...en circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may result i...

Page 352: ...NO DATA ...

Page 353: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 354: ......

Page 355: ......

Page 356: ...01 4 KYRON 2007 04 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 357: ... Connecting rod 3 Resonance flap 14 Exhaust manifold 4 Cylinder head cover 15 Crankshaft 5 Exhaust camshaft 16 Engine mounting 6 Intake camshaft 17 Starter 7 Cylinder head 18 Crankcase 8 Spark plug connector 19 Oil pump sprocket 9 Valve tappet 20 Oil strainer 10 Injector 21 Oil pan 11 Exhaust valve 22 Drain plug Front View ...

Page 358: ... 04 0000 00 ENGINE INFORMATION 2 SIDE VIEW NO FUNCTION NO FUNCTION 23 Camshaft adjuster 27 Oil pump drive chain 24 Cooling fan and viscous clutch 28 Oil return pipe 25 Piston 29 Timing chain 26 Flywheel of drive plate ...

Page 359: ...They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or whe...

Page 360: ......

Page 361: ...02 3 ENGINE ASSEMBLY KYRON 2007 04 1113 01 1113 01 ENGINE ASSEMBLY 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 362: ...02 4 KYRON 2007 04 1113 01 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 363: ...02 5 ENGINE ASSEMBLY KYRON 2007 04 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 364: ...02 6 KYRON 2007 04 1113 01 ENGINE ASSEMBLY ...

Page 365: ...02 7 ENGINE ASSEMBLY KYRON 2007 04 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 366: ...02 8 KYRON 2007 04 1113 01 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 367: ...02 9 ENGINE ASSEMBLY KYRON 2007 04 1113 01 4 FASTENER TIGHTENING SPECIFICATIONS CONT D ...

Page 368: ...le Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly ear...

Page 369: ...03 4 KYRON 2007 04 2211 22 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 370: ...NO DATA ...

Page 371: ...tion is discovered upon inspection of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 OVER...

Page 372: ...05 4 KYRON 2007 04 2420 01 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 373: ...06 3 LUBRICATION SYSTEM KYRON 2007 04 9210 01 9210 01 ENGINE LUBRICATION SYSTEM 1 OIL CIRCULATION ...

Page 374: ...e tappet 7 Oil gallery at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chain...

Page 375: ...07 3 COOLING SYSTEM KYRON 2007 04 2110 01 2110 01 ENGINE COOLING SYSTEM 1 GENERAL SPECIFICATIONS ...

Page 376: ...07 4 KYRON 2007 04 2110 01 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 377: ...07 5 COOLING SYSTEM KYRON 2007 04 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 378: ...stem to operation The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to the heat core Thi...

Page 379: ...07 7 COOLING SYSTEM KYRON 2007 04 2110 01 2 COMPONENT LOCATOR ...

Page 380: ... pieces Bolt M6 4 pieces Bolt M6 4 pieces Upper radiator insulator Lower radiator insulator Plate Clip 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Inlet hose Outlet hose 3 way hose Deaeration hose reserver tank Clamp Clamp Make up hose holder Reserver tank Bolt M6 2 piece Cooling fan Viscous clutch Bolt M6 1 piece Bolt M6 3 piece 15 16 17 18 19 20 21 22 23 24 25 26 27 ...

Page 381: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2007 04 1452 01 1452 01 ENGINE ELECTRIC DEVICES 1 GENERAL SPECIFICATIONS ...

Page 382: ...08 4 KYRON 2007 04 1452 01 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 383: ...te as the battery warms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the cu...

Page 384: ... exhaust stroke requires very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These systems use the EST signal from the ECM to control the EST The ECM uses the following information Engine load mass air flow sensor manifold air pressure sensor Engine coolant temperature Intake air temperature Cranks...

Page 385: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2007 04 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 386: ...09 3 ENGINE CONTROL SYSTEM KYRON 2007 04 1522 16 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE ...

Page 387: ...09 4 KYRON 2007 04 1522 16 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 388: ...ering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usin...

Page 389: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 390: ...10 5 CRUISE CONTROL SYSTEM KYRON 2007 04 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 391: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 392: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 393: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 394: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 395: ...en circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may result i...

Page 396: ... during assembly to protect and lubricate the surfaces on initial operation Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever valve train components are removed for service they should be kept in order They should be installed in the same locations and with the sa...

Page 397: ...posed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Any time the air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the ...

Page 398: ...01 5 ENGINE ASSEMBLY KYRON 2007 04 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 399: ...01 6 KYRON 2007 04 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 400: ...01 7 ENGINE ASSEMBLY KYRON 2007 04 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 401: ...ting Rod 6 Fuel Distributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan NO FUNCTION NO FUNCTION 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flyw...

Page 402: ...location of the leak by the drippings on the paper Visually check around the suspected component Check around all the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well Dry the area Operate the vehicle for s...

Page 403: ...source the cause of the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check for the following conditions and correct them as they may cause a leak Repairing the Leak Gaskets The fluid level pressure is too high The...

Page 404: ... compression pressure tester A9912 0012B 001 589 76 21 00 and install it into the spark plug hole Crank the engine approx eight revolutions by using the start motor Compare the measurements of compression pressure tester A9912 0012B 001 589 76 21 00 with the specifications Measure the compression pressure of the other cylinders in the same way If measured value is not within the specifications per...

Page 405: ...sure LeakageTest Permissible Pressure Leakage At Whole Engine Max 25 At Valve and Cylinder Head Gasket Max 10 At Piston and Piston Ring Max 20 OT TDC 1 4 UT BDC 180 2 3 Cylinder Number Cylinder Number Cylinder Pressure Leakage Tester Bosch EFAW210A Sun CLT 228 ...

Page 406: ... pressure line and adjust the scale of tester Install the connecting hose to spark plug hole Position the piston of No 1 cylinder at TDC by rotating the crankshaft Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable Perform the...

Page 407: ...01 14 KYRON 2007 04 1113 01 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 408: ...01 15 ENGINE ASSEMBLY KYRON 2007 04 1113 01 General Diagnosis Cont d ...

Page 409: ...01 16 KYRON 2007 04 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 410: ...01 17 ENGINE ASSEMBLY KYRON 2007 04 1113 01 General Diagnosis Cont d ...

Page 411: ...01 18 KYRON 2007 04 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 412: ...01 19 ENGINE ASSEMBLY KYRON 2007 04 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 413: ...01 20 KYRON 2007 04 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 414: ...01 21 ENGINE ASSEMBLY KYRON 2007 04 1113 01 Fastener Tightening Specifications Cont d ...

Page 415: ...01 22 KYRON 2007 04 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 416: ......

Page 417: ...02 3 ENGINE INTAKE SYSTEM KYRON 2007 04 1713 08 1713 08 ENGINE INTAKE SYSTEM 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 418: ...03 3 ENGINE EXHAUST SYSTEM KYRON 2007 04 2420 01 2420 01 ENGINE EXHAUST SYSTEM 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 419: ...alytic converter Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter 1 2 Catalytic Converter Structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith Washer coat operates f...

Page 420: ...normal range of temperature CO purification rate becomes the best near the temperature of 450 C and NOx does so near the temperature of 400 to 500 C Purification of Catalytic Converter Adhesion of soluble organic fraction SOF below 180 C Purification of soluble organic fraction SOF over 180 C Chemical reaction formula SOF HC O2 CO2 H2O 2CO O2 2CO2 2C2H6 7O2 4CO2 6H20 By catalytic action of two pri...

Page 421: ... factor are high EGR valve can decrease NOx 30 to 35 decrease by making temperature of combustion chamber fall by means of exhaust gas re circulation EGR valve is installed on the diesel engine of Musso Korando Istana and Rexton And micro switch is installed together to control EGR valve The setting method of micro switch is identical with the existing one ...

Page 422: ...04 3 ENGINE COOLING SYSTEM KYRON 2007 04 2110 01 2110 01 ENGINE COOLING SYSTEM 1 GENERAL SPECIFICATIONS ...

Page 423: ...04 4 KYRON 2007 04 2110 01 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 424: ... 01 1 COMPONENT LOCATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 4 Outlet Hose 5 3 way Hose 6 Clamp 7 Clamp 8 Bolt M6 2 piece 9 Radiator 10 Lower Radiator Insulator 11 Plate 12 Clip 13 Upper Radiator Insulator 14 Bracket 15 PWM Electric Fan ...

Page 425: ...he correct coolant level The cooling system for this vehicle has no radiator cap or filler neck The coolant is added to the cooling system through the coolant reservoir 2 Radiator This vehicle has a lightweight tube and fin aluminum radiator Plastic tanks are mounted on the upper and the lower sides of the radiator core On vehicles equipped with automatic transaxles the transaxle fluid cooler line...

Page 426: ...sing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits The wax pellet in the thermostat is hermetically sealed in a metal case The wax element of the thermostat expands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the engine coolant temperature increases When ...

Page 427: ... cooling fan relay and a cooling fan motor relay The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C 203 F and at high speed when the coolant temperature reaches 105 C 221 F The ECM will change the cooling fans from high peed to low speed at 100 C 212 F and will turn the cooling fans off at 90 C 194 F A C On The ECM will turn the cooling fans on at low spee...

Page 428: ...MODULATION ELECTRIC FAN OPERATION 1 Function The PWM Pulse Width Modulation high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise 2 Mounting Location PWM Fan shroud Electric fan PWM unit ...

Page 429: ...h Modulation Unit It controls the time of the output voltage to control the fan motor speed independently Internal functions Motor power shutting off function when overcurrent is applied Adverse voltage prevention function Detection function for the motor lock Temperature detecting function The electric fan operates at FULL speed to cool down the PWM unit when the interior temperature of PWM unit ...

Page 430: ... for 4 seconds after engine starting abrupt acceleration and A C refrigerant pressure sensor detecting the followings A C compressor is turned off when the refrigerant pressure is below 2 0 kg cm2 and then is turned on when the refrigerant pressure is over 2 4 kg cm2 A C compressor is turned off when the refrigerant pressure is over 30 kg cm2 and then is turned on when the refrigerant pressure is ...

Page 431: ...05 3 ENGINE ELECTRICAL SYSTEM KYRON 2007 04 1452 01 1452 01 ENGINE ELECTRIC DEVICES 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 432: ...05 4 KYRON 2007 04 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 433: ... More power available in a lighter smaller case The battery has three major functions in the electrical system First the battery provides a source of energy for cranking the engine Second the battery acts as a voltage stabilizer for the electrical system Finally the battery can for a limited time provide energy when the electrical demand exceeds the output of the generator 2 Ratings A battery has ...

Page 434: ...eep the battery cable terminals clean and tight or a loose battery hold down clamp Mechanical problems in the electrical system such as shorted or pinched wires 3 Charging Time Required The time required to charge a battery will vary depending upon the following factors Size of Battery A Completely discharged large heavy duty battery required more than twice the recharging time as a completely dis...

Page 435: ...ry may not have enough voltage to activate this circuitry even though the leads are connected properly making it appear that the battery will not accept charging current Therefore follow the specific charger manufacturer apos s instruction for by passing or overriding the circuitry so that the charger will turn on and charge a low voltage battery Continue to charge the battery until the charge cur...

Page 436: ...Do not attach the cable directly to the neg ative terminal of the discharged battery Doing so could cause sparks and possible battery explosion Clamp one end of the second cable to the negative terminal of the booster battery Make the final connection to a solid engine ground such as the engine lift bracket at least 450 millimeters 18 inches from the discharged battery Start the engine of the vehi...

Page 437: ...cal loads the on time may be 90 percent and the off time 10 percent 7 Charging System Generators use a new type of regulator that incorporates a diode trio A Delta stator a rectifier bridge and a rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan are used There is no test hole 8 Starter Wound field starter motors have pole pieces arranged...

Page 438: ... all the related wiring Diagnostic tables will aid in troubleshooting system faults When a fault is traced to a particular component refer to that component section of the service manual The starting system circuit consists of the battery the starter motor the ignition switch and all the related electrical wiring All of these components are connected electrically ...

Page 439: ...ering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usin...

Page 440: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 441: ...06 5 CRUISE CONTROL SYSTEM KYRON 2007 04 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 442: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 443: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 444: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 445: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 446: ...en circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may result i...

Page 447: ...NS OF INTERIOR UNITS AND SENSORS 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT 3 INTERIOR SWITCHES 4 AUDIO VIDEO SYSTEM 5 ELECTRIC COMPONENTS AND LAYOUT 6 FUSE AND RELAY 7 FUSE AND RELAY G23D 8 INTERIOR FUSE BOX ELECTRIC SYSTEM ELECTRIC SYSTEM 2 4 6 8 10 12 24 28 ...

Page 448: ...OR UNITS AND SENSORS Under Instrument Panel Steering Wheel Angular Sensor Immobilizer PAS Unit Driver Seat Memory Switch TCCU and TCU Steering wheel angular sensor Immobilizer Curtain air bag module Sun sensor TV antenna amplifier Door lock relay Chime bell Buzzer for PAS RK STICS TCCU TCU ...

Page 449: ...ECM Sensor Cluster Sun Roof Unit and Motor Air Bag ECU Curtain Air Bag Sensor Interior Temperature and Humidity Sensor Engine ECU and SSPS Unit Sun roof unit Sun roof motor Curtain air bag module TV antenna amplifier DSP amp TV tuner DVD changer SSPS unit under the engine ECU Sub woofer ...

Page 450: ...ON 2007 04 0000 00 ELECTRIC SYSTEM 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT FFH Ambient Temperature Sensor Receiver Drier and Triple Pressure Switch Horn RH FFH Assembly FFH ambient temperature sensor ...

Page 451: ... ELECTRIC SYSTEM KYRON 2007 04 0000 00 IWE Vacuum Solenoid Valve 4WD Horn LH Hood Contact Switch Theft Deterrent Horn Under the Battery Fuse and Relay Box ESP Pressure Sensor Primary Secondary ABS ESP HECU ...

Page 452: ...OR SWITCHES Bezel Assembly on Outside Rearview Mirror Adjusting Switch Seat Position Memory Switch Driver s Door Driver s Power Window Main Switch Outside rearview mirror folding switch Outside rearview mirror adjusting switch ESP OFF switch Audio remote control switch Audio remote control switch ...

Page 453: ...Switch Bezel Assembly on Hazard Switch Center Fascia Switch Room lamp main switch Sun roof switch HDC switch Outside rearview mirror and rear glass heated switch Hazard switch TRIP switch Front defogger switch 1 2 3 4 5 Passenger seat warmer switch Driver seat warmer switch 4WD switch ...

Page 454: ...SYSTEM AV System Audio remote control switches Center speaker DVD changer DVD tape Other Audio Head Unit 6 INDASH CD TAPE RADIO CD RADIO Front speaker RH Tweeter speaker DVD changer Center speaker AV head unit Front speaker LH Tweeter speaker LH Sub woofer amplifier integrated type ...

Page 455: ...2007 04 0000 00 Location Inside of panel above glove box 6 DVD changer AV System Tweeter speaker LH Rear speaker LH Rear speaker RH Tweeter speaker TV antenna amplifier LH TV antenna amplifier RH Tuner Amp Radio antenna amplifier ...

Page 456: ...01 10 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Wiring Harness Arrangement 5 ELECTRIC COMPONENTS AND LAYOUT ...

Page 457: ...01 11 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Components Locator ...

Page 458: ...ion lamp There are three fuse and relay boxes in this vehicle one at each side of the instrument panel and one in the engine compartment The designation and capacity of relays and fuses are shown on the fuse and relay box cover Engine compartment Instrument panel 6 FUSE AND RELAY Location of Fuses and Relays Fuse and relay box LH Fuse and relay box RH ...

Page 459: ...ox indicate only major circuits connected Therefore some system may not be shown on the labels For details about the fuse and relay connection refer to Power distribution diagram in this section Designation and Capacity for Fuses and Relays in Engine Compartmentd Relays ...

Page 460: ...01 14 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Designation and capacity for fuses and relays in instrument panel Fuse and relay box driver side ...

Page 461: ...01 15 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Fuse and relay box passenger side ...

Page 462: ...01 16 KYRON 2007 04 0000 00 ELECTRIC SYSTEM POWER DISTRIBUTION DIAGRAM 2 Fuse and Relay Box in Engine Compartment I Fuse and relay box in engine compartment ...

Page 463: ...01 17 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Fuse and relay box in engine compartment II ...

Page 464: ...01 18 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Fuse and relay box in engine compartment III ...

Page 465: ...01 19 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Interior fuse and relay box driver side I Interior fuse and relay box driver side ...

Page 466: ...01 20 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Interior fuse and relay box driver side II ...

Page 467: ...01 21 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Interior fuse and relay box driver side III ...

Page 468: ...01 22 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Interior fuse and relay passenger side Interior fuse and relay passenger side ...

Page 469: ... Fuse and relay box in engine compartment Battery Open the box cover and unscrew box mounting nuts 1 Lift up the ruse and relay box assembly and disconnect the connector from behind the box Then remove the fuse and relay box assembly 2 3 REMOVAL AND INSTALLATION OF FUSE AND RELAY BOX ...

Page 470: ...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 Engine Room G23D Interior G23D 7 FUSE AND RELAY G23D 1 FUSES AND RELAYS Fuse and relay box LH Fuse and relay box RH ...

Page 471: ...01 25 ELECTRIC SYSTEM KYRON 2007 04 0000 00 2 DESIGNATION AND CAPACITY OF FUSES AND RELAYS IN ENGINE COMPARTMENT ...

Page 472: ...01 26 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Fuse and Relay G23D 3 DESIGNATION AND CAPACITY OF INTERIOR FUSES AND RELAYS ...

Page 473: ...01 27 ELECTRIC SYSTEM KYRON 2007 04 0000 00 Fuse and Relay RH G23D ...

Page 474: ...01 28 KYRON 2007 04 0000 00 ELECTRIC SYSTEM 8 INTERIOR FUSE BOX Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 475: ...01 29 ELECTRIC SYSTEM KYRON 2007 04 0000 00 1 Designation and Capacity Driver Side ...

Page 476: ...01 30 KYRON 2007 04 0000 00 ELECTRIC SYSTEM Passenger Side ...

Page 477: ... Scan 100 and Diagnostic Connector Scan 100 CAN module Diagnostic connector Additional cable for CAN module Additional Devices of Scan 100 Diagnosis EAS EPB Only Connection of Scan 100 Including CAN Module and Additional Cable CAN module connecting cable CAN module ...

Page 478: ...7 04 0000 00 ELECTRIC SYSTEM 2 Pin Arrangement of Diagnostic Connector It is installed under the instrument panel and consists of 16 pins The REKES key coding should be performed with Scan 100 3 Functions of Terminal ...

Page 479: ...01 33 ELECTRIC SYSTEM KYRON 2007 04 0000 00 4 ELECTRICAL WIRING DIAGRAMS ...

Page 480: ......

Page 481: ...grated Control System communicates with the transmitter remote controller and other electronic systems to transmit and receive the data The STICS also includes a diagnosis function that can inspect the error for related devices PAS Buzzer Door Lock Relay Door Lock Relay STICS 8710 01 STICS ...

Page 482: ...Performance 2 Characteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 483: ...02 5 STICS KYRON 2007 04 8710 01 Rated Load ...

Page 484: ...02 6 KYRON 2007 04 8710 01 STICS Input Signals ...

Page 485: ...n each function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time from...

Page 486: ......

Page 487: ...ansponder 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 encryptedcoding from the engine ECU Refer to the informationthat follows for specific functions and their descriptions 7010 06 IMMOBILIZER SYSTEM The immobilizer unit communicates with the enginecontrol unit to enable the engine starting Immobilize r...

Page 488: ...or unlock Briefly press If the unlock button on the remote control is pressed the door will be opened and the theft deterrent mode will be activated If the door coupled switch of front room lamp is pressed the lamp will come on for 30 seconds It will turn off immediately after the lock button of the remote control is pressed Panic function activated in the theft deterrent mode If you press and hol...

Page 489: ......

Page 490: ...TION WITH MEMORY OVERVIEW Functions of SPWM Adjusting the power seat s position with the seat adjusting switch Adjusting the angle of the outside rearview mirrors OSRVM Seat memory positions for 3 persons Folding Unfolding the outside rearview mirrors SPWM Location Bottom of diver s seat ...

Page 491: ...utside rearviewmirror Outside rearview mirror folding switch Seat memory switch RH outside rearviewmirror 1 SEAT POSITION WITH MEMORY COMPONENTS Front cushion motor sensor Seat adjusting switch Sliding motor sensor 1 2 3 Rear cushion motor sensor Reclining motor sensor SPWM Unit 4 5 6 ...

Page 492: ...Mirror Folding Unfolding Switch controlled by STICS 2 SEAT POSITION WITH MEMORY OPERATIONS 1 Outside Rearview Mirror Control Aiming Switch Select the driver side mirror L or pas senger side mirror R with the mirrorselection switch And then adjust theselected mirror up down left or rightby pressing the corresponding edgesof the switch to get the direct rearview 2 Seat Position Control ...

Page 493: ...can be recalled automatically by pressing the position button SET button Positionbuttons 1 2 3 Storing Memory Settings Position the transmission shift lever to P with the ignition switch ON for your safety do not start the engine Apply the parking brake if the vehicle is equipped with M T Adjust the driver s seat and outside rearview mirrors to the desired positions Press the SET button The indica...

Page 494: ...failed the buzzer sounds threetimes The position memory recall is canceled if operating the seat or the outside rearview mirrors during itsoperation In the vehicle equipped with automatic transmission the position memory recall is not available if the parkingbrake is released and the gear shift lever is not in P position In the vehicle equipped with manual transmission the position memory recall i...

Page 495: ...04 8 KYRON 2007 04 7410 13 SPWM 3 SEAT POSITION WITH MEMORY INPUT OUTPUT OF SPWM UNIT ...

Page 496: ...le when the vehicle speed is over 3 km h or the gear shift lever is not in P position with the parking brake released The memory set can be unlimitedly renewed The stored positions are erased when disconnecting the battery cables The buzzer sounds once if the memory set mode is activated The buzzer sounds twice if the memory setting recalling is completed The buzzer sounds three times if an error ...

Page 497: ...a position switch is pressed If any of the following conditions is met the memory recall function is deactivated When turning off the ignition switch When the gear shift lever is not in P position with the parking brake released When the parking brake is released only for the vehicle equipped with manual transmission When the vehicle speed is over 3 km h When pressing the STOP button during the me...

Page 498: ...ec to prevent the irruptive current frombeing overlapped The priorities are as follows Seat sliding Seatback reclining Seat cushion height adjusting front Seat cushion height adjusting rear Continuous motor driving timeSeat sliding 16 seconds Seatback reclining 50 seconds Cushion height adjusting 6 seconds Reverse controlWhen reversing the control motor the motor starts to rotate in the opposite d...

Page 499: ... operation stops However the seat can be adjusted by manual switches The memory recall operation can be activated after the failure is corrected This is determined when the systemdetects the value changes from the position sensor This is called the Release of automatic control stop Relay Protection Once the relay is turned on it will not be turned off within 60 ms Specifications Rated voltage DC 1...

Page 500: ...racteristics LOCK detection Timer monitors the motor driving time to detect LOCK condition Monitoring the memory recall time If the memory recall operation cannot be finished within 40 seconds after activating it the system stop themotor output and terminate the control Error Detection Even though the motor runs if the drive input change for 5 seconds from the position sensor doesn t change it isd...

Page 501: ...7 04 8010 01 8010 01 CLUSTER 1 DESCRIPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the data through CAN communication The HDC warning light and the engine hood open warning light are newly introduced ...

Page 502: ...05 4 KYRON 2007 04 8010 01 CLUSTER ...

Page 503: ......

Page 504: ...05 6 KYRON 2007 04 8010 01 CLUSTER 2 WARNING INDICATOR PANEL ...

Page 505: ...05 7 CLUSTER KYRON 2007 04 8010 01 ...

Page 506: ...05 8 KYRON 2007 04 8010 01 CLUSTER Main Connector Sub Connector 1 CLUSTER CONFIGURATION Front View Rear View ...

Page 507: ...ator 11 A T P Parking output 12 Air bag 13 Seat blet driver 14 High beam 15 RH indicator lamp 16 High beam 17 LH indicator lamp 18 Oil pressure 19 Parking brake signal input STICS 20 PIN NO Function 1 2 3 4P output 4 Buzzer output 5 Light 6 PGND signal 7 Engine check 8 Door open 9 10 Battery 11 Troubleshooting 12 Fuel input signal 13 RESET MODE switch 14 M T N Neutral input 15 M T P Parking input ...

Page 508: ...om 4 500 rpm Gasoline Engine 6 250rpm Connect the tachometer for tune up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds abnormal noise there could be defectivesin tachometer If there is a differ...

Page 509: ...pointer vibrates stands at a certain range or sounds abnormal noise there could be defectives in speedometer However these symptoms also could be appeared when the tire has uneven wear different tire inflation pressures or different tire specifications Perform the speedometer test regarding the tolerance as described However it is not similar simple work in fielddue to lack of measuring conditions...

Page 510: ...only when the fuel tank is removed The powersupply and resistance value should be measured at the connector in front of the fuel sender refer to wiring diagram When the power supply and output resistance are normal the float operation by fuel level may be defective if so replace the fuel sender Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value c...

Page 511: ... resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is outof specified range Resistance value by coolant temperature 20 C 2449W 5 50 C 826W 5 80 C 321W 5 100 C 12W 5 When the resistance value by coolant temperature is within the specified range check thermostat waterpump radiator related coolant circuit for normal operation Also che...

Page 512: ... 01 CLUSTER 5 TRIP ODOmeter TRIP A TRIP B and ODOmeter Odometer Trip Odometer When pressing the TRIP RESET switch on the cen ter panel the odometer trip odometer is convertedand the meter resets to 0 0 km in Trip A and Trip B ...

Page 513: ...el has two modes green function lamp and red warning lamp The HDCswitch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Initial ignition ON HDC system error occurs Brake system overheat Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above th...

Page 514: ...or over approximately 150 ms the ESP system will be cancelled and thevehicle will be driven regardless of the output values from the corresponding sensors Then the ESPwarning lamp on the instrument panel comes on The detailed operation procedures are as follows The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms The switch returns to normal position when the OFF switch...

Page 515: ...en the ESP OFF switch is pushed within 350 ms of being turned off the ESP warning lamp and ESP systemwill not be turned on 3 Resuming the ESP System by Using the ESP OFF Switch The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switchat the center switch panel is pushed for over approximately 150 ms while the ESP system is not operating The detail...

Page 516: ...erminesit as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms andthen goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESPunit resets the ESP OFF switch for approx 3 5 seconds ...

Page 517: ...Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compen sate the vehicle stability posture during ESP operation ...

Page 518: ...e or switch that detects the 1stgear position It detects only the forward reverse direction through the rear light switch and the neutral switch and cannot solely detect the 1st gear position The reason for noting the 1st gear above although the HDC alsooperates at over the 2nd gear is because the engine may be turned off during the HDC operation The HDC operates on the very steep road Thus it sho...

Page 519: ... of the ABS ESP installation This sensor is to signal the vehicle speed to the engine ECU TCCU transmission and instrument panel There isno separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication ...

Page 520: ...05 22 KYRON 2007 04 8010 01 CLUSTER 5 CLUSTER ELECTRICAL WIRING DIAGRAMS Gauge Speed RPM Fuel Temp Warning Lamp Fuel Fuel Filter ABS ESP Brake HDC 4WD EPB EAS TPMS ...

Page 521: ...05 23 CLUSTER KYRON 2007 04 8010 01 Warning Lamp EAS EPB Auto Park s TPMS Grobal Easy Load g TPMS Display ...

Page 522: ...r Combination Lamp Assembly Fog Lamp Assembly High beam and position lamp Low beam Turn signal lamp Fog lamp angle adjustment Fog lamp angle adjustment Stop Position lamp Turn signal lamp 8310 01 LAMP 1 LOCATIONS OF LAMPS AND SPECIFICATIONS 1 EXTERIOR LAMPS ...

Page 523: ...310 01 Side Repeater Assembly High Mounted Stop Lamp Assembly Reflector Assembly License Plate Assembly Tailgate Combination Lamp Assembly Tail lamp Backup lamp Rear fog lamp or stop lamp Rear fog lamp Regulation required only ...

Page 524: ...06 4 KYRON 2007 04 8310 01 LAMP BULB SPECIFICATIONS ...

Page 525: ......

Page 526: ... on and stays for 30 seconds When the door is closed the lamp will go off When this switch is pushed towards the tailgate the lamp comes on when the tailgate is open If the switch is pushed to the opposite direction the lamp will go off and will not come on even if the tailgate is open 2 INTERIOR LAMPS Toward tailgate Toward dirver side Center room lamp coupled operation with door Luggage room lam...

Page 527: ...e separately turned on when pressing the switch 1 2 However the front lamps are turned on when opening a door and turned off when closing it The front room lamps and center are turned on when pressing the room lamp main switch 3 Glove Box Door Courtesy Lamp 12V 5W One at glove box 12V 5W one at each door ...

Page 528: ... Lock Unlock with this switch unit The position memory is available for up to three drivers Each driver can set his her own driver s seat and outside rearview mirrors positions and it will be separately stored in the integrated computer If somebody has moved the seat the memory positions can be recalled automatically by pressing the position button When this button is pressed once HDC is ready for...

Page 529: ...ore than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer fluid will be sprayed onto the rear window glass once during rear wiper operation Auto Washer Switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid ...

Page 530: ...nit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity To control the system the sensed values of rain sensor and auto light sensor are sent to pin no 63 in STICS unit Rain sensor emitter lens Light receiving area of auto light sensor The wiper and washer system are controlled by STICS according to driver s wiper switch operation And the ...

Page 531: ...d reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone 3 Rear washer fluid supply system Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 532: ...s a shape of the inside of nozzle It is designed to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time Whirlwind Washer fluid outlet Passage Counter current Spray passage Washer fluid inlet It is designed to be changed spraying direction using the whirlwind and backflow generate...

Page 533: ...EM LAYOUT OF WIPER AND WASHER WITH RAIN SENSOR Rain Sensor Unit Multifunction Wiper and Washer Switch Front Nozzle Assembly Washer Reservoir Tank Assemblyt Rear Washer Nozzle and Check Valve Rear nozzle assembly Rear nozzle Check valve 1 2 3 ...

Page 534: ...prove the spraying performance Front Nozzle Assembly There is no separate washer reservoir tank for the rear washer fluid The rear washer system uses the front washer fluid reservoir Washer Reservoir Tank Assemblyt Rear Washer Nozzle and Check Valve STICS STICS receives the rain sensing datafrom the rain sensor and controls the wiper and washer systems Rear Washer Hose Mounting There is no separat...

Page 535: ...08 8 KYRON 2007 04 7810 01 WIPER 2 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 536: ...on 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch ...

Page 537: ...econds the operation in step 1 is performed 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced...

Page 538: ...d on with the ignition switch ON and the INT switch OFF the washer motor output is activated for 1 second If the system recognizes this output the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second Then the wiper relay output is deactivated after 3 cycles ...

Page 539: ...uring the auto washer operation the auto washer operation stops and the auto INT operation is activated 5 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer sw...

Page 540: ...08 13 WIPER KYRON 2007 04 7810 01 3 WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS ...

Page 541: ...fraindropsbyreceiving reflectedraysagainstsensingsection rainsensor mountingsectiononthewindshield with photodiode TheautolightsensorisIntegratedinto therainsensor refertothebelowpicture Multifunction wiper switch AUTO and sensitivity control AUTO Wiperoperatesautomaticallybyrainsensor FAST SLOW Autodelay Autospeedcontrol Apositionthatcancontrolsensitivityagainstrains onthewindshieldandtransmitswi...

Page 542: ...n sensor STICS Wiper relay LO Wiper relay HI Rear washer relay Front washer relay 1 Auto Light Sensor And Rain Sensor Coupled Control Rain detected headlamp Night detected wiping If it rains heavy which requires the highest INT speed the headlamps are turned on automatically When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatical...

Page 543: ...ardless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions while the ignition key is in ON position When the wiper switch is turned to ON position again from other positions the system Drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Ra...

Page 544: ...ng the washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation ...

Page 545: ...is in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position control the tail lamp and headlamp by communicating with ...

Page 546: ... is in ON position and the INT switch is in ON position The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN HIGH the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position The wiper mo...

Page 547: ...eceiving the malfunction signal 1 from the rain sensor while the ignition key is in ON position and the INT switch is in ON position The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal 2 from the rain sensor while the ignition key is in ON position and the INT switch is in ON position ...

Page 548: ...h requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level ...

Page 549: ...09 11 RAIN SENSOR KYRON 2007 04 8610 09 3 ELECTRICAL WIRING DIAGRAM ...

Page 550: ...ENT SPECIFICATIONS OVERVIEW AND OPERATION PROCESS 1 SYSTEM CONFIGURATION 2 ALARM INTERVAL AND TROUBLE SHOOTING 3 CAUTIONS ON PARKING AID SYSTEM 4 CIRCUIT DIAGRAM REMOVAL AND INSTALLATION 8790 03 PARKING AID SENSOR 8790 01 PARKING AID UNIT 8790 00 PAS PIEZOMETRIC BUZZER 3 4 5 7 8 9 12 13 ...

Page 551: ......

Page 552: ...ar selector lever is in R position The alarm interval becomes faster as the obstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit Detecting type Supersonic wave Detecting distance 25 cm 100 cm direct distance between sensor and obstacle 2 Parking Aid Sensor Detecting type Supersonic wave Piezometric ceramic element measuring time taken that t...

Page 553: ...nds the calculated value to the PAS unit which will warn a driver by controlling the activation of the Piezo buzzer in relation to the distance The PAS unit of KYRON from Mach 07 has been changed for its installed positions and shape due to the shape change of the rear bumper and also its internal elements have been changed due to the setting values of the PAS unit Parking Aid Unit PAS Sensor Comp...

Page 554: ...ear selector lever is in R position the sensor will be diagnosed once If normal the warning buzzer sounds only for 65 ms If found any failure due to open circuit to sensor or communication error the data in failed sensor is transmitted to notice its failure by buzzer sound If more than one sensor is defective warning buzzer sounds for 3 seconds ...

Page 555: ...10 6 KYRON 2007 04 8790 00 PAS When failed ...

Page 556: ...an the bumper Not defective but improperly working 2 When the sensing portion is frozen operates normally after thawed When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned When receiving other ultrasonic signals metal sound or air braking noises from heavy commercial vehicles When a high power radio is turned on Narrowed sensing area 3 When the sensin...

Page 557: ...ds operating signals to the buzzer not only for parking aid system but also for other warning functions such as ESP warning overspeed warning and insufficient fuel warning functions Warning functions which use the buzzer may vary depending on regions where vehicles are sold ...

Page 558: ...D UNIT OVERVIEW DVD Cassette player 10 speakers center speaker woofer speakers tweeter speakers AV head unit DVD Cassette Radio Cassette tape slot DVD title insert slot MUTE button Tuner DVD 6 DISC changer DSP amplifier Subwoofer 8930 14 AV ...

Page 559: ...11 4 KYRON 2007 04 8930 14 AV 1 AV SYSTEM CONFIGURATION AV System DVD Head Unit DVD Changer Audio System 6 Speakers ...

Page 560: ...11 5 AV KYRON 2007 04 8930 14 6 DISC changer TAPE RADIO CD RADIO DISC changer CD slot Tape ...

Page 561: ...er TV antenna AMP LH and RH The glass antennas at both rear quarter glasses are to receive TV and AM radio quarter RH glass signals and transmits each 2 channel video and audio signals to tuner Each AMP amplifies receives TV signals and then transmits to tuner It is installed in the center console Audio signal of DVD changer outputs to corresponding speakers through the cable Video signal is trans...

Page 562: ...11 7 AV KYRON 2007 04 8930 14 ...

Page 563: ...7 04 8930 14 AV 3 AV SYSTEM FUNCTIONS AV system head unit operates Radio TV Audio CD DVD and Video CD The touch screen type 6 5 TFT LCD monitor is installed on the system DVD slot Display when turning on the monitor ...

Page 564: ...11 9 AV KYRON 2007 04 8930 14 4 AV SYSTEM SPECIFICATIONS AND CONTROL ...

Page 565: ...11 10 KYRON 2007 04 8930 14 AV Function Settings on Touch Panel Example ...

Page 566: ...n Adjusting the sound according to the music genre Press EQ SETTING button in SET ADJ screen and adjust the sound To adjust the tone press TONE button The tone can be adjusted by BAS MID TRE bars on the screen BALANCE function and POSITION function cannot be used simultaneously DSP control EQ control BALANCE POSITION control Adjusting the sound according to the seated position Press BAL POS button...

Page 567: ...01 3 ION 4 SPEED KYRON 2007 04 3410 01 3410 01 ION 4 SPEED 1 SPECIFICATIONS ...

Page 568: ...01 4 KYRON 2007 04 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 569: ...e TCU utilizes throttle position rate of throttle opening engine speed vehicle speed transmission fluid temperature gear selector position and mode selector inputs and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects The output pressure of...

Page 570: ...01 6 KYRON 2007 04 3410 01 ION 4 SPEED 2 APPEARANCE 1 4WD Automatic Transmission 2 2WD Automatic Transmission Torque converter Oil cooler return Servo Inhibiter switch Adapter housing Oil cooler outlet ...

Page 571: ...01 7 ION 4 SPEED KYRON 2007 04 3410 01 3 SHIFT PATTERN DIAGRAM 1 Normal Mode WINTER mode has same shift pattern with NORMAL mode except 2nd gear drive off 2 Power Mode ...

Page 572: ...ugh the transmission in Neutral But the final drive is not locked by the parking pawl so thewheels are free to rotate D Overdrive range is used for all normal driving conditions 4th gear overdrive gear reduces the fuel consumption and the engine noise Engine braking is applied with reduced throttle First to second 1 2 first to third 1 3 second to third 2 3 second to fourth 2 4 third to fourth 3 4 ...

Page 573: ...fts will occur to give maximum performance and the POWER mode indicator light is switched ON When WINTER mode is selected starting in second gear is facilitated the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF 3 Indicator Light The indicator light is located on the instrument panel Auto shift indicator light comes ON when the ignition switch ON and ...

Page 574: ... electromagnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn ON and OFF the two regulator valves that control the shift feel The seventh solenoid is the proportional or Variable Pressure Solenoid VPS which works with the two regulator valves to control shift feel 1 Transmission Control Modul...

Page 575: ...djusts the variable pressure solenoid ramp pressure then executes the shift The TCU continuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends upon the failure detected with ...

Page 576: ...he output shaft speed signal to the Engine Control Module ECM The information is then transferred to the TCU via the CAN Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission This sensor is a typical Negative Temperature Coefficient NTC resistor with low temperatures producing a high re...

Page 577: ...01 13 ION 4 SPEED KYRON 2007 04 3410 01 ...

Page 578: ...ensor 10 White Temperature Sensor 4 Gear Position Sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case The gear position sensor is a multi function switch providing three functions Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is selected Indi...

Page 579: ...Battery Voltage Monitoring Input The battery voltage monitoring input is connected to the positive side of the battery This signal is taken from the main supply to the TCU If the battery voltage at the TCU falls below 11 3 V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may not occur because of the reduced...

Page 580: ...N S4 switches the front band regulator valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pressures S5 also provides the signal pressure for the converter clutch...

Page 581: ...01 17 ION 4 SPEED KYRON 2007 04 3410 01 Solenoid Operation during Gearshifts ...

Page 582: ...n gear state and engine speed S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures VPS pressure is multiplexed to the clutch regulator valve the band regulator valve and the converter clutch regulator valve during automatic gearshifts A variable pressure solenoid produces a hydraulic pressur...

Page 583: ...lectrically controlled for each gearshift Mode indicator light Depending on the application the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists The mode indicator light is usually located on the instrument cluster 9 Communication Systems 1 CAN The Controller Area Network CAN connects various control modules by using a twisted pair of ...

Page 584: ...and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to return to stand by pressure The primary regulator valve is l...

Page 585: ...01 21 ION 4 SPEED KYRON 2007 04 3410 01 1 Hydraulic Control Circuit ...

Page 586: ...into the PRND fluid circuits 1 2 shift valve The 1 2 shift valve is a two position valve that must be switched to the 2 3 and 4 position in order to get any forward gear other than first gear It is used for all 1 2 and 2 1 gearshifts The switching of this valve is achieved by using S1 and or S2 During a 1 2 gearshift drive oil from the manual valve passes through to the second gear circuit During ...

Page 587: ...1 which is located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve Exhausts the front band release B1R circuit thereby allowing the application of the front band B1 Connects the inner apply area of the front servo B1AI to the Band Apply Feed BAF circuit thus allowing greater apply forces to the front band Exhausts the Overrun Clutch OC circuit which allows the C4 clutch to...

Page 588: ...oid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids S1 to S7 Line pressure is used as the feeding oil to this regulator and the output is termed line 500 Line pressure control valve Line pressure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primary Regulator...

Page 589: ...re of 2 25 times the S5 signal pressure when S3 is ON When S3 is OFF the output pressure is 2 25 times the line 500 pressure Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio 1 4 1 valve It provides a regulated pressure to the front servo and controls the change rate of the front band B1 state to give the desired shift quality Second gear oil supplied to the valv...

Page 590: ...onditions are satisfied In P or N vehicle speed 3 km h In R vehicle speed 10 km h Engine speed 1600 rpm Throttle position 12 Under these conditions the TCU switches solenoids S1 and S2 to OFF The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston applying B2 ...

Page 591: ...cause all shifting pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slippage This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and S6 pressure Th...

Page 592: ...clutch The switching of this valve is governed by the signal pressure from S7 When the valve is in the OFF or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the ON or applied position regulated o...

Page 593: ... permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the needto force the oil back from the front servo through the valve body and through the 3 4 shift valve The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa ...

Page 594: ...e operation of the Power Train System is detailed below First gear is engaged by applying the C2 clutch and locking the 1 2 One Way Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3 4 OWC Reve...

Page 595: ...01 31 ION 4 SPEED KYRON 2007 04 3410 01 ...

Page 596: ...er and piston assembly en ables the torque converter to lock up under favorable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted slippage W...

Page 597: ... occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting Clutch packs Bands The transmission utilizes two bands the B1 band sometimes known as the 2 4 band and the B2 band sometimes known as the low reverse band The B1 band is a flexible band which is engag...

Page 598: ...tween the C4 and the C2 clutch assemblies This allows the C2 clutch to drive the forward sun gear in first second and third gears but unlocks in fourth gear and during overrun The B2 band is a solid band which is engaged by the rear servo piston B2 is activated in Park Reverse Neutral and Manual 1 When activated B2 prevents the planet carrier assembly from rotating In Manual 1 only the inner area ...

Page 599: ...wer Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a ret...

Page 600: ...01 36 KYRON 2007 04 3410 01 ION 4 SPEED 1 Park and Neutral ...

Page 601: ...2 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regulator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by the solenoi...

Page 602: ...01 38 KYRON 2007 04 3410 01 ION 4 SPEED 2 Reverse ...

Page 603: ...valve Reverse oil is routed from the manual valve to the C3 clutch Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value All other clutch and band apply circuits are open to exhaust The elements of the transmission function as follows The C3 clutch is engaged and drives the reverse sun gear in a clock wise direction T...

Page 604: ...01 40 KYRON 2007 04 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 605: ...the inner apply area of the rear servo piston for B2 band application In Manual 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The B2 band is engaged to hold the planetary gear carrier stationary The forward sun gear drives the short pinion anticlo...

Page 606: ...01 42 KYRON 2007 04 3410 01 ION 4 SPEED 4 Drive 1 ...

Page 607: ...h In Drive 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under reaction forc...

Page 608: ...01 44 KYRON 2007 04 3410 01 ION 4 SPEED 5 Drive 2 and Manual 2 ...

Page 609: ...ch In Drive 2 and Manual 2 transmission drive is via the input shaft and forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under re...

Page 610: ...01 46 KYRON 2007 04 3410 01 ION 4 SPEED 6 Drive 3 and Manual 3 ...

Page 611: ... sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed The C4 clutch is applied to bypass the 3 4 OWC and provide engine braking on overrun The outer apply area of the front servo The 1 2 shift valve to provid...

Page 612: ...01 48 KYRON 2007 04 3410 01 ION 4 SPEED ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 3 and Manual 3 x x x x ...

Page 613: ...01 49 ION 4 SPEED KYRON 2007 04 3410 01 7 Drive 3 Lock Up and Manual 3 Lock Up ...

Page 614: ... S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converter...

Page 615: ...01 51 ION 4 SPEED KYRON 2007 04 3410 01 8 Drive 4 Overdrive ...

Page 616: ...e reverse sun gear stationary As the planet carrier tuns the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i e in overdrive ratio The forward sun gear is also driven faster than the input shaft and overruns the 3 4 OWC The C2 clutch is en...

Page 617: ...01 53 ION 4 SPEED KYRON 2007 04 3410 01 ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 4 Overdrive x x x ...

Page 618: ...01 54 KYRON 2007 04 3410 01 ION 4 SPEED 9 Drive 4 Lock Up ...

Page 619: ... valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converter clutch control valve Converter ...

Page 620: ...h a step up ratio of 0 83 as an overdrive The selector lever is controlled by electronically and mechanically The gears are shifted by the corresponding combination of three hydraulically actuated multiple disc brakes three hydraulically actuated multiple disc clutches and two mechanical one way clutches This electronically controlled automatic transmission adjusts the operating pressure to provid...

Page 621: ...e the lock up function as shown in figure S mode is used in normal driving When W mode is selected the vehicle starts from 2nd gear forward and reverse to achieve smooth starting on the slippery road Selector Lever Downshift Manual Mode 1 2 3 4 D The shiftable gear is down by one step as the lever is moved to left direction Upshift Manual Mode 1 2 3 4 D The shiftable gear is up by one step as the ...

Page 622: ...02 6 KYRON 2007 04 3650 01 DC 5 SPEED 2 AUTOMATIC TRANSMISSION DC 5 SPEED APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View ...

Page 623: ... 1 Torque converter 2 Oil pump 3 Input shaft 4 Disc brake B1 5 Disc clutch C1 6 Disc clutch C2 7 Disc brake B3 8 Disc clutch C3 9 Disc brake B2 10 Output shaft 11 Parking lock gear 12 Intermediate shaft 13 Freewheel F2 14 Center planetary gear set 15 Electric control unit valve body 16 Freewheel F1 Front planetary gear set 17 Stator shaft 18 Converter lockup clutch ...

Page 624: ...02 8 KYRON 2007 04 3650 01 DC 5 SPEED Specifications ...

Page 625: ...02 9 DC 5 SPEED KYRON 2007 04 3650 01 ...

Page 626: ... when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Upshift Downshift Lockup slipping Unlock open FAST OFF Dynamic shift zone 4th gear 1 000 5th gear 0 833 Rev 1st gear 3 147 Rev 2nd gear 1 93 Dynamic shift zone When operating the accelerator pedal B the 4 3 shift is completed by kick down signal after completion of 4 3 shift 100 of pedal position When promptly ope...

Page 627: ... by kick down signal after completion of 4 3 shift 100 of pedal position When promptly operating the accelerator pedal C the 4 3 shift is done in shaded area 93 of pedal position FAST OFF When abruptly releasing the accelerator pedal the transmission remains at 4th gear other than 4 5 shift when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Upshift Downshift Lockup...

Page 628: ...02 12 KYRON 2007 04 3650 01 DC 5 SPEED General Characteristics ...

Page 629: ...02 13 DC 5 SPEED KYRON 2007 04 3650 01 Brake B1 disk assembly Brake B3 disk assembly Brake B2 disk assembly C1 Disk clutch assembly C2 Disk clutch assembly C3 Disk clutch assembly 1 POWER FLOW ...

Page 630: ...02 14 KYRON 2007 04 3650 01 DC 5 SPEED Shifting Elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 631: ...lanetary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front sun gear Locked by F1 and B1 Planetary gear carrier Rotation with reduced speed Rear ring gear clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Clockwise rotation with reduced speed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with red...

Page 632: ...tary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Sun gear and planetary gear carrier Clockwise rotation by C1 activation Rear ring gear Clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Rotation with reduced speed Center ring gear Clockwise rotation Sun gear Locked by B2 Planetary gear carrier Rotation with reduced speed O...

Page 633: ...Rear planetary gear set L Stator M Center planetary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Center ring gear Clockwise rotation by clutch 2 activation direct connection Center sun gear Locked by B2 Planetary gear carrier Clockwise rotation with reduced speed Output shaft Clockwise rotation 1 2 3 4 5 ...

Page 634: ...wise rotation Center ring gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center sun gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring ge...

Page 635: ...t sun gear Locked by B1 Planetary gear carrier Rotation with reduced speed Rear planetary gear ring gear Clockwise rotation with reduced speed Center ring gear and rear planetary gear carrier Clockwise rotation by clutch C2 activation Rear sun gear Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear increased speed Center sun gear Clockwise rotation with incre...

Page 636: ...l V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locked by B3 Cent...

Page 637: ...r T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Front ring gear Clockwise rotation Front planetary gear carrier Clockwise rotation by clutch C1 activation direct connection Rear ring gear Clockwise rotation Rear planetary gear carrier and center ring gear Locked by brake B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center planetary gear...

Page 638: ... when driving on bumpy road during engine braking Gear shifting with the tip switches is only possible when the selector lever is in the M position For safety reason it is possible to move the selector lever from the N P or R position to any other positions only when the ignition key is in the ON position and the brake pedal is depressed N P and R lock functions The TGS lever of KYRON from March 0...

Page 639: ... the vehicle speed and the brake operation for P R and N lock functions and turns on the backup lamp when reversing with the lever in R position Also it detects signals from the tip switches on the lever knob and the steering wheel and sends them to TCU to shift into a gear driver wants ...

Page 640: ...04 3 T M LEVER KYRON 2007 04 3170 01 3170 01 T M LEVER 1 CIRCUIT OF ION 4 SPEED AUTOMATIC T M ...

Page 641: ...04 4 KYRON 2007 04 3170 01 T M LEVER 2 CIRCUIT OF SHIFT INTER LOCK ...

Page 642: ...echanism is used to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 3 4 The clutch release system is available to use CSC Concentric Slave Cylinder or Fork type according to the vehicle model 5 TSM54...

Page 643: ...05 4 KYRON 2007 04 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications 2 Tightening Torque ...

Page 644: ...05 5 M T KYRON 2007 04 3170 01 Inside N Switch 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch ...

Page 645: ...ion The gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm increase When the...

Page 646: ...iver must operate the HDC only in the 1st gear when driving a vehicle with the manual transmission When not depressing the accelerator pedal or brake pedal The vehicle speed is above 7 km h based on the automatic transmission 4H drive mode The ESP s vehicle position control function and HBA function are not in operation and and and The HDC is added to aid drivers when driving down the hill but whe...

Page 647: ...te sensor for the input signal and detects the inclination of hills by using the G sensor acceleration sensor in the sensor cluster HDC Switch When you see a steep downhill ahead press the HDC switch and the green HDC indicator comes on When the G sensor within the sensor cluster detects a inclination exceeding 10 the ESP s HDC function operates When this occurs the green HDC indicator goes off al...

Page 648: ... operates the green HDC indictor blinks with 0 5 seconds of interval Red Letters HDC Green Letters HDC The G sensor within the sensor cluster measures the actual road inclination However it may recognize a sharp turn or rough road as a downhill with a inclination exceeding 10 and the HDC may operate For the specific information please refer to the ABS ESP section ...

Page 649: ... to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Variant Coding Options ...

Page 650: ......

Page 651: ...06 3 CLUTCH KYRON 2007 04 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTTENING TORQUE ...

Page 652: ... steel cover which is bolted to the flywheel The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clut...

Page 653: ...06 5 CLUTCH KYRON 2007 04 3010 01 3 Functions Components of Clutch Assembly Adapter Pipe Assembly Clutch Assembly Concentric Slave Cylinder ...

Page 654: ...06 6 KYRON 2007 04 3010 01 CLUTCH Cross Sectional View of Clutch Assembly 1 Transmission housing 2 Clutch disc assembly 3 Clutch disc cover assembly 4 Bolt 5 Washer 6 Bolt ...

Page 655: ...07 3 AXLE KYRON 2007 04 4120 01 1 AXLE SPECIFICATIONS Specification Torque Gear ratio Type Size Offset Housing Specification Capacity Length Width Weight ...

Page 656: ...tion to existing 5 link suspension the IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle The below figures for rear axle show the rear axle with the independent type suspension 4WD A T Front Axle Rear Axle IRDA Independent Rear Drive Axle ...

Page 657: ...W The 2007 Kyron is equipped with different types of front and rear axles As the IOP axle is installed AWD All Wheel Driver transfer case and the switchable engine mount are installed This vehicle is equipped with front IOP axle system and IRDA with new technology ...

Page 658: ...e vibration is reduced There is not much different in the rear axle system However as EAS and EPB with new technology are adopted suspension specification and rear axle module have been changed IOP axle Front Axle Conventional axle Non IOP axle 5 link type rear axle semi floating type integrated type Independent suspension type rear axle IRDA Rear Axle ...

Page 659: ...ions Before performing the wheel alignment unload all the items from the vehicle When setting the wheel alignment tools the above adjustment values should be followed The difference of the front camber and the caster at both ends should be below 30 0 5 1 2 3 ...

Page 660: ...entional part time transfer case but the changes in comparison to the conventional transfer case are as follows No additional coding is required when replacing TCCU Delete the devices tone wheel speed sensor wiring etc related to the speed sensor in the transfer case This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 through the CAN communicatio...

Page 661: ...09 4 KYRON 2007 04 3240 01 T C 1 STRUCTURE Rear propeller shaft Part time transfer case Rear axle IRS type Transmission Front propeller shaft Front locking hub system IWE Front axle ...

Page 662: ...fer case main connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper Shift motor connector ...

Page 663: ...CTIONS 1 System Layout Indicators T C control indicator lamp T C control switch HECU Wheelspeedsignal TCCU CAN Communication Vacuum line Front output shaft Transfer case Magnetic clutch Motor Output Solenoid valve Atmo sphere FL Locking hub FR Locking hub ...

Page 664: ... and its components also have changed The vacuum locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Operating Process Vacuum gen...

Page 665: ...end hub gear In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released from the hub...

Page 666: ...40 01 4 POWER FLOW 1 POWER FLOW Switch Transfer 2H 4H 4L TCCU Locking Hub Solenoid Locking Hub Operation Internal vacuum released Front Propeller Shaft Transfer Rear Propeller Shaft Front Axle Front Wheel Rear Wheel Front Axle ...

Page 667: ...09 10 KYRON 2007 04 3240 01 T C 2 2H MODE 2WD Power Flow Transmission Output Shaft Transfer Case Input Shaft Output Shaft Rear Propeller Shaft Rear Wheel Rear Axle Rear Wheel ...

Page 668: ...E 4WD HIGH SPEED Power Flow Transmission Input Shaft TCCU Motor Shift Cam Rail Fork Magnetic Clutch T C Output Shaft Rear Propeller Shaft Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive 4WD HI ...

Page 669: ... LOW SPEED Power Flow Transmission Input Shaft TCCU Motor Shift Cam Rail Fork Planetary Gear Output Shaft Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Front Wheel Drive 4WD LO Rear Propeller Shaft Magnetic Clutch ...

Page 670: ... 3310 06 PROPELLER SHAFT GENERAL 1 SPECIFICATION OVERVIEW AND OPERATION PROCESS 1 OVERVIEW 2 COMPONENT LOCATOR 3310 01 FRONT PROPELLER SHAFT 3310 06 REAR PROPELLER SHAFT 3310 00 DISASSEMBLY AND REASSEMBLY PROPELLER SHAFT 3 4 5 7 9 11 ...

Page 671: ......

Page 672: ...10 3 PROPELLER SHAFT KYRON 2007 04 3310 00 3310 00 PROPELLER SHAFT 1 SPECIFICATION ...

Page 673: ... is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vib...

Page 674: ...1 Cross Sectional View 1 Flange yoke 2 Journal bearing cap 3 Spider journal 4 Slip yoke assembly 5 Grease nipple 6 Dust cap 7 Oil seal 8 Split washer 9 Slip tube shaft 10 Tube 11 Tube yoke 12 Flange yoke 13 Center bearing Front propeller shaft Rear Propeller Shaft ...

Page 675: ...10 6 KYRON 2007 04 3310 00 PROPELLER SHAFT 2 Propeller Shaft Assemble 1 Propeller shaft 2 Joint propeller front 3 Joint propeller rear 4 Yoke front 5 Yoke rear ...

Page 676: ...Manual Transmission Automatic Transmission For Gasoline Engine Remove the flange yoke mounting bolt on the transfer case side of the front propeller shaft 1 Put installation marks on the yoke to the propeller and the flange to the transfer case ...

Page 677: ...ELLER SHAFT Remove the flange yoke mounting bolt and nut on the front axle side of the front propeller shaft 2 Put installation marks on the yoke to the propeller and the flange to the transfer case Remove the front propeller shaft 3 ...

Page 678: ...AFT KYRON 2007 04 3310 06 Remove the yoke mounting bolt and nut on the transfer case side of the rear propeller shaft 1 Put installation marks on the yoke of the rear propeller shaft and the flange of the transfer case ...

Page 679: ...07 04 3310 06 PROPELLER SHAFT Remove the intermediate bearing center bolts 2 Remove the yoke and flage mounting bolts and nuts on the rear axle side of the rear propeller shaft Then remove the rear propeller shaft 3 ...

Page 680: ... alignment on the spiders before removing 1 2 Remove the snap ring with snap ring pliers 3 Tap the yoke shoulder on shaft with copper hammer to remove the roller bearing Remove the other bearings with same manner 4 If it cannot be removed hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer 5 ...

Page 681: ...0 PROPELLER SHAFT Disassemble the universal joint The universal joint compensates the angle changes due to vertical movement of the axle shaft 6 Remove the intermediate bearing bracket and remove the bearing with special tool 7 ...

Page 682: ...of the specified range correct it with press or replace it with new one 4 Starting torque of universal joint 5 Specified value 17 893 mm Limit 17 910 mm Specified value 0 03 0 098 mm Limit 0 25 mm Limit 0 4 mm Specified value 3 8 kg cm Major causes of vibration 6 Balance weights missing Excessive run out of propeller shaf When using the general bolts Excessive wear of universal joint Stuck in slee...

Page 683: ...ssemble the needle roller 2 Install the yoke bearing shaft on the shaft and insert the spider Place the cap on the opposite side and tap it with plastic hammer to seat it Adjust the clearance of spider below 0 1 mm and install the snap ring 3 Install the intermediate bearing to the rear propeller shaft Apply the grease on the propeller shaft and install it 4 5 Clean the components and replace if d...

Page 684: ...11 3 SUSPENSION KYRON 2007 04 4411 01 1 FRONT SUSPENSION SPECIFICATIONS 2 REAR SUSPENSION SPECIFICATIONS 4411 01 SUSPENSION ...

Page 685: ...ernal Cylinders ABS ESP 5Link Suspension solid type disc ABS ESP Independent suspension ventilated disc 2 REAR BRAKE Rear Disc and Caliper 1 Internal Cylinder For the rear brake system specifications differ between ABS ESP system equipped vehicles and non ABS ESP system equipped vehicles The drum type brake is installed on non ABS equipped vehicles When ABS ESP is installed on the 5 link type susp...

Page 686: ...e parking brake is installed on vehicles with the manual transmission and the foot operated type parking brake is installed on vehicles with the automatic transmission Hand Operated Type Vehicle with Manual Transmission Foot Operated Type Vehicle with Automatic Transmission ...

Page 687: ...12 5 ESP KYRON 2007 04 4890 01 3 SECTIONAL DRAWING Front Disc Brake Rear Disc Brake ...

Page 688: ... the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication Location of the wheel speed sensor rear right wheel Location of the Sensor Connector Connector Appearance Invehicl...

Page 689: ...12 7 ESP KYRON 2007 04 4890 01 2 BRAKE SYSTEM SPECIFICATIONS ...

Page 690: ...t imply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disk and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is in com...

Page 691: ...ive on rough roads the HDC may suddenly operate for these sudden shocks influence the G sensor values When such occurs the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle 3 During the HDC operation a loud noise and the vehicle vibration may occur from the HECU and the brake system but this is a normal condition during th...

Page 692: ... in HDC operation The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the ...

Page 693: ...by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 about 5 71 degree ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Brake Force Distri...

Page 694: ...rance of wheel speed sensor Location Layout of relevant components ESP HECU ActiveWheelSpeedSensor HDC Switch The transfer case T C installed on this vehicle doesn t have the internal speed sensing device and receives the speed signal for T C control from ESP HECU via CAN bus With speed sensor Conventional T C ...

Page 695: ...12 13 ESP KYRON 2007 04 4890 01 New T C Without speed sensor ...

Page 696: ...ding on the vacuum condition within the actuator Thus the wheel speed sensor is installed on the front wheel end area It is installed inside the backing plate to be protected from heat and foreign materials Therefore the front wheel end system including disc should be removed before removing the front wheel speed sensor Front Wheel Speed Sensor 4WD Rear Wheel Speed Sensor IRS Type Backing plate Wh...

Page 697: ... and foreign materials from entering the IWE system In addition when installing the hub actuator of the IWE system you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed Please refer to the part time transfer case section for more specific information Rubber O ring Rubber seal ring Internal steel spring included ...

Page 698: ...c Control Unit and wheel speed sensor used in the ABS system The devices are as follows 2 pressure sensors installed on the master cylinder Sensor cluster integrated yaw rate sensor and lateral sensor and longitudinal sensor installed in IP SWAS Steering Wheel Angle Sensor installed in the steering column 1 2 3 Comparison with ABS System ...

Page 699: ......

Page 700: ...steering during cornering The yaw rate sensor lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the spin present at any wheels during over steering under steering or cornering The ESP ECU controls against over steering or under steering during cornering by controlling the vehicle stability using the input values from t...

Page 701: ...due to rear wheel moment when the rear tires lose traction and the vehicle speed increases ESP controls during under steering ESP controls during oversteering The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeering with the yaw rate sensor and the lateral se...

Page 702: ...perate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 degree seconds the ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function When various systems operate simultaneously under a certain situation there may be vehicle control problems due to internal mal...

Page 703: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 704: ...g is required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the ...

Page 705: ... that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions 1 Pressure over 20 bar 2 Pressure changes ...

Page 706: ...software is added to the existing ESP system and no additional device or switch is needed One must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s ...

Page 707: ...ut signals from wheel speed sensor steering angle sensor and lateral sensor During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane ...

Page 708: ...1G on steep roads slope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation The G sensor in sensor cluster measures the actual road steepness However it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10 and the HDC may op...

Page 709: ......

Page 710: ...eutral switch and cannot solely detect the 1st gear position The reason for noting the 1st gear above though the HDC also operates in 2nd gear position is because the engine may turn off during the HDC operation process You may face a very dangerous situation if the engine turns off at a steep hill The HDC is the device to improve the engine brake effect during downhill driving on a steep hill For...

Page 711: ...et speed in 4L mode Forward and reverse driving 3 km h 5 Vehicle position control function in ESP and HBA function are not in operation and The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden 6 Slope level exceeds 10 When the slope level exceeds 10 the HDC operates until the vehicle reaches...

Page 712: ...d on the operating numbers and conditions of HDC The red HDC warning lamp blinks when the internal temperature goes over 350 C When it reaches 450 C the HDC warning lamp comes on The HDC can be operated in the range even where the HDC warning lamp blinks 6 When the slope level is below 10 When the slope level exceeds 10 the HDC operates until the vehicle reaches the speed condition given in step 4...

Page 713: ...12 31 ESP KYRON 2007 04 4890 01 4 Input Output Signals for HDC Operation ...

Page 714: ...has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON HDC system erro...

Page 715: ......

Page 716: ...890 01 ESP 6 ESP COMPONENTS AND LOCATIONS Master cylinder pressure sensor Steering wheel angle sensor Sensor cluster Yaw rate lateral sensor longitudinal sensor HECU Valve body and ECU integrated type Valve body Motor pump ...

Page 717: ...12 35 ESP KYRON 2007 04 4890 01 Comparison with ABS System ABS ESP Indicator ESP OFF Switch HDC Indicator HDC Switch ActiveWheelSpeedSensor ...

Page 718: ...12 36 KYRON 2007 04 4890 01 ESP 7 INPUT OUTPUT SIGNALS FOR HDC OPERATION Input Output of ESP System ...

Page 719: ...12 37 ESP KYRON 2007 04 4890 01 8 ESP HYDRAULIC CIRCUIT DIAGRAM ...

Page 720: ...stem is operating the normally open separation valve will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve Then the inlet and outlet valves will be closed or open depending on the braking pressure increase decrease or unchanged conditions For details refer to Hydraulic Pressure for each ESP Operating Range ESP Hydraulic unit in idling and...

Page 721: ...eels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel ge...

Page 722: ...ing depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the w...

Page 723: ...earance of wheel speed sensor Location Layout of relevant components ABS HECU Active Wheel Speed Sensor for 4WD The transfer case T C installed on this vehicle doesn t have the internal speed sensing device and receives the speed signal for T C control from ABS HECU Conventional Transfer Case With Speed Sensor ...

Page 724: ...12 42 KYRON 2007 04 4890 01 ESP New Transfer Case Without Speed Sensor ...

Page 725: ...ks the 4WD depending on the vacuum condition within the actuator Thus the wheel speed sensor is installed on the front wheel end area It is installed inside the backing plate to be protected from heat and foreign materials Therefore the front wheel end system including disc should be removed before removing the front wheel speed sensor Front Wheel Speed Sensor Rear Wheel Speed Sensor Backing Plate...

Page 726: ... and foreign materials from entering the IWE system In addition when installing the hub actuator of the IWE system you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed Please refer to the part time transfer case section for more specific information Rubber O ring Rubber seal ring Internal steel spring included ...

Page 727: ...4 4890 01 12 CONFIGURATION OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor ...

Page 728: ...12 46 KYRON 2007 04 4890 01 ESP 13 INPUT AND OUTPUT DIAGRAM OF ABS Input Output of ABS without TPMS ...

Page 729: ...ront wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 730: ...et valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually No Hydraulic Pressure Circuit when ABS is Operating As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases...

Page 731: ... again The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber ci...

Page 732: ...valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydraulic pressure ...

Page 733: ...mbly 4 Tie rod end 2 Power steering return pipe 5 Power steering gear box pipe 3 Power steering high pressure hose and pipe 6 Power steering gear box assembly 1 POWER STEERING SYSTEM LAYOUT Feed pipe nut Steering gear box mounting bracket bolts 14 mm 2EA 30 40 Nm ...

Page 734: ...13 5 STEERING KYRON 2007 04 4610 00 With SSPS 1 Power steering gear box 3 Power steering high pressure hose and pipe 2 Gear box pipe 4 Return hose and pipe SSPS Solenoid Valve cannot be replaced ...

Page 735: ...13 6 KYRON 2007 04 4610 00 STEERING Installation Drawing of SSPS Pipe bracket bolt 10 mm Pipe mounting nut Pipe bracket bolt 10 mm Gear box mounting bolt ...

Page 736: ...13 7 STEERING KYRON 2007 04 4610 00 Components Tie rod end Steering gear box Lower shaft Steering wheel Column shaft ...

Page 737: ...13 8 KYRON 2007 04 4610 00 STEERING Steering wheel Column shaft Lower shaft Steering gear box ...

Page 738: ...he vehicle speed which is called Speed Sensitive Power Steering SSPS SSPS by providing appropriate steerability to a driver according to the changes of vehicle speed gives steering stability The power steering control unit adjusts the hydraulic pressure to reaction plunger by controlling the pressure solenoid valve located in the gear box to optimize the steerability In other words the steering wh...

Page 739: ...pressure supplied to reaction device by moving the spool valve according to the changes of solenoid valve Reaction device This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from SSPS control unit ...

Page 740: ...d In other words the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve spool position that is linked with solenoid valve according to the amount of electric current The changes of hydraulic pressure applied to input shaft according to the pressure changes applied to the reaction plunger provide proper steerability based on the amount of electric curre...

Page 741: ...cut off and the manipulation of steering wheel becomes lighter 1 2 3 4 In medium and high speed driving The shaft operating force of solenoid rod is reduced due to the reduction of output current from the SSPS control unit The coil spring pulls the PCV spool toward solenoid valve to open it The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to...

Page 742: ...icle speed and the throttle position data via CAN communication The SSPS control unit controls the working current for the solenoid valve with PWM type duty ratio of 333 Hz frequency and sets the target current to 1A during 1 second after the ignition is ON When a trouble occurs in the system the SSPS control unit generates a trouble code using fail safe function 1 2 3 SSPS unit ...

Page 743: ...13 14 KYRON 2007 04 4610 00 STEERING 3 CIRCUIT DIAGRAM ...

Page 744: ...ovides heavy steerability with low current as the vehicle speed increases Also it provides light steerability with high current as the vehicle speed decreases During parking and low speed driving During parking and driving in low speed the control unit supplies approx 1 A of electric current to solenoid valve Then the spool located in PCV compresses the upper spring and elevates upward and the wor...

Page 745: ...s weak electric current to solenoid valve Then the spool located PCV moves from top to bottom and the working pressure A port from oil pump is applied to reaction plunger C port through B port As a result the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier ...

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