SSANGYONG KYRON 2008.07 Manual Download Page 1

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GENERAL INFORMATION

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GENERAL INFORMATION

GENERAL INFORMATION

1. HOW TO READ ELECTRICAL WIRING
DIAGRAM...............................................
2. 2. LAYOUT OF ELECTRICAL SYSTEM.

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Summary of Contents for KYRON 2008.07

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

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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...

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Page 7: ...CONNECTOR GROUND 8201 00 8210 00 8210 02 8210 03 8210 09 8210 10 8210 06 8210 07 8210 08 CONNECTOR GROUND WIRING HARNESS 0000 00 WIRING HARNESS COMPONENTS LOCATION 3 ...

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Page 9: ...0 3 CONNECTOR GROUND KYRON 2008 07 0000 00 WIRING HARNESS 0000 00 WIRING HARNESS COMPONENTS LOCATION 1 WIRING HARNESS 2 COMPONENTS LOCATION ...

Page 10: ...0 4 KYRON 2008 07 0000 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 11: ...0 5 CONNECTOR GROUND KYRON 2008 07 0000 00 GROUND SPLICE PACK 4 SPLICE PACK CIRCUIT S101 S201 S202 CAN ...

Page 12: ...0 6 KYRON 2008 07 0000 00 CONNECTOR GROUND S203 GND S204 ILL S205 GND S301 CAN S302 S206 ...

Page 13: ...0 7 CONNECTOR GROUND KYRON 2008 07 0000 00 WIRNING CONNECTOR MODE CONNECTOR 5 CONNECTOR WIRNING CONNECTOR WIRNING CONNECTOR ...

Page 14: ...0 8 KYRON 2008 07 0000 00 CONNECTOR GROUND UNIT CONNECTOR SENSOR CONNECTOR LAMP CONNECTOR SWITCH CONNECTOR ...

Page 15: ...0 9 CONNECTOR GROUND KYRON 2008 07 0000 00 ETC ...

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Page 17: ...10 00 ENGINE ROOM FUSE RELAY BOX 8410 00 I P LH FUSE RELAY BOX 8401 00 I P RH FUSE RELAY BOX ELECTRICITY DIVIDE 8210 00 ENGINE ROOM FUSE RELAY BOX CIRCUIT 8410 00 I P LH FUSE RELAY BOX CIRCUIT 8410 00 I P RH FUSE RELAY BOX CIRCUIT 8410 00 ICM RELAY BOX CIRCUIT 3 5 6 7 12 16 18 ...

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Page 19: ...0 3 POWER DISTRIBUTION KYRON 2008 07 8210 00 FUSE RELAY 8210 00 ENGINE ROOM FUSE RELAY BOX 1 UPPER 2 LOW 3 ENGINE ROOM FUSE RELAY BOX 4 ENGINE ROOM FUSE RELAY BOX RUSSIA ...

Page 20: ...0 4 KYRON 2008 07 8210 00 POWER DISTRIBUTION 5 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 6 ENGINE ROOM FUSE BOX CONNECTOR NUMBER ...

Page 21: ...0 5 POWER DISTRIBUTION KYRON 2008 07 8410 00 8410 00 I P LH FUSE RELAY BOX 1 I P LH FUSE RELAY BOX 2 POWER SUPPLY ...

Page 22: ...0 6 KYRON 2008 07 8410 00 POWER DISTRIBUTION 8410 00 I P RH FUSE RELAY BOX 1 I P RH FUSE RELAY BOX ...

Page 23: ...0 7 POWER DISTRIBUTION KYRON 2008 07 8210 00 ELECTRICITY DIVIDE 8210 00 ENGINE ROOM FUSE RELAY BOX CIRCUIT 1 SB5 SB6 Ef4 Ef5 Ef11 HORN RELAY HEAD LAMP RELAY HI LO 2 SB2 SB4 SB7 SB9 Ef3 P WINDOW RELAY ...

Page 24: ...0 8 KYRON 2008 07 8210 00 POWER DISTRIBUTION 3 SB10 SB11 CONDENSOR FAN RELAY HI LO 4 SB12 SB16 START RELAY PTC RELAY ...

Page 25: ...0 9 POWER DISTRIBUTION KYRON 2008 07 8210 00 5 Ef1 Ef2 Ef6 Ef7 6 Ef8 Ef10 TAIL LAMP RELAY FRT FOG LAMP RELAY ...

Page 26: ...0 10 KYRON 2008 07 8210 00 POWER DISTRIBUTION 7 Ef12 Ef14 ENG MOUNT RELAY COMPRESSOR RELAY 8 Ef15 Ef23 ...

Page 27: ...0 11 POWER DISTRIBUTION KYRON 2008 07 8210 00 9 WIPER MOTOR RELAY HI LO WASHER RELAY FRT RR ...

Page 28: ...0 12 KYRON 2008 07 8410 00 POWER DISTRIBUTION 8410 00 I P LH FUSE RELAY BOX CIRCUIT 2 F29 F34 1 F24 F28 ...

Page 29: ...0 13 POWER DISTRIBUTION KYRON 2008 07 8410 00 3 F35 F40 RR WIPER RELAY 4 F41 F48 ...

Page 30: ...0 14 KYRON 2008 07 8410 00 POWER DISTRIBUTION 5 F49 F51 RR FOG LAMP RELAY 6 F52 F55 BURGLAR HORN RELAY RR SEAT WARMER RELAY ...

Page 31: ...0 15 POWER DISTRIBUTION KYRON 2008 07 8410 00 7 F56 F57 HDC RELAY FLASHER UNIT ...

Page 32: ...0 16 KYRON 2008 07 8410 00 POWER DISTRIBUTION 8410 00 I P RH FUSE RELAY BOX CIRCUIT 1 F58 F64 ENG MAIN RELAY 2 F65 F71 SHIFT RELAY 4 A T ...

Page 33: ...0 17 POWER DISTRIBUTION KYRON 2008 07 8410 00 4 FOLD G RELAY UNFOLD G RELAY 3 BLOWER RELAY INJECTOR RELAY SNR RELAY ...

Page 34: ...0 18 KYRON 2008 07 84100 00 POWER DISTRIBUTION 8410 00 ICM RELAY BOX CIRCUIT 1 DEICER RELAY DR LOCK UNLOCK RELAY 2 HAZARD RELAY DRL SIGNAL ...

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Page 36: ...ROOM MIRROR CIRCUIT 8910 00AUDIO CLOCK CIRCUIT 8930 00A V SYSTEM 8790 00PARKING AID CIRCUIT 6810 00PTC HEATER POSITIVE TEMPERATURE COEFFICIENT 6910 00FFH FUEL FIRED HEATER 6810 00FATC FULL AUTO TEMP CONTROL CIRCUIT 6810 00AIR CON MANUAL CIRCUIT 8810 00 AIR BAG CURTAIN AIR BAG 8010 00 CLUSTER 7410 00 POWER SEAT DRIVER W MEMORY 7410 00 POWER SEAT DRIVER W O MEMORY 7410 00 POWER SEAT PASSENGER 8510 0...

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Page 38: ...0 3 CIRCUIT KYRON 2008 07 1461 00 1461 00 STARTING CHARGING 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 5 AT M T 1 ...

Page 39: ...0 4 KYRON 2008 07 1461 00 CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 6 A T 4 A T 2 ...

Page 40: ...0 5 CIRCUIT KYRON 2008 07 2820 00 2820 00 PREHEATING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 41: ...1 00 ECU ENGINE CONTRIV 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ECU ENGINE CONTROL UNIT D20 D27DT EU IV ENG MAIN RELAY INTAKE THROTTLE A CRUISE SW VALVE EGR WASTE GATE INLET METERING SENSOR HFM PEDAL ...

Page 42: ...IT KYRON 2008 07 1491 00 2 SENSOR FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT KNOCK FUEL TEMP FUEL FILTER WARNING PTC RELAY 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 43: ...TION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION INJECTOR STOP LAMP IMMOBILIZER CLUSTER PREHEATING UNIT SENSOR EXHAUST GAS TEMP TRIPPLE PRESSURE SW INJECTOR STOP LAMP IMMOBILIZER CLUSTER PREHEATING UNIT SENSOR EXHAUST GAS TEMP TRIPPLE PRESSURE SW ...

Page 44: ...N 2008 07 1491 00 1491 00 ECU ENGINE CONTROL UNIT D20 D27DT 1 1 CONNECTOR INFORMATION ENG MAIN RELAY PEDAL SENSOR HFM SENSOR VALVE CRUISE CONTROL SW ENG MOUNT RELAY 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 45: ...1491 00 CIRCUIT 2 FUEL FILTER WARNING LAMP IMMOBILIZER SENSOR FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT KNOCK COOLANT TEMP FUEL TEMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 46: ...0 11 CIRCUIT KYRON 2008 07 1491 00 3 INJECTOR CAN LINE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 47: ...0 12 KYRON 2008 07 1490 00 CIRCUIT 1490 00 ECU ENGINE CONTROL UNIT GSL G32 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION IGN COIL INJECTOR PEDAL MODULE THROTTLE SENSOR ...

Page 48: ...0 13 CIRCUIT KYRON 2008 07 1490 00 2 O SENSOR CPS KNOCK SENSOR HFM SENSOR CANISTER PURGE VALVE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 49: ...0 14 KYRON 2008 07 1490 00 CIRCUIT 3 S AIR PUMP STOP LAMP CRUISE CONTROL SW FUEL PUMP IMMOBILIZER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 50: ...0 15 CIRCUIT KYRON 2008 07 1490 00 1490 00 ECU ENGINE CONTROL UNIT GSL G23 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION IGN COIL INJECTOR PEDAL MODULE THROTTLE SENSOR ...

Page 51: ...0 16 KYRON 2008 07 1490 00 CIRCUIT 2 O SENSOR CPS KNOCK SENSOR MAP SENSOR CANISTER PURGE VALVE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 52: ...0 17 CIRCUIT KYRON 2008 07 1490 00 3 STOP LAMP CRUISE CONTROL SW FUEL PUMP IMMOBILIZER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 53: ...0 18 KYRON 2008 07 8210 00 CIRCUIT 8210 00 DIAGNOSIS CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 54: ...0 19 CIRCUIT KYRON 2008 07 3110 00 3110 00 TCU 6 A T 1 START MOTOR TGS LEVER INHIBITOR SW 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 55: ...0 20 KYRON 2008 07 3110 00 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 56: ...0 21 CIRCUIT KYRON 2008 07 3110 00 3110 00 TCU 5 A T 1 START MOTOR TGS LEVER CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 57: ...0 22 KYRON 2008 07 3110 00 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 58: ...0 23 CIRCUIT KYRON 2008 07 3110 00 3110 00 TCU 4 A T 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 59: ...0 24 KYRON 2008 07 3740 00 CIRCUIT 3740 00 A T SHIFT LOCK 4 A T 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 60: ...0 25 CIRCUIT KYRON 2008 07 3410 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3410 00 TCCU ...

Page 61: ...0 26 KYRON 2008 07 4480 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4480 00 EAS ...

Page 62: ...0 27 CIRCUIT KYRON 2008 07 4920 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4920 00 EPB ...

Page 63: ...0 28 KYRON 2008 07 4892 00 CIRCUIT 4892 00 ABS ESP TPMS W SPEED SENSOR STOP LAMP SW DIAGNOSIS WARNING LAMP ABS ESP HDC 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 64: ...0 29 CIRCUIT KYRON 2008 07 4892 00 PRESSURE SENSOR S W A SENSOR SENSOR CLUSTER ESP OFF SW 2 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 65: ...0 30 KYRON 2008 07 4620 00 CIRCUIT 4620 00 S S P S SPEED SENSITIVE POWER STEERING 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 66: ...0 31 CIRCUIT KYRON 2008 07 8810 00 8810 00 AIR BAG CURTAIN AIR BAG 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 67: ... 2008 07 8010 00 CIRCUIT 8010 00 CLUSTER 1 GAUGE SPEED RPM FUEL TEMP WARNING LAMP FUEL FUEL FILTER ABS ESP BRAKE HDC 4WD EPB EAS TPMS 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 68: ...0 33 CIRCUIT KYRON 2008 07 8010 00 2 WARNING LAMP EAS EPB AUTO PARK G TPMS GROBAL EASY LOAD G TPMS DISPLAY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 69: ...ON 2008 07 8010 00 CIRCUIT 3 WARNING LAMP BATT CHARGE OIL HOOD DOOR ENG CHECK AIR BAG SSPS SEAT BELT TURN SIGNAL FRT FOG HAZARD LAMP 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 70: ...0 35 CIRCUIT KYRON 2008 07 7410 00 7410 00 POWER SEAT DRIVER W MEMORY 1 DRIVER POWER SEAT SEAT MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 71: ...0 36 KYRON 2008 07 7410 00 CIRCUIT 2 ELECTRIC OUTSIDE MIRROR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 72: ...0 37 CIRCUIT KYRON 2008 07 7410 00 7410 00 POWER SEAT DRIVER W O MEMORY 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 73: ...0 38 KYRON 2008 07 7410 00 CIRCUIT 7410 00 POWER SEAT PASSENGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 74: ...0 39 CIRCUIT KYRON 2008 07 8510 00 8510 00 null ELECTRIC OUTSIDE MIRROR FOLDING W O MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 75: ...0 40 KYRON 2008 07 8510 00 CIRCUIT 8510 00 FRT SEAT WARMER 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 76: ...0 41 CIRCUIT KYRON 2008 07 8610 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8610 00 RR SEAT WARMER ...

Page 77: ...0 42 KYRON 2008 07 8710 00 CIRCUIT 8710 00 STICS 1 POWER GROUND CHIME BELL BUZZER WARNING LAMP BRAKE S BELT DR OPEN 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 78: ...0 43 CIRCUIT KYRON 2008 07 8710 00 2 CENTRAL DOOR LOCK CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 79: ...0 44 KYRON 2008 07 8710 00 CIRCUIT 3 TAIL LAMP HAZARD POWER WINDOW 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 80: ...0 45 CIRCUIT KYRON 2008 07 8710 00 4 DEFOGGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 81: ...0 46 KYRON 2008 07 8710 00 CIRCUIT 5 PANIC AUTO LIGHT RAIN SENSING ROOM LAMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 82: ...0 47 CIRCUIT KYRON 2008 07 8710 00 6 FRT WIPER WASHER RR WASHER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 83: ...0 48 KYRON 2008 07 8710 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 7 MIRROR FOLD G UNFOLD G FOLD SW ...

Page 84: ...0 49 CIRCUIT KYRON 2008 07 7830 00 7830 00 RR WIPER CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 85: ...0 50 KYRON 2008 07 8510 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8510 00 POWER WINDOW CIRCUIT ...

Page 86: ...0 51 CIRCUIT KYRON 2008 07 8610 00 8610 00 HORN 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 87: ...0 52 KYRON 2008 07 7632 00 CIRCUIT 7632 00 CIGAR LIGHTER POWER OUTLET CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 88: ...0 53 CIRCUIT KYRON 2008 07 7340 00 7340 00 SUN ROOF CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 89: ...0 54 KYRON 2008 07 8310 00 CIRCUIT 8310 00 HEAD LAMP DRL 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION HEAD LAMP DRL DAY TIME RUNNING LIGHT UNIT CIRCUIT ...

Page 90: ...0 55 CIRCUIT KYRON 2008 07 8510 00 8510 00 HLLD HEAD LAMP LEVEL G DEVICE CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 91: ...0 56 KYRON 2008 07 8320 00 CIRCUIT 8320 00 TAIL LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 92: ...0 57 CIRCUIT KYRON 2008 07 8410 00 8410 00 TURN SIGNAL HAZARD LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 93: ...0 58 KYRON 2008 07 8210 00 CIRCUIT 8210 00 TRAILER LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 94: ...0 59 CIRCUIT KYRON 2008 07 8310 00 8310 00 FOG LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 95: ...0 60 KYRON 2008 07 4810 00 CIRCUIT 4810 00 STOP BACK UP LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 96: ...0 61 CIRCUIT KYRON 2008 07 7770 00 7770 00 INTERIOR LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 97: ...0 62 KYRON 2008 07 7770 00 CIRCUIT 7770 00 AUTO DIMMING ROOM MIRROR CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 98: ...0 63 CIRCUIT KYRON 2008 07 8910 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8910 00 AUDIO CLOCK CIRCUIT ...

Page 99: ...0 64 KYRON 2008 07 8930 00 CIRCUIT 8930 00 A V SYSTEM 1 A V HEAD UNIT TUNER UNIT DSP UNIT DVD CHANGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 100: ...0 65 CIRCUIT KYRON 2008 07 8930 00 2 DSP UNIT SPEAKER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 101: ...0 66 KYRON 2008 07 8790 00 CIRCUIT 8790 00 PARKING AID CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 102: ...0 67 CIRCUIT KYRON 2008 07 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6810 00 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT ...

Page 103: ...0 68 KYRON 2008 07 6910 00 CIRCUIT 6910 00 FFH FUEL FIRED HEATER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 104: ...0 69 CIRCUIT KYRON 2008 07 6810 00 6810 00 FATC FULL AUTO TEMP CONTROL CIRCUIT 1 C FAN SENSOR AIR MIX MOTOR D27DT EU IV A T 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 105: ...0 70 KYRON 2008 07 6810 00 CIRCUIT 2 PWM MOTOR AIR MIX MOTOR D27DT EU IV M T 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 106: ...0 71 CIRCUIT KYRON 2008 07 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3 C FAN SENSOR AIR MIX MOTOR D27DT EU Ⅲ ...

Page 107: ...0 72 KYRON 2008 07 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4 C FAN SENSOR AIR MIX MOTOR GSL 3 2 ...

Page 108: ...0 73 CIRCUIT KYRON 2008 07 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 5 PWM MOTOR AIR MIX MOTOR GSL 2 3 ...

Page 109: ...0 74 KYRON 2008 07 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6 BLOWER ACTUATOR MODE INTAKE AMBI SENSOR ...

Page 110: ...0 75 CIRCUIT KYRON 2008 07 6810 00 6810 00 AIR CON MANUAL CIRCUIT 1 COMPRESSOR MOTOR D27DT EU IV A T 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 111: ...0 76 KYRON 2008 07 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 PWM MOTOR MOTOR D27DT EU IV M T ...

Page 112: ...0 77 CIRCUIT KYRON 2008 07 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3 COMPRESSOR MOTOR D27DT EU Ⅲ ...

Page 113: ...0 78 KYRON 2008 07 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4 COMPRESSOR MOTOR GSL 3 2 ...

Page 114: ...0 79 CIRCUIT KYRON 2008 07 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 5 PWM MOTOR MOTOR GSL 2 3 ...

Page 115: ...0 80 KYRON 2008 07 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6 BLOWER ...

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Page 117: ...OUT AND COMPONENTS 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 118: ...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 119: ...01 4 KYRON 2008 07 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM COMPONENTS Locations of Vents Air Duct ...

Page 120: ...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 121: ...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 122: ...01 7 AIR CONDITIONER KYRON 2008 07 6810 15 3 Components ...

Page 123: ...01 8 KYRON 2008 07 6810 15 AIR CONDITIONER 4 PTC HEATER AND FFH HEATER LAYOUT 1 PTC HEATER ASSEMBLY LAYOUT 2 FFH HEATER ASSEMBLY LAYOUT ...

Page 124: ...008 07 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 125: ... 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 126: ...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 127: ... 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 128: ...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 129: ... 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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...01 19 AIR CONDITIONER KYRON 2008 07 6810 15 2 Exploded View ...

Page 135: ...01 20 KYRON 2008 07 6810 15 AIR CONDITIONER ...

Page 136: ...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 137: ...01 22 KYRON 2008 07 6810 15 AIR CONDITIONER 3 SPECIFICATIONS ...

Page 138: ...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 139: ...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 140: ...01 25 AIR CONDITIONER KYRON 2008 07 6810 15 4 Circuit Diagram ...

Page 141: ...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 142: ...01 27 AIR CONDITIONER KYRON 2008 07 6810 15 6 Specification Water Pump 7 Characteristic Curve of Water Pump 12 V ...

Page 143: ...01 28 KYRON 2008 07 6810 15 AIR CONDITIONER 8 Function Diagram 9 Switching Diagram According to Temperature Changes ...

Page 144: ...r 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 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 ...

Page 145: ...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 146: ...the front and longitudinal 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 t...

Page 147: ...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 148: ......

Page 149: ...N 2008 07 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 150: ... 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 151: ...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 152: ...02 11 AIR BAG KYRON 2008 07 8810 03 ...

Page 153: ...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 154: ...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 155: ...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 156: ...02 15 AIR BAG KYRON 2008 07 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 157: ... 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 35 55 Nm 35 55 Nm ...

Page 158: ... 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 159: ...02 18 KYRON 2008 07 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 160: ...ag sensor 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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...02 25 AIR BAG KYRON 2008 07 8810 03 8 AIR BAG ELECTRICAL WIRING DIAGRAM ...

Page 167: ...03 3 SEAT KYRON 2008 07 7410 01 7410 01 SEAT AND SEAT BELT GENERAL 1 SEAT OVERVIEW 1 FRONT SEAT DRIVER S SEAT Reclining Motor Lumbar support lever ...

Page 168: ...ition 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 OVERVIEW AND OPERATION PROCESS ...

Page 169: ...03 5 SEAT KYRON 2008 07 7410 01 Seat cushion angle adjusting lever rear Seat height control switch Seat cushion angle adjusting lever front Reclining lever Sliding lever ...

Page 170: ...03 6 KYRON 2008 07 7410 01 SEAT Location of Seat Position With Memory Unit Bottom of Driver Seat SPWM unit ...

Page 171: ...03 7 SEAT KYRON 2008 07 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 172: ...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 173: ...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 174: ... 7340 01 GENERAL 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 175: ... 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 176: ...04 5 SUNROOF KYRON 2008 07 7340 01 3 TROUBLE DIAGNOSIS ...

Page 177: ...04 6 KYRON 2008 07 7340 01 SUNROOF OVERVIEW AND OPERATION PROCESS 1 SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Sunroof Switch ...

Page 178: ... 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 179: ...04 8 KYRON 2008 07 7340 01 SUNROOF 3 SUNROOF CIRCUIT DIAGRAM ...

Page 180: ...NO DATA ...

Page 181: ...NO DATA ...

Page 182: ...07 3 BODY REPAIR KYRON 2008 07 4110 01 4110 01 BODY REPAIR GENERAL 1 DIMENSIONS ...

Page 183: ...07 4 KYRON 2008 07 4110 01 BODY REPAIR 2 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 184: ...07 5 BODY REPAIR KYRON 2008 07 4110 01 2 5 Link System Lifting Point Dotted Circles ...

Page 185: ...Dash Panel and Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision Dash panel Dash reinforcement Deadening sheet ...

Page 186: ... Body Panel Reinforcement Sealer to the Door Outer Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise BPR sealer to reinforce the body panel and reduce the noise Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 187: ...l Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise The foaming pads are applied to the symmetry surface of the vehicle Thus totally 6 foaming pad are applied to the vehicle body ...

Page 188: ...07 9 BODY REPAIR KYRON 2008 07 4110 01 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 189: ...ICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE INTERVAL 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 STANDARD BOLTS SPECIFICATIONS GENERAL 3 4 6 7 13 14 16 17 19 ...

Page 190: ...01 2 undefined 0000 00 GENERAL ...

Page 191: ...01 3 GENERAL undefined 0000 00 0000 00 GENERAL GENERAL 1 DIMENSIONS Unit mm Optional ...

Page 192: ...01 4 undefined 0000 00 GENERAL 2 SPECIFICATIONS Optional ...

Page 193: ...01 5 GENERAL undefined 0000 00 Optional ...

Page 194: ...wer area of cylinder block in exhaust manifold side 2 Chassis Number The chassis number is stamped on the frame behind the front right tire Diesel Engine The engine number is stamped on the lower area of cylinder block behind the Intake manifold 3 Certification Label The certification label is located on the driver s door sill ...

Page 195: ... Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Shorten the service interval Inspect the en...

Page 196: ...le is operated under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then change every 60 000 ...

Page 197: ...8 After completion of off road operation the drive shaft boots should be inspected 9 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain I R Use only approved Ssangyong genuine parts EU ...

Page 198: ... their related parts If necessary correct clean replenish adjust or replace Replace or change In order to secure engine long life and effective break in first oil factory filled would be recommended to drain with in 10 000 km I R 1 If vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition shorten the service interval 2 If vehicle is operate...

Page 199: ...quired if the vehicle is operated under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then c...

Page 200: ...pletion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness 7 If necessary rotate and balance wheels 8 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or hi...

Page 201: ...BRICANTS Use only Ssangyong recommended fluids and lubricants Keep the specified levels when adding or replacing the fluids Do not mix any different types or brands of oils or fluids This may cause damages IOP Integrated Oil Pan IRDA Independent Rear Drive Axle ...

Page 202: ...01 14 undefined 0000 00 GENERAL 6 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

Page 203: ...01 15 GENERAL undefined 0000 00 2 5 Link System Lifting Point Dotted Circles ...

Page 204: ...01 16 undefined 0000 00 GENERAL 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 205: ...01 17 GENERAL undefined 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 206: ...01 18 undefined 0000 00 GENERAL 2 Components Locator ...

Page 207: ...01 19 GENERAL undefined 0000 00 9 STANDARD BOLTS SPECIFICATIONS ...

Page 208: ... 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 above...

Page 209: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 210: ......

Page 211: ...0 3 ECU GASOLINE KYRON 2008 07 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 212: ...0 4 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 213: ...0 5 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 214: ...0 6 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 215: ...0 7 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 216: ...0 8 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 217: ...0 9 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 218: ...0 10 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 219: ...0 11 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 220: ...0 12 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 221: ...0 13 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 222: ...0 14 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 223: ...0 15 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 224: ...0 16 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 225: ...0 17 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 226: ...0 18 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 227: ...0 19 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 228: ...0 20 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 229: ...0 21 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 230: ...0 22 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 231: ...0 23 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 232: ...0 24 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 233: ...0 25 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 234: ...0 26 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 235: ...0 27 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 236: ...0 28 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 237: ...0 29 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 238: ...0 30 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 239: ...0 31 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 240: ...0 32 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 241: ...0 33 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 242: ...0 34 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 243: ...0 35 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 244: ...0 36 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 245: ...0 37 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 246: ...0 38 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 247: ...0 39 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 248: ...0 40 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 249: ...0 41 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 250: ...0 42 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 251: ...0 43 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 252: ...0 44 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 253: ...0 45 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 254: ...0 46 KYRON 2008 07 0000 00 ECU GASOLINE ...

Page 255: ...0 47 ECU GASOLINE KYRON 2008 07 0000 00 ...

Page 256: ......

Page 257: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 258: ......

Page 259: ...0 3 ECU DIESEL KYRON 2008 07 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 260: ...0 4 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 261: ...0 5 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 262: ...0 6 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 263: ...0 7 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 264: ...0 8 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 265: ...0 9 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 266: ...0 10 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 267: ...0 11 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 268: ...0 12 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 269: ...0 13 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 270: ...0 14 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 271: ...0 15 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 272: ...0 16 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 273: ...0 17 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 274: ...0 18 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 275: ...0 19 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 276: ...0 20 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 277: ...0 21 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 278: ...0 22 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 279: ...0 23 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 280: ...0 24 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 281: ...0 25 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 282: ...0 26 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 283: ...0 27 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 284: ...0 28 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 285: ...0 29 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 286: ...0 30 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 287: ...0 31 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 288: ...0 32 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 289: ...0 33 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 290: ...0 34 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 291: ...0 35 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 292: ...0 36 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 293: ...0 37 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 294: ...0 38 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 295: ...0 39 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 296: ...0 40 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 297: ...0 41 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 298: ...0 42 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 299: ...0 43 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 300: ...0 44 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 301: ...0 45 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 302: ...0 46 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 303: ...0 47 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 304: ...0 48 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 305: ...0 49 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 306: ...0 50 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 307: ...0 51 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 308: ...0 52 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 309: ...0 53 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 310: ...0 54 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 311: ...0 55 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 312: ...0 56 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 313: ...0 57 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 314: ...0 58 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 315: ...0 59 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 316: ...0 60 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 317: ...0 61 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 318: ...0 62 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 319: ...0 63 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 320: ...0 64 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 321: ...0 65 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 322: ...0 66 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 323: ...0 67 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 324: ...0 68 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 325: ...0 69 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 326: ...0 70 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 327: ...0 71 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 328: ...0 72 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 329: ...0 73 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 330: ...0 74 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 331: ...0 75 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 332: ...0 76 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 333: ...0 77 ECU DIESEL KYRON 2008 07 0000 00 ...

Page 334: ...0 78 KYRON 2008 07 0000 00 ECU DIESEL ...

Page 335: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 336: ......

Page 337: ...0 3 BRAKE KYRON 2008 07 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 338: ...0 4 KYRON 2008 07 0000 00 BRAKE ...

Page 339: ...0 5 BRAKE KYRON 2008 07 0000 00 ...

Page 340: ...0 6 KYRON 2008 07 0000 00 BRAKE ...

Page 341: ...0 7 BRAKE KYRON 2008 07 0000 00 ...

Page 342: ...0 8 KYRON 2008 07 0000 00 BRAKE ...

Page 343: ...0 9 BRAKE KYRON 2008 07 0000 00 ...

Page 344: ...0 10 KYRON 2008 07 0000 00 BRAKE ...

Page 345: ...0 11 BRAKE KYRON 2008 07 0000 00 ...

Page 346: ...0 12 KYRON 2008 07 0000 00 BRAKE ...

Page 347: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 348: ......

Page 349: ...0 3 AIR BAG KYRON 2008 07 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 350: ...0 4 KYRON 2008 07 0000 00 AIR BAG ...

Page 351: ...0 5 AIR BAG KYRON 2008 07 0000 00 ...

Page 352: ...0 6 KYRON 2008 07 0000 00 AIR BAG ...

Page 353: ...0 7 AIR BAG KYRON 2008 07 0000 00 ...

Page 354: ...0 8 KYRON 2008 07 0000 00 AIR BAG ...

Page 355: ...0 9 AIR BAG KYRON 2008 07 0000 00 ...

Page 356: ...0 10 KYRON 2008 07 0000 00 AIR BAG ...

Page 357: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 358: ......

Page 359: ...0 3 CCCS KYRON 2008 07 0000 00 0000 00 CCCS 1 CCCS ...

Page 360: ...0 4 KYRON 2008 07 0000 00 CCCS ...

Page 361: ...0 5 CCCS KYRON 2008 07 0000 00 ...

Page 362: ...0 6 KYRON 2008 07 0000 00 CCCS ...

Page 363: ...0 7 CCCS KYRON 2008 07 0000 00 ...

Page 364: ...0 8 KYRON 2008 07 0000 00 CCCS ...

Page 365: ...0 9 CCCS KYRON 2008 07 0000 00 ...

Page 366: ...0 10 KYRON 2008 07 0000 00 CCCS ...

Page 367: ...0 11 CCCS KYRON 2008 07 0000 00 ...

Page 368: ...0 12 KYRON 2008 07 0000 00 CCCS ...

Page 369: ...0 13 CCCS KYRON 2008 07 0000 00 ...

Page 370: ...0 14 KYRON 2008 07 0000 00 CCCS ...

Page 371: ...0 15 CCCS KYRON 2008 07 0000 00 ...

Page 372: ...0 16 KYRON 2008 07 0000 00 CCCS ...

Page 373: ...0 17 CCCS KYRON 2008 07 0000 00 ...

Page 374: ...0 18 KYRON 2008 07 0000 00 CCCS ...

Page 375: ...0 19 CCCS KYRON 2008 07 0000 00 ...

Page 376: ...0 20 KYRON 2008 07 0000 00 CCCS ...

Page 377: ...0 21 CCCS KYRON 2008 07 0000 00 ...

Page 378: ...0 22 KYRON 2008 07 0000 00 CCCS ...

Page 379: ...0 23 CCCS KYRON 2008 07 0000 00 ...

Page 380: ...0 24 KYRON 2008 07 0000 00 CCCS ...

Page 381: ...0 25 CCCS KYRON 2008 07 0000 00 ...

Page 382: ...0 26 KYRON 2008 07 0000 00 CCCS ...

Page 383: ...0 27 CCCS KYRON 2008 07 0000 00 ...

Page 384: ......

Page 385: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 386: ......

Page 387: ...TC 1 SELF DIAGNOSIS 1 Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds Check LED segments on the vacuum fluorescent display VFD Press OFF switch more than 5 seconds ...

Page 388: ...e digit 2 is displayed implying step 2 on the display window and the trouble diagnosis for sensors is executed If no failure exists 20 is displayed If any failure exists the appropriate trouble code is displayed as below Trouble Code The symbol in front of step number 2 means a short circuit of the blinking sensor Short circuit in the ambient air temperature sensor ...

Page 389: ...MP dial to the right to set in the trouble diagnosis step 3 Indication of Step 2 Starting self diagnosis Sensor failure code blinking 30 no failure Trouble Code 4 Set in Trouble Diagnosis Step 4 In this step check the position of actuator door check the fan speed and check the compressor operation Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window When pressing DEF...

Page 390: ...mbient air temperature Interior air temperature Intake air temperature Press Press Press 6 Set in Trouble Diagnosis Step 6 In this step the temperature can be compensated within the range of 3 C to 3 C in the control process according to the temperature to air conditioner controller The step 6 initiates when slightly rotating the fan speed switch other than TEMP switch in step 5 Step 6 Min tempera...

Page 391: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 392: ......

Page 393: ...0 3 FFH KYRON 2008 07 0000 00 0000 00 FFH 1 FFH ...

Page 394: ...0 4 KYRON 2008 07 0000 00 FFH ...

Page 395: ...0 5 FFH KYRON 2008 07 0000 00 ...

Page 396: ...0 6 KYRON 2008 07 0000 00 FFH ...

Page 397: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 398: ......

Page 399: ...0 3 P TRUNK KYRON 2008 07 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 400: ...0 4 KYRON 2008 07 0000 00 P TRUNK ...

Page 401: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 402: ......

Page 403: ...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 404: ...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 405: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 406: ......

Page 407: ...0 3 STICS KYRON 2008 07 0000 00 0000 00 STICS 1 STICS ...

Page 408: ...0 4 KYRON 2008 07 0000 00 STICS ...

Page 409: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 410: ......

Page 411: ...0 3 TC KYRON 2008 07 0000 00 0000 00 TC 1 TC ...

Page 412: ...0 4 KYRON 2008 07 0000 00 TC ...

Page 413: ...0 5 TC KYRON 2008 07 0000 00 ...

Page 414: ...0 6 KYRON 2008 07 0000 00 TC ...

Page 415: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 416: ......

Page 417: ...0 3 TCU KYRON 2008 07 0000 00 0000 00 TCU 1 TCU ...

Page 418: ...0 4 KYRON 2008 07 0000 00 TCU ...

Page 419: ...0 5 TCU KYRON 2008 07 0000 00 ...

Page 420: ...0 6 KYRON 2008 07 0000 00 TCU ...

Page 421: ...0 7 TCU KYRON 2008 07 0000 00 ...

Page 422: ...0 8 KYRON 2008 07 0000 00 TCU ...

Page 423: ...0 9 TCU KYRON 2008 07 0000 00 ...

Page 424: ...0 10 KYRON 2008 07 0000 00 TCU ...

Page 425: ...0 11 TCU KYRON 2008 07 0000 00 ...

Page 426: ...0 12 KYRON 2008 07 0000 00 TCU ...

Page 427: ...0 13 TCU KYRON 2008 07 0000 00 ...

Page 428: ...0 14 KYRON 2008 07 0000 00 TCU ...

Page 429: ...0 15 TCU KYRON 2008 07 0000 00 ...

Page 430: ...0 16 KYRON 2008 07 0000 00 TCU ...

Page 431: ...0 17 TCU KYRON 2008 07 0000 00 ...

Page 432: ...0 18 KYRON 2008 07 0000 00 TCU ...

Page 433: ...0 19 TCU KYRON 2008 07 0000 00 ...

Page 434: ......

Page 435: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 436: ......

Page 437: ...0 3 TGS LEVER KYRON 2008 07 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 438: ...0 4 KYRON 2008 07 0000 00 TGS LEVER ...

Page 439: ...0 5 TGS LEVER KYRON 2008 07 0000 00 ...

Page 440: ...0 6 KYRON 2008 07 0000 00 TGS LEVER ...

Page 441: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

Page 442: ......

Page 443: ...01 3 ENGINE GENERAL undefined 0000 00 0000 00 ENGINE GENERAL GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 444: ...01 4 undefined 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 445: ...FH L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 446: ...01 6 undefined 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 447: ...01 7 ENGINE GENERAL undefined 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 448: ... 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 449: ...ter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 450: ... undefined 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 451: ...TION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 452: ...YSTEM LAYOUT Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 453: ...efined 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 454: ... 14 undefined 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM LAYOUT DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 455: ...will happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the in...

Page 456: ...01 16 undefined 0000 00 ENGINE GENERAL Cylinder Head Cover Oil Pressure Warning Lamp Cluster 6 LUBRICATION SYSTEM LAYOUT Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 457: ...pen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake sid...

Page 458: ...UT Coolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 459: ...01 19 ENGINE GENERAL undefined 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 460: ...LAYOUT Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 461: ...01 21 ENGINE GENERAL undefined 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 462: ...sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decreas...

Page 463: ...pen Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very h...

Page 464: ...on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing cap...

Page 465: ... The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to sp...

Page 466: ...by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history faults 10 1...

Page 467: ...heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to ...

Page 468: ...ntenance 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 engi...

Page 469: ...ervice 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 br...

Page 470: ...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 Howev...

Page 471: ...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 polari...

Page 472: ...oreign 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 M...

Page 473: ...ween 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 dr...

Page 474: ...cle and then support with chassis stand before service work Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 ...

Page 475: ...ase 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 bet...

Page 476: ... 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 of...

Page 477: ...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 alignment ...

Page 478: ... cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Inspec...

Page 479: ... Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system includin...

Page 480: ...e glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the cool...

Page 481: ...01 41 ENGINE GENERAL undefined 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 482: ...ing 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 ab...

Page 483: ...ally controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque Coolant reservoir FFH Engine oil dipstick Oil separator PCV valve Vacuum pump Air cleaner assembly HFM sensor VGT Turbo charger Engine Engine oil filler cap ...

Page 484: ...INE ASSEMBLY undefined 1212 01 EGR valve Vacuum modulator Brake fluid reservoir ABS ESP modulator Fuel filter priming pump Power steering oil reservoir PWM electric fan fan shroud Washer fluid reservoir Battery ...

Page 485: ... VGT Turbo charger 5 EGR pipe 6 Water pump pulley 7 Alternator 8 Crankshaft pulley 9 Oil pan 10 Auto tensioner 11 Air conditioner compressor 12 Auto tensioner pulley 13 Power steering pump pulley 14 Power steering pump 15 EGR valve 16 Idle pulley 17 Viscos clutch pulley 1 Engine Structure Front View 12 1 7 Nm ...

Page 486: ...over 10 1 0 Nm 180 20 3 Oil pipe 4 Fuel pressure sensor 5 Water outlet port 6 EGR valve 7 Oil filler 8 Booster pressure sensor 9 Common rail 10 Vacuum pump 11 Glow plug 12 Cylinder head cover 13 VGT Turbo charger Top View 10 1 0 Nm 40 4 0 Nm 25 2 5 Nm 10 1 0 Nm 15 3 Nm ...

Page 487: ...HP pump assembly 6 Air conditioner compressor 7 Engine mounting bracket 8 Vacuum modulator for VGT turbocharger actuator 9 Flywheel 10 Crank position sensor 11 Vacuum modulator for EGR valve 12 Oil filter oil cooler 13 Vacuum pump 14 Booster pressure sensor 15 Intake manifold 0 8 0 4 Nm Gap 0 7 1 5 mm Right Side View 20 2 6 Nm ...

Page 488: ... 1212 01 1 Cylinder head jack valve screw 2 VGT Turbo charger assembly 3 Cylinder block assembly 4 Engine mounting bracket 5 Oil pan 6 Alternator 7 Water pump 8 EGR pipe 9 Oil dipstick gauge 10 Oil separator with PCV Left Side View ...

Page 489: ...02 8 undefined 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 490: ...02 9 ENGINE ASSEMBLY undefined 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 491: ...02 10 undefined 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 492: ...02 11 ENGINE ASSEMBLY undefined 1212 01 ...

Page 493: ...02 12 undefined 1212 01 ENGINE ASSEMBLY ...

Page 494: ...pm and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining p...

Page 495: ...r drain plug water separating operation every 10 000km 3 Priming pump When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 496: ...l 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 p...

Page 497: ...n driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from cool...

Page 498: ...letely 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 tra...

Page 499: ...03 8 undefined 1881 01 ENGINE FUEL SYSTEM 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE High pressure supply line Transfer pressure supply line Return line ...

Page 500: ...nt 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 con...

Page 501: ...erials 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 502: ...ases system pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High Pressure Pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value It...

Page 503: ...ector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line 6 Fuel Filter Replacement Fuel filter ch...

Page 504: ...03 13 ENGINE FUEL SYSTEM undefined 1881 01 6 CIRCUIT DIAGRAM ...

Page 505: ...03 14 undefined 1881 01 ENGINE FUEL SYSTEM ...

Page 506: ...03 15 ENGINE FUEL SYSTEM undefined 1881 01 ...

Page 507: ......

Page 508: ... Element Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2321 01 ENGINE INTAKE SYSTEM ...

Page 509: ... chamber and the air temperature Major Functions It controls the EGR feedback It controls the pressure control valve for the turbocharger booster 1 Plug in sensor 2 Cylinder housing 3 Protection grid 4 Hybrid cover 5 Measuring duct cover 6 Housing 7 Hybrid 8 Sensor 9 Mounting plate 10 O ring 11 Temperature sensor Turbocharger actuator Intake air cleaner Com pressed air intercooler Exhaust gas Exha...

Page 510: ...red or the knocking may happen as the intake air is heated and the density of air is lowered The intercooler is the device which cools the supercharged air Intake manifold Intake air Exhaust gas Exhaust gas Intake manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum pump EGR valve IP interior fuse RH No 63 7 5A Engine ECU No 96 Intake Manifold Intake air ...

Page 511: ...04 6 undefined 2321 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 512: ...al and helical port which increases the swirl ratio in mid low operating range improves acceleration fuel consumption and decreases particle materials However there are some differences in the form of the EGR valve and 4 cylinder engine The inlet port and coolant outlet port is integrated together Therefore be careful not to let the residual coolant in the manifold enter the inlet port when removi...

Page 513: ... valve 4 Intake air intercooler Intake Manifold Incoming of intake air and exhaust gas Operation of EGR valve Incoming of intake air No operation of EGR valve Coolant emission port Coolant emission port The SUS Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect Intake air Intake air Exhaust gas ...

Page 514: ...sion process in the turbocharger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine from high temperature 100 110 C to maintain the turbocharging efficiency Thus more air is entered the cylinder than the engine only with the turbocharger to give more power Intercooler For removal and installation procedures refer to the Cooling syste...

Page 515: ...04 10 undefined 2321 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 516: ...s complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to r...

Page 517: ... the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing input signal from the related sensors such as acceleration pedal sensor and engine RPM rec...

Page 518: ...lve and Installation Location 1 EXHAUST SYSTEM LAYOUT OVERVIEW AND OPERATION PROCESS Intake manifold Intake manifold EGR pipe Intake manifold Intake air intercooler EGR pipe LH To turbo charger To EGR valve Exhaust manifold Diesel catalytic converter Muffler EGR pipe RH ...

Page 519: ...05 6 undefined 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 520: ...s than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature 40 140 C Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH GENERAL 1533 01 LUBRICATION SYSTEM ...

Page 521: ...oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Inlet port Blow by gas air duct ho...

Page 522: ...06 5 LUBRICATION SYSTEM undefined 1533 01 Cylinder Head Cover Oil pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil Filter Oil Cooler Oil cooler Oil filter ...

Page 523: ...BRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 ...

Page 524: ...ndefined 1533 01 2 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 525: ...07 3 COOLING SYSTEM undefined 9210 05 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 526: ...07 4 undefined 9210 05 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING OVERVIEW AND OPERATION PROCESS ...

Page 527: ...PTC Engine Coolant Flows FFH Engine Coolant Flows 2 COOLING SYSTEM FLOW Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 528: ... in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley Cylinder head Intake manifold Coolant outlet port Improved shape and gasket material to prevent coolant from leaking It prevents co...

Page 529: ...08 3 ENGINE ELECTRIC DEVICES undefined 1461 01 1461 01 ENGINE ELECTRICAL SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 530: ...uel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF ELECTRIC IN ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 531: ...NGINE ELECTRIC DEVICES undefined 1461 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 532: ...08 6 undefined 1461 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 533: ...08 7 ENGINE ELECTRIC DEVICES undefined 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 534: ...S GENERAL Water Pump and Pipe Coolant Port Engine Oil Filter and Cooler Cylinder block Reservior coolant inlet hose Radiator Thermostat inside Coolant outlet port Oil cooler Oil filter Oil cooler Oil Filter cap Oil pressure switch Radiator Coolant outlet hose Return hose Coolant reservoir Coolant inlet hose ...

Page 535: ...09 4 undefined 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 536: ...09 5 ENGINE CONTROL SYSTEM undefined 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 537: ...ock sensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preh...

Page 538: ...ange 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 i...

Page 539: ...mplete 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 acco...

Page 540: ...ng advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liable ...

Page 541: ... made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a function o...

Page 542: ... flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order t...

Page 543: ...re 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 acc...

Page 544: ...s 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 choos...

Page 545: ...ke 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...

Page 546: ... the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The di...

Page 547: ...ot 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...

Page 548: ... be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled and t...

Page 549: ...sion 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 I...

Page 550: ... optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number 16 ...

Page 551: ...mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 552: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 553: ...ways 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 554: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 555: ... 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 us...

Page 556: ...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 ru...

Page 557: ... 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 DE...

Page 558: ...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 spee...

Page 559: ... 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 in ...

Page 560: ...OR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The electronically controlled advanced 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 D20DT EURO D20DT ...

Page 561: ...01 4 undefined 1114 00 ENGINE ASSEMBLY 1 Engine Assembly Structure Front View Top View Touch idler equipped for A T ...

Page 562: ...01 5 ENGINE ASSEMBLY undefined 1114 00 Right Side View Left Side View ...

Page 563: ...01 6 undefined 1114 00 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 564: ...01 7 ENGINE ASSEMBLY undefined 1114 00 2 Engine Performance Curve 1 Output and Torque General EU4 2 Oil Temperature Pressure and Boost Pressure General EU4 ...

Page 565: ...01 8 undefined 1114 00 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 566: ...01 9 ENGINE ASSEMBLY undefined 1114 00 ...

Page 567: ...01 10 undefined 1114 00 ENGINE ASSEMBLY ...

Page 568: ... head bolt changes of the DI engine D20DT Cylinder head bolt wrench Tightening Torque A Removal order Remove the bolts in the order as shown in the figure Installation order Based on the number in the picture B 10 9 8 7 6 5 4 3 2 1 14 13 12 11 Reverse order of removal W9912 003 0B I D of head bolt head 14 5 mm O D of head bolt wrench 13 3 mm ...

Page 569: ...114 00 ENGINE ASSEMBLY 4 MAJOR CHANGES IN D20DT EU IV ENGINE COMPARED TO D20DT 1 Engine Assembly D20DT EURO 4 Engine D20DT Engine Front Side View Top Side View Right Side View Left Side View Touch idler equipped for A T ...

Page 570: ... due to the increased capacity D20DT EURO4 Added damping orifice Orifice is added to fuel inlet outlet ports in order to dampen the pulsation in fuel flow caused by multi injections E EGR valve ECU controls the EGR valve directly without any media It provide more precise EGR control by transmitting the electric signal of EGR valve operating position Injector Fuel pipe Fuel high pressure pipe Commo...

Page 571: ... to intake manifold is blocked by closed flap when the engine is switched off To enhance EGR function coolant EGR cooler is adopted to reduce the temperature of exhaust gas into the intake manifold Reason of changes To satisfy the emission regulation E EGR valve and EGR cooler are adopted And the layout also has a great difference from D27DT HFM 6 0 HFM 5 0 Throttle body EGR cooler EGR center pipe...

Page 572: ...mounting location of booster pressure sensor is changed For D20DT EURO4 engine Additional connecting port for EGR cooler hose For D20DT EURO4 engine Additional port for coolant of EGR cooler Coolant outlet port Water pump Intake manifold PCV oil separator PCV valve Cylinder head cover oil gas Oil To oil gage pipe Oil separator Blow by gas To air duct hose PCV valve Oil separator Oil To oil gage pi...

Page 573: ...digits 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 co...

Page 574: ...ail 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 575: ......

Page 576: ...Rail Orifice for Preventing Fuel Pulsation Added OVERVIEW AND OPERATION PROCESS 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 577: ...ng 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 578: ...02 8 undefined 1881 09 ENGINE FUEL SYSTEM 2 FUEL FLOW OF D20DT EU IV ENGINE ...

Page 579: ...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 OVERVIEW AND OPERATION PROCESS ...

Page 580: ...ined 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 581: ... 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 582: ...lve electrically 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 ...

Page 583: ... and D27DT engines including its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors are same 3 System Met with EURO IV Regulations The Ssangyong vehicles ...

Page 584: ...nifold As it is installed in front of the VGT turbocharger it also monitors the exhaust gas tempera ture coming to the turbocharger If the temperature of the exhaust gas flowing to the turbocharger is higher than the specification the engine lowers the exhaust gas temperature Rear Exhaust Gas Tempera ture Sensor Measures the increased ex haust gas temperature after the oxidation process of DOC If ...

Page 585: ...ap to block the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Turbocharger may become weaker if high tem perature exhaust gas passes through the tur bocharger for DPF regeneration process The front exhaust gas temperature sensor moni tors ...

Page 586: ...e amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is anintegrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in...

Page 587: ...re of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Front exhaust gas temperature sensor Measuring temperature of exhaust gas in exhaust manifold Rear exhaust gas temperature sensor Measuring temperature of exhaust gas escaping DOC Norma...

Page 588: ...ion patterns pilot injection pre injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temperature of exh...

Page 589: ...gine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Page 590: ...nge with two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filt...

Page 591: ...l pressure snesor When the soot is accumulated the pressure difference be tween the front and the rear side occurs Then the engineECU performs the post injec tion to raise the exhaust gas temperature and burn the collected soot at approx 600 C The exhaust gas enters intoCDPF assembly after passing through the exhaust manifold Normal temperature of ex haust gas approx 250 C When the exhaust gas ent...

Page 592: ...ing style Then the engine ECU performs the CDPF regeneration operation However the driver is not in formed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection dur ing the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increas...

Page 593: ...is case perform the step 2 1 2 3 If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumu lated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp c...

Page 594: ...tion and Location Differential Pressure Sensor Engine compartment RH Rear exhaust gas temperature sensor Throttle Body Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Rear pressure port CDPF assembly Front pressure port Differential pressure sensor ...

Page 595: ... oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase PCV valve Oil separator PCV valve Oil separator Blow by gas T...

Page 596: ...erlapped 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 th...

Page 597: ...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 598: ...07 2 undefined 2112 00 ENGINE COOLING SYSTEM ...

Page 599: ...EM 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 600: ...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 601: ...07 5 ENGINE COOLING SYSTEM undefined 1520 00 1 Structure of Water Pump for D20DT Engine ...

Page 602: ......

Page 603: ...s of engine ECU 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...

Page 604: ...08 4 undefined 1491 01 ENGINE ELECTRICAL SYSTEM 2 D20DT EU IV ENGINE S ECU CIRCUIT ...

Page 605: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 606: ...ways 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 607: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 608: ... 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 us...

Page 609: ...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 ru...

Page 610: ... 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 DE...

Page 611: ...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 spee...

Page 612: ... 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 in ...

Page 613: ...NO DATA ...

Page 614: ...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 615: ......

Page 616: ...01 3 ENGINE D20DT undefined 0000 00 GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH Side View D20DT D27DT 0000 00 ENGINE GENERAL ...

Page 617: ...01 4 undefined 0000 00 ENGINE D20DT 2 RH side view D20DT D27DT ...

Page 618: ...01 5 ENGINE D20DT undefined 0000 00 3 Front view D20DT D27DT ...

Page 619: ...01 6 undefined 0000 00 ENGINE D20DT 4 Fan belt D20DT D27DT ...

Page 620: ...01 7 ENGINE D20DT undefined 0000 00 2 COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ...

Page 621: ...01 8 undefined 0000 00 ENGINE D20DT ...

Page 622: ...01 9 ENGINE D20DT undefined 0000 00 ...

Page 623: ...01 10 undefined 0000 00 ENGINE D20DT ...

Page 624: ...01 11 ENGINE D20DT undefined 0000 00 3 ENGINE CONTROLS LAYOUT 1 Ecu related componets 1 D20DT Engine ...

Page 625: ...01 12 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 626: ...01 13 ENGINE D20DT undefined 0000 00 2 ENGINE AND SENSORS 1 D20DT Engine ...

Page 627: ...01 14 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 628: ...01 15 ENGINE D20DT undefined 0000 00 4 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1 D20DT Engine ...

Page 629: ...01 16 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 630: ...01 17 ENGINE D20DT undefined 0000 00 5 INTAKE SYSTEM LAYOUT 1 D20DT Engine ...

Page 631: ...01 18 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 632: ...01 19 ENGINE D20DT undefined 0000 00 6 EXHAUST SYSTEM LAYOUT 1 D20DT Engine ...

Page 633: ...01 20 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 634: ...01 21 ENGINE D20DT undefined 0000 00 7 LUBRICATION SYSTEM LAYOUT 1 D20DT Engine ...

Page 635: ...01 22 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 636: ...01 23 ENGINE D20DT undefined 0000 00 8 COOLING SYSTEM LAYOUT 1 D20DT Engine ...

Page 637: ...01 24 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 638: ...01 25 ENGINE D20DT undefined 0000 00 9 FUEL SYSTEM LAYOUT 1 D20DT Engine ...

Page 639: ...01 26 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 640: ...es 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 emissions...

Page 641: ...01 28 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 642: ...s 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 operating...

Page 643: ...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 thor...

Page 644: ...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 sp...

Page 645: ...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 fault...

Page 646: ...M 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 cau...

Page 647: ......

Page 648: ...tenance 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 engin...

Page 649: ...rvice 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 bra...

Page 650: ...y 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 Howeve...

Page 651: ...ontacted 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 polarit...

Page 652: ...reign 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 Ma...

Page 653: ...een 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 dro...

Page 654: ...le 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 5 ...

Page 655: ...se 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 betw...

Page 656: ...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 of ...

Page 657: ...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 alignment ...

Page 658: ...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 dam...

Page 659: ...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 the...

Page 660: ...inges 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 coola...

Page 661: ...01 48 undefined 0000 00 ENGINE D20DT 17 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 662: ...ng bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of abo...

Page 663: ......

Page 664: ...12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 1114 01 ENGINE ASSEMBLY 1 MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT 1 D20DT ENGINE GENERAL The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque ...

Page 665: ...olant 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 666: ... 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 2 ...

Page 667: ...r 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 668: ...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 669: ...ure 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 670: ...02 9 ENGINE D20DT undefined 1114 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 671: ...02 10 undefined 1114 01 ENGINE D20DT 2 Engine Performance Curve 1 Vehicle with A T Output and Torque D20DT engine D27DT engine ...

Page 672: ...02 11 ENGINE D20DT undefined 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 673: ...02 12 undefined 1114 01 ENGINE D20DT Output and Torque 2 Vehicle with M T D20DT engine D27DT engine ...

Page 674: ...02 13 ENGINE D20DT undefined 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 675: ...02 14 undefined 1114 01 ENGINE D20DT 4 TIGHTENING TORQUE ...

Page 676: ...02 15 ENGINE D20DT undefined 1114 01 ...

Page 677: ...02 16 undefined 1114 01 ENGINE D20DT ...

Page 678: ...and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining proc...

Page 679: ... 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 680: ...ts 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 perfo...

Page 681: ...ver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant t...

Page 682: ...letely 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 tra...

Page 683: ...03 8 undefined 1881 01 ENGINE D20DT 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Page 684: ...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 condit...

Page 685: ...als 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 686: ...em 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 becau...

Page 687: ... 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 use...

Page 688: ...NE D20DT undefined 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 689: ...03 14 undefined 1881 01 ENGINE D20DT 7 Circuit Diagram ...

Page 690: ...03 15 ENGINE D20DT undefined 1881 01 ...

Page 691: ...03 16 undefined 1881 01 ENGINE D20DT ...

Page 692: ... complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to re...

Page 693: ...05 4 undefined 1913 01 ENGINE D20DT D20DT D27DT HUBER EGR System for IDI Engine Including the EGR Valve Potentiometer EGR System for DI Engine ...

Page 694: ...NE D20DT undefined 1913 01 1 COMPONENTS LOCATOR OF EXHAUST SYSTEM Muffler Exhaust Manifold EGR Valve Turbo Charger Catalytic Converter DOC EGR Pipe Vacuum Modulator OVERVIEW AND OPERATION PROCESS 1 D20DT ENGINE ...

Page 695: ...05 6 undefined 1913 01 ENGINE D20DT Turbo Charger EGR Valve Muffler Exhaust Manifold Catalytic Converter DOC EGR Pipe Vacuum Modulator ...

Page 696: ...05 7 ENGINE D20DT undefined 1913 01 2 EXHAUST GAS FLOWS ...

Page 697: ... 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 GENER...

Page 698: ...ined 1533 01 ENGINE D20DT 1 COMPONENTS OF LUBRICATION SYSTEM 1 D20DT ENGINE Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover OVERVIEW AND OPERATION PROCESS ...

Page 699: ...06 5 ENGINE D20DT undefined 1533 01 Oil Pressure Switch Oil Cooler Oil Pan Oil Pump Oil Filter Oil Separator Oil Dipstick Cylinder Head Cover 2 D27DT Engine ...

Page 700: ... 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 701: ...ned 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 702: ...07 3 ENGINE D20DT undefined 2112 01 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 703: ...ndefined 2112 01 ENGINE D20DT Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING OVERVIEW AND OPERATION PROCESS 1 D20DT Engine ...

Page 704: ...07 5 ENGINE D20DT undefined 2112 01 Coolant Reservoir FFH Coolant Temperature Sensor Radiator Water Pump Cooling Fan 2 D27DT Engine ...

Page 705: ... 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 706: ... 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 coola...

Page 707: ...08 3 ENGINE D20DT undefined 1461 01 1461 01 ENGINE ELECTRIC SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 708: ...Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF ELECTRIC IN ENGINE 1 D20DT ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 709: ... undefined 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 710: ...efined 1461 01 ENGINE D20DT 2 COMPONENTS OF ELECTRIC DEVICES IN ENGINE 1 D20DT ENGINE Glow Plug Alternator Air Conditioner Compressor Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 711: ...08 7 ENGINE D20DT undefined 1461 01 1 D27DT ENGINE Air Conditioner Compressor Alternator Glow Plug Starter Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 712: ...08 8 undefined 1461 01 ENGINE D20DT 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 713: ...08 9 ENGINE D20DT undefined 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 714: ... EGINE CONTROL SYSTEM 1 ENGINE ECU AND OTHER COMPONENTS 1 D20DT Engine GENERAL ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay ...

Page 715: ...defined 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 716: ...09 5 ENGINE D20DT undefined 1491 01 3 TOP VIEW 1 D20DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 717: ...09 6 undefined 1491 01 ENGINE D20DT Fuel Pressure Sensor 2 D27DT Engine Booster Pressure Sensor Injectors 5 EA Glow Plugs 5 ...

Page 718: ...09 7 ENGINE D20DT undefined 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 719: ...09 8 undefined 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 720: ...ensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheater...

Page 721: ... 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 injec...

Page 722: ...te 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 accordin...

Page 723: ...dvance 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 o...

Page 724: ...e 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 th...

Page 725: ... 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 mai...

Page 726: ...s 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 accordi...

Page 727: ...e 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 t...

Page 728: ...missions 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 fau...

Page 729: ...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 differe...

Page 730: ...e 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 thi...

Page 731: ...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 e...

Page 732: ...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 is ...

Page 733: ...imal 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 digi...

Page 734: ...num 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 735: ......

Page 736: ...his switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator peda...

Page 737: ...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 738: ...10 5 ENGINE D20DT undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 739: ...eached 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 the...

Page 740: ...old 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 running...

Page 741: ... 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 s...

Page 742: ...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 pro...

Page 743: ...cuit 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 syst...

Page 744: ... 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 745: ......

Page 746: ...01 3 ENGINE GENERAL undefined 0000 00 0000 00 ENGINE GENERAL GENERAL 1 STRUCTURE AND COMPARISON D27DT EU IV Engine Front View D27DT EU IV Engine Front View ...

Page 747: ...01 4 undefined 0000 00 ENGINE GENERAL D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Page 748: ...01 5 ENGINE GENERAL undefined 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Page 749: ...01 6 undefined 0000 00 ENGINE GENERAL D27DT Engine General Side View D27DT Engine General Left Side View ...

Page 750: ...01 7 ENGINE GENERAL undefined 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 751: ...01 8 undefined 0000 00 ENGINE GENERAL 2 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 752: ...01 9 ENGINE GENERAL undefined 0000 00 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Page 753: ...01 10 undefined 0000 00 ENGINE GENERAL ...

Page 754: ...01 11 ENGINE GENERAL undefined 0000 00 ...

Page 755: ... 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 756: ...01 13 ENGINE GENERAL undefined 0000 00 2 Major Changes and Summary ...

Page 757: ...01 14 undefined 0000 00 ENGINE GENERAL ...

Page 758: ...01 15 ENGINE GENERAL undefined 0000 00 ...

Page 759: ...01 16 undefined 0000 00 ENGINE GENERAL ...

Page 760: ...01 17 ENGINE GENERAL undefined 0000 00 ...

Page 761: ...01 18 undefined 0000 00 ENGINE GENERAL ...

Page 762: ...01 19 ENGINE GENERAL undefined 0000 00 ...

Page 763: ...01 20 undefined 0000 00 ENGINE GENERAL ...

Page 764: ...01 21 ENGINE GENERAL undefined 0000 00 OVERVIEW AND OPERATION PROCESS 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Page 765: ...01 22 undefined 0000 00 ENGINE GENERAL ...

Page 766: ...ompartment 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 T3...

Page 767: ...01 24 undefined 0000 00 ENGINE GENERAL Major Sensors and Components ...

Page 768: ...01 25 ENGINE GENERAL undefined 0000 00 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Page 769: ...01 26 undefined 0000 00 ENGINE GENERAL ...

Page 770: ...01 27 ENGINE GENERAL undefined 0000 00 2 Preheat System ...

Page 771: ...01 28 undefined 0000 00 ENGINE GENERAL 3 Fuel System ...

Page 772: ...01 29 ENGINE GENERAL undefined 0000 00 Fuel Supply System ...

Page 773: ...01 30 undefined 0000 00 ENGINE GENERAL 4 Lubrication System ...

Page 774: ...01 31 ENGINE GENERAL undefined 0000 00 5 Cooling System ...

Page 775: ...01 32 undefined 0000 00 ENGINE GENERAL 6 Intake System ...

Page 776: ...01 33 ENGINE GENERAL undefined 0000 00 7 Exhaust System ...

Page 777: ...les are added 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 i...

Page 778: ...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 779: ...mp 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 780: ...02 6 undefined 1881 09 ENGINE FUEL SYSTEM 2 COMPONENTS OF FUEL SYSTEM ...

Page 781: ...02 7 ENGINE FUEL SYSTEM undefined 1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 782: ...P POWER UP engine 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 783: ...on signal to 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 de...

Page 784: ... and D27DT engines including its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors are same 3 System Met with EURO IV Regulations The Ssangyong vehicles ...

Page 785: ...nifold As it is installed in front of the VGT turbocharger it also monitors the exhaust gas tempera ture coming to the turbocharger If the temperature of the exhaust gas flowing to the turbocharger is higher than the specification the engine lowers the exhaust gas temperature Rear Exhaust Gas Tempera ture Sensor Measures the increased ex haust gas temperature after the oxidation process of DOC If ...

Page 786: ...ap to block the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Turbocharger may become weaker if high tem perature exhaust gas passes through the tur bocharger for DPF regeneration process The front exhaust gas temperature sensor moni tors ...

Page 787: ...e amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is anintegrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in...

Page 788: ...re of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Front exhaust gas temperature sensor Measuring temperature of exhaust gas in exhaust manifold Rear exhaust gas temperature sensor Measuring temperature of exhaust gas escaping DOC Norma...

Page 789: ...ion patterns pilot injection pre injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temperature of exh...

Page 790: ...gine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Page 791: ...nge with two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filt...

Page 792: ...l pressure snesor When the soot is accumulated the pressure difference be tween the front and the rear side occurs Then the engineECU performs the post injec tion to raise the exhaust gas temperature and burn the collected soot at approx 600 C The exhaust gas enters intoCDPF assembly after passing through the exhaust manifold Normal temperature of ex haust gas approx 250 C When the exhaust gas ent...

Page 793: ...ing style Then the engine ECU performs the CDPF regeneration operation However the driver is not in formed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection dur ing the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increas...

Page 794: ...is case perform the step 2 1 2 3 If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumu lated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp c...

Page 795: ...tion and Location Differential Pressure Sensor Engine compartment RH Rear exhaust gas temperature sensor Throttle Body Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Rear pressure port CDPF assembly Front pressure port Differential pressure sensor ...

Page 796: ...NO DATA ...

Page 797: ...OOLING SYSTEM 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 798: ...07 4 undefined 1520 01 ENGINE COOLING SYSTEM D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 799: ...NO DATA ...

Page 800: ...NO DATA ...

Page 801: ...NO DATA ...

Page 802: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 803: ......

Page 804: ......

Page 805: ...01 4 KYRON 2008 07 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 806: ... 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 807: ... 07 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 808: ...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 809: ......

Page 810: ...02 3 ENGINE ASSEMBLY KYRON 2008 07 1113 01 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 811: ...02 4 KYRON 2008 07 1113 01 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 812: ...02 5 ENGINE ASSEMBLY KYRON 2008 07 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 813: ...02 6 KYRON 2008 07 1113 01 ENGINE ASSEMBLY ...

Page 814: ...02 7 ENGINE ASSEMBLY KYRON 2008 07 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 815: ...02 8 KYRON 2008 07 1113 01 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 816: ...02 9 ENGINE ASSEMBLY KYRON 2008 07 1113 01 4 FASTENER TIGHTENING SPECIFICATIONS CONT D ...

Page 817: ...ck of your vehicle Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must...

Page 818: ...03 4 KYRON 2008 07 2211 22 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 819: ...NO DATA ...

Page 820: ...ioration is discovered upon inspection of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 ...

Page 821: ...05 4 KYRON 2008 07 2420 01 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 822: ...06 3 LUBRICATION SYSTEM KYRON 2008 07 9210 01 9210 01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1 OIL CIRCULATION ...

Page 823: ...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 824: ...07 3 COOLING SYSTEM KYRON 2008 07 2110 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 825: ...07 4 KYRON 2008 07 2110 01 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 826: ...07 5 COOLING SYSTEM KYRON 2008 07 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 827: ...r the cooling system to operation The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to t...

Page 828: ...07 7 COOLING SYSTEM KYRON 2008 07 2110 01 2 COMPONENT LOCATOR ...

Page 829: ... 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 830: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2008 07 1452 01 1452 01 ENGINE ELECTRIC DEVICES GENERAL 1 GENERAL SPECIFICATIONS ...

Page 831: ...08 4 KYRON 2008 07 1452 01 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 832: ...igher current rate as the battery warms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharge...

Page 833: ... 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 834: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2008 07 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 835: ...09 3 ENGINE CONTROL SYSTEM KYRON 2008 07 1522 16 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE GENERAL ...

Page 836: ...09 4 KYRON 2008 07 1522 16 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 837: ... when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerat...

Page 838: ...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 839: ...10 5 CRUISE CONTROL SYSTEM KYRON 2008 07 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 840: ...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 841: ...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 842: ...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 843: ...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 844: ...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 845: ...reas 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 th...

Page 846: ...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 847: ...01 5 ENGINE ASSEMBLY KYRON 2008 07 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 848: ...01 6 KYRON 2008 07 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 849: ...01 7 ENGINE ASSEMBLY KYRON 2008 07 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 850: ...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 851: ...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 852: ...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 853: ... 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 854: ...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 855: ... 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 856: ...01 14 KYRON 2008 07 1113 01 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 857: ...01 15 ENGINE ASSEMBLY KYRON 2008 07 1113 01 General Diagnosis Cont d ...

Page 858: ...01 16 KYRON 2008 07 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 859: ...01 17 ENGINE ASSEMBLY KYRON 2008 07 1113 01 General Diagnosis Cont d ...

Page 860: ...01 18 KYRON 2008 07 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 861: ...01 19 ENGINE ASSEMBLY KYRON 2008 07 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 862: ...01 20 KYRON 2008 07 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 863: ...01 21 ENGINE ASSEMBLY KYRON 2008 07 1113 01 Fastener Tightening Specifications Cont d ...

Page 864: ...01 22 KYRON 2008 07 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 865: ......

Page 866: ...02 3 ENGINE INTAKE SYSTEM KYRON 2008 07 1713 08 1713 08 ENGINE INTAKE SYSTEM GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 867: ...03 3 ENGINE EXHAUST SYSTEM KYRON 2008 07 2420 01 2420 01 ENGINE EXHAUST SYSTEM GENERAL 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 868: ...d damage the catalytic 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...

Page 869: ...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 870: ... 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 871: ...04 3 ENGINE COOLING SYSTEM KYRON 2008 07 2110 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 872: ...04 4 KYRON 2008 07 2110 01 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 873: ...D OPERATION PROCESS 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 874: ...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 875: ...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 876: ... 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 877: ...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 878: ...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 879: ... 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 880: ...05 3 ENGINE ELECTRICAL SYSTEM KYRON 2008 07 1452 01 1452 01 ENGINE ELECTRIC DEVICES GENERAL 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 881: ...05 4 KYRON 2008 07 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 882: ...periods of time 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...

Page 883: ...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 884: ...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 885: ...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 886: ...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 887: ... 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 888: ... when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerat...

Page 889: ...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 890: ...06 5 CRUISE CONTROL SYSTEM KYRON 2008 07 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 891: ...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 892: ...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 893: ...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 894: ...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 895: ...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 896: ... SYSTEM ELECTRIC GENERAL 1 LOCATIONS OF INTERIOR UNITS AND SENSORS 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT 3 INTERIOR SWITCHES 4 AUDIO VIDEO SYSTEM 5 ELECTRIC COMPONENTS AND LAYOUT ELECTRIC SYSTEM ELECTRIC SYSTEM 2 4 6 8 10 ...

Page 897: ...F INTERIOR UNITS AND SENSORS Under Instrument Panel Steering Wheel Angular Sensor Immobilizer PAS Unit Driver Seat Memory Switch TCCU and TCU Steering wheel angular sensor Immobilizer Curtain air bag module Sun sensor TV antenna amplifier Door lock relay Chime bell Buzzer for PAS RK STICS TCCU TCU ...

Page 898: ...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 899: ...ON 2008 07 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 900: ... ELECTRIC SYSTEM KYRON 2008 07 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 901: ...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 902: ...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 903: ...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 904: ...2008 07 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 905: ...01 10 KYRON 2008 07 0000 00 ELECTRIC SYSTEM Wiring Harness Arrangement 5 ELECTRIC COMPONENTS AND LAYOUT ...

Page 906: ...01 11 ELECTRIC SYSTEM KYRON 2008 07 0000 00 Components Locator ...

Page 907: ......

Page 908: ... model and is installed to the back of the STICKS As the ICM box is newly installed the following relays are integrated into the ICM box Door lock relay previously installed to STICKS bracket Windshield de icer relay previously installed next to floor on the driver side Turn signal lamp relay previously installed to passenger side fuse relay box Some relays have been integrated into the ICM box PR...

Page 909: ...CS is integrated with the door lock relay windshield de icer relay and turn signal lamp relay There are four fuse relay units 2 FUSE AND RELAY MOUNTING LOCATION 1 In engine compartment Fuse Relay Box InEngine Compartment Interior Fuse Relay Box On The Driver Side RH 2 In vehicle Interior Fuse Relay Box On The Driver Side LH Mounting Location of ICM ...

Page 910: ...AY IN ENGINE COMPARTMENT The label attached on each fuse box indicates only major fuses and relays Therefore there are more fuses and relays than indicated For details about the connection of fuses and relays refer to the power distribution circuit diagram on the following pages ...

Page 911: ...02 6 KYRON 2008 07 8410 02 FUSE AND RELAY 4 CAPACITY AND NAME OF INTERIOR FUSE AND RELAY 1 Interior Fuse and Relay Box On the Driver Side ...

Page 912: ...02 7 FUSE AND RELAY KYRON 2008 07 8410 02 2 Interior Fuse and Relay Box On the Passenger Side ...

Page 913: ...ICM box is newly installed the following relays are integrated into the ICM box Door lock relay previously installed to STICKS bracket Windshield de icer relay previously installed next to floor on the driver side Turn signal lamp relay previously installed to passenger side fuse relay box 2 Mounting Location Relays in the ICM box cannot be replaced respectively so if the components on the PCB are...

Page 914: ...TICS 6 pin 15 pin it operates the door actuator 11 pin 13 pin through its door lock relay to lock unlock the door In order to check the operation of the relay measure the voltage at the connector of the ICM box and check the output through the ICM box after operating the corresponding door Of course the components for the corresponding system should be checked in advance ...

Page 915: ...lamp blinks 10 times at an interval of 0 35 seconds This function is only available when the ignition key is in the ON position If the ignition key is turned to the OFF position during this function is activated this function is immediately deactivated If the system receives signals for the turn signal lamp operation during this function is activated this function is immediately deactivated While ...

Page 916: ...cer operation Pressing the windshield de icer switch activates the de icer for 12 minutes and pressing the switch again deactivates the de icer At this time pressing the switch again activates the de icer for 12 minutes from the time the switch is pressed again ...

Page 917: ...ed 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 GENERAL ...

Page 918: ...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 919: ...03 5 STICS KYRON 2008 07 8710 01 Rated Load ...

Page 920: ...03 6 KYRON 2008 07 8710 01 STICS Input Signals ...

Page 921: ...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 922: ......

Page 923: ...onder 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 GENERAL Immobili...

Page 924: ...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 925: ......

Page 926: ...POSITION WITH MEMORY OVERVIEW Functions of SPWM Adjusting the power seat s position with the seat adjusting switch Adjusting the angle of the outside rearview mirrors OSRVM Seat memory positions for 3 persons Folding Unfolding the outside rearview mirrors SPWM Location Bottom of diver s seat ...

Page 927: ...irror Outside rearview mirror folding switch Seat memory switch RH outside rearviewmirror 1 SEAT POSITION WITH MEMORY COMPONENTS OVERVIEW AND OPERATION PROCESS Front cushion motor sensor Seat adjusting switch Sliding motor sensor 1 2 3 Rear cushion motor sensor Reclining motor sensor SPWM Unit 4 5 6 ...

Page 928: ...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 929: ...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 930: ...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 931: ...05 8 KYRON 2008 07 7410 13 SPWM 3 SEAT POSITION WITH MEMORY INPUT OUTPUT OF SPWM UNIT ...

Page 932: ...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 933: ...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 934: ...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 935: ... 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 936: ...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 937: ...iew mirrors are folded Normal operation modeMode changes between Folding and Unfolding The outside rearview mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignitionswitch To prevent the outside rearview mirrors from stopping during its operation the mirror operating time is extended13 seconds when pressing the switch again Timing Chart ...

Page 938: ... 8010 01 GENERAL 8010 01 CLUSTER 1 DESCRIPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the data through CAN communication The HDC warning light and the engine hood open warning light are newly introduced ...

Page 939: ...06 4 KYRON 2008 07 8010 01 CLUSTER ...

Page 940: ......

Page 941: ...06 6 KYRON 2008 07 8010 01 CLUSTER 2 WARNING INDICATOR PANE ...

Page 942: ...06 7 CLUSTER KYRON 2008 07 8010 01 ...

Page 943: ...06 8 KYRON 2008 07 8010 01 CLUSTER Main Connector Sub Connector 1 CLUSTER CONFIGURATION Front View Rear View OVERVIEW AND OPERATION PROCESS ...

Page 944: ...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 945: ...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 946: ...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 947: ...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 948: ... 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 949: ... 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 950: ...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 951: ...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 952: ...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 953: ...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 954: ...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 955: ...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 956: ... 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 957: ...06 22 KYRON 2008 07 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 958: ...06 23 CLUSTER KYRON 2008 07 8010 01 Warning Lamp EAS EPB Auto Park s TPMS Grobal Easy Load g TPMS Display ...

Page 959: ...06 24 KYRON 2008 07 8010 01 CLUSTER Warning Lamp BATT Charge Oil Hood Door Eng Check Air Bag SSPS Seat Belt Turn Signal FRT Fog Hazard Lamp ...

Page 960: ...mbination 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 GENERAL 1 LOCATIONS OF LAMPS AND SPECIFICATIONS 1 EXTERIOR LAMPS ...

Page 961: ...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 962: ...07 4 KYRON 2008 07 8310 01 LAMP BULB SPECIFICATIONS ...

Page 963: ......

Page 964: ... 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 965: ...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 966: ...nse plate lamp Make sure the location and LOCK direction are correct 3 1 Bulb Replacement Pry off the side of the license plate lamp from the rear garnish of the tailgate 1 Remove the bulb from the removed license plate lamp 2 Use only specified bulb for replacement ...

Page 967: ...or unit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity To control the system the sensed values of rain sensor and auto light sensor are sent to pin no 63 in STICS unit Rain sensor emitter lens Light receiving area of auto light sensor The wiper and washer system are controlled by STICS according to driver s wiper switch operation And ...

Page 968: ...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 969: ...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 970: ...ER AND WASHER OVERVIEW AND OPERATION PROCESS WITH RAIN SENSOR Rain Sensor Unit Multifunction Wiper and Washer Switch Front Nozzle Assembly Washer Reservoir Tank Assemblyt Rear Washer Nozzle and Check Valve Rear nozzle assembly Rear nozzle Check valve 1 2 3 ...

Page 971: ...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 972: ...09 8 KYRON 2008 07 7810 01 WIPER 2 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 973: ...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 974: ...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 975: ...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 976: ...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 977: ...09 13 WIPER KYRON 2008 07 7810 01 3 WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS ...

Page 978: ...owings are comparison of the system equipped in NEW KYRON with the system in previous version of KYRON Previous version Wiper motor Arm Blade Circuit diagram KYRON from March 07 Manufacturer Kamco Manufacturer Dongyang mechatronics Blade length 12 Manufacturer Kamco Blade length 14 Manufacturer KCW Corporation Modification in connector pin arrangement 4 REAR WIPER 1 OVERVIEW ...

Page 979: ...untofraindropsbyreceiving reflectedraysagainstsensingsection rainsensor mountingsectiononthewindshield with photodiode TheautolightsensorisIntegratedinto therainsensor refertothebelowpicture Multifunction wiper switch AUTO and sensitivity control AUTO Wiperoperatesautomaticallybyrainsensor FAST SLOW Autodelay Autospeedcontrol Apositionthatcancontrolsensitivityagainstrains onthewindshieldandtransmi...

Page 980: ...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 981: ...gh LOW relay regardless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions while the ignition key is in ON position When the wiper switch is turned to ON position again from other positions the system Drives the wiper motor through LOW relay one cycle only when the rain senso...

Page 982: ...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 983: ...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 984: ... 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 985: ...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 986: ...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 987: ...10 11 RAIN SENSOR KYRON 2008 07 8610 09 3 ELECTRICAL WIRING DIAGRAM ...

Page 988: ...e gear 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 th...

Page 989: ...obstacles and sends 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...

Page 990: ...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 991: ...11 6 KYRON 2008 07 8790 00 PAS When failed ...

Page 992: ...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 993: ...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 994: ... HEAD UNIT OVERVIEW DVD Cassette player 10 speakers center speaker woofer speakers tweeter speakers AV head unit DVD Cassette Radio Cassette tape slot DVD title insert slot MUTE button Tuner DVD 6 DISC changer DSP amplifier Subwoofer 8930 14 AV ...

Page 995: ...12 4 KYRON 2008 07 8930 14 AV OVERVIEW AND OPERATION PROCESS 1 AV SYSTEM CONFIGURATION AV System DVD Head Unit DVD Changer Audio System 6 Speakers ...

Page 996: ...12 5 AV KYRON 2008 07 8930 14 6 DISC changer TAPE RADIO CD RADIO DISC changer CD slot Tape ...

Page 997: ...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 998: ...12 7 AV KYRON 2008 07 8930 14 ...

Page 999: ...8 07 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 1000: ...12 9 AV KYRON 2008 07 8930 14 4 AV SYSTEM SPECIFICATIONS AND CONTROL ...

Page 1001: ...12 10 KYRON 2008 07 8930 14 AV Function Settings on Touch Panel Example ...

Page 1002: ...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 1003: ...01 3 ION 4 SPEED KYRON 2008 07 3410 01 3410 01 ION 4 SPEED GENERAL 1 SPECIFICATIONS ...

Page 1004: ...01 4 KYRON 2008 07 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 1005: ...Transfer Case The 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 ou...

Page 1006: ...01 6 KYRON 2008 07 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 1007: ...01 7 ION 4 SPEED KYRON 2008 07 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 1008: ...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 1009: ...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 1010: ... 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 1011: ...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 1012: ...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 1013: ...01 13 ION 4 SPEED KYRON 2008 07 3410 01 ...

Page 1014: ...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 1015: ...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 1016: ...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 1017: ...01 17 ION 4 SPEED KYRON 2008 07 3410 01 Solenoid Operation during Gearshifts ...

Page 1018: ...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 1019: ...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 1020: ...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 1021: ...01 21 ION 4 SPEED KYRON 2008 07 3410 01 1 Hydraulic Control Circuit ...

Page 1022: ...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 1023: ...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 1024: ...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 1025: ...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 1026: ...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 1027: ...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 1028: ...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 1029: ... 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 1030: ...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 1031: ...01 31 ION 4 SPEED KYRON 2008 07 3410 01 ...

Page 1032: ...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 1033: ... 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 1034: ...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 1035: ...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 1036: ...01 36 KYRON 2008 07 3410 01 ION 4 SPEED 1 Park and Neutral ...

Page 1037: ...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 1038: ...01 38 KYRON 2008 07 3410 01 ION 4 SPEED 2 Reverse ...

Page 1039: ...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 1040: ...01 40 KYRON 2008 07 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 1041: ...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 1042: ...01 42 KYRON 2008 07 3410 01 ION 4 SPEED 4 Drive 1 ...

Page 1043: ...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 1044: ...01 44 KYRON 2008 07 3410 01 ION 4 SPEED 5 Drive 2 and Manual 2 ...

Page 1045: ...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 1046: ...01 46 KYRON 2008 07 3410 01 ION 4 SPEED 6 Drive 3 and Manual 3 ...

Page 1047: ... 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 1048: ...01 48 KYRON 2008 07 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 1049: ...01 49 ION 4 SPEED KYRON 2008 07 3410 01 7 Drive 3 Lock Up and Manual 3 Lock Up ...

Page 1050: ... 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 1051: ...01 51 ION 4 SPEED KYRON 2008 07 3410 01 8 Drive 4 Overdrive ...

Page 1052: ...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 1053: ...01 53 ION 4 SPEED KYRON 2008 07 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 1054: ...01 54 KYRON 2008 07 3410 01 ION 4 SPEED 9 Drive 4 Lock Up ...

Page 1055: ... 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 1056: ... with a step up ratio of 0 83 as an overdrive The selector lever is controlled by electronically and mechanically The gears are shifted by the corresponding combination of three hydraulically actuated multiple disc brakes three hydraulically actuated multiple disc clutches and two mechanical one way clutches This electronically controlled automatic transmission adjusts the operating pressure to pr...

Page 1057: ...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 1058: ...02 6 KYRON 2008 07 3650 01 DC 5 SPEED 2 AUTOMATIC TRANSMISSION DC 5 SPEED APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View ...

Page 1059: ... 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 1060: ...02 8 KYRON 2008 07 3650 01 DC 5 SPEED Specifications ...

Page 1061: ...02 9 DC 5 SPEED KYRON 2008 07 3650 01 ...

Page 1062: ... 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 1063: ... 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 1064: ...02 12 KYRON 2008 07 3650 01 DC 5 SPEED General Characteristics ...

Page 1065: ...SPEED KYRON 2008 07 3650 01 Brake B1 disk assembly Brake B3 disk assembly Brake B2 disk assembly C1 Disk clutch assembly C2 Disk clutch assembly C3 Disk clutch assembly OVERVIEW AND OPERATION PROCESS 1 POWER FLOW ...

Page 1066: ...02 14 KYRON 2008 07 3650 01 DC 5 SPEED Shifting Elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 1067: ...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 1068: ...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 1069: ...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 1070: ...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 1071: ...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 1072: ...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 1073: ...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 1074: ... Two hydraulically controlled brake bands Three multi plate clutches All hydraulic functions are directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications The TCU receives input signals from certain transmission related sensors and switches The TCU also uses these signals when determining transmission operating strategy U...

Page 1075: ...hen winter mode is selected starting in second gear is facilitated and the WINTER mode indicator light is switched ON To prevent wheel spin on slippery surfaces the transmission will not allow first gear unless manually overridden Standard Mode is selected when the lever is in the D position with the mode switch in the standard S position and the transmission is within normal temperature ranges Sh...

Page 1076: ...03 4 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 1 Specifications 2 STRUCTURE CHARACTERISTICS AND SPECIFICATIONS ...

Page 1077: ... 5 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 4WD Automatic Transmission 2 Appearance 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Adapter housing Inhibiter switch ...

Page 1078: ...03 6 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 3 Internal Assembly Figure 2WD 4WD ...

Page 1079: ...03 7 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 4 Shift Pattern ...

Page 1080: ...03 8 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 3 TIGHTENING TORQUE ...

Page 1081: ...g Modulated torque converter clutch applications The transmission contains fully synthetic automatic transmission fluid ATF and is filled for life therefore it does not require periodic servicing Engine power reaches the transmission via a torque converter with integral converter lock up clutch The six forward gears and one reverse gear are obtained from a single planetary set followed by a double...

Page 1082: ...ions Drive and Reverse engagements from either Park or Neutral are performed in less than 2 2 seconds There is no drive engagement prevention strategy implemented on the transmission system as there is sufficient engine strategy to protect the system However reverse engagement is prevented until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12 and vehicle speed...

Page 1083: ...ooler 3 Shift Strategy Transmission gear change is controlled by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change Gear Hold Going Uphill Downhill Coastdown Coastdown downshifts occur at 0 pedal when the vehicle is coasting down to a stop Torque Demand Torque ...

Page 1084: ...he attempt To shift into any other positions from the P position after stopping the vehicle you have to depress the brake pedal with the ignition switch ON 2 Selection of Manual Automatic Shift Function Shift from the P Position D Automatic shift according to the driving condition M Manual shift 3 Mode Switch W Winter mode S Standard mode Use the standard mode in normal driving c 4 Gear Position P...

Page 1085: ... gear state will display on the instrument cluster Unlike the normal 1st gear engine braking will be available in this manual 1st state 2st Gear State 3st Gear State 4st Gear State 5st Gear State 6st Gear State The 2nd gear state will display on the instrument cluster 2 1 automatic kick down shifts are available 2nd gear has engine braking available The 3rd gear state will display on the instrumen...

Page 1086: ...p home mode for service The TCU monitors all factors which can af The TCU enters the limp home mode when the batter voltage drops below 8 V If the transmission is overheated the shift pattern is changed to the hot mode to cool the transmission more efficiently While the transmission is overheated the selector lever symbol and engine temperature warning lamp on the instrument cluster blink until th...

Page 1087: ...om certain transmission related sensors and switches The TCU also uses these signals when determining transmission operating strategy Using all of these input signals the TCU can determine when the time and conditions are right for a shift or when to apply or release the torque converter clutch It will also determine the pressure needed to optimise shift feel To accomplish this the TCU operates si...

Page 1088: ... switch ON process checking for the above faults The gear ratio diagnostic checks if each gear ratio is correctly engaged Also following a gear shift the diagnostic checks if the transmission has engaged the target gear within the allowed time The TCU checks if the torque converter can be locked correctly If torque converter lock up does not occur correctly the TCU performs the appropriate fail sa...

Page 1089: ...peration High and Low range operation has different parameters to optimise shift quality 4 Shift Map Selection The driver can manually select between normal S and winter modes W via the mode switch Depending on the transmission temperature uphill and downhill grades and altitude shift maps will be selected by the TCU to suit the driving conditions The following maps are available Normal Mode Norma...

Page 1090: ...converter As additional assistance to the hot mode the following are activated Above 110 C the electrical radiator fans are switch ON Above 130 C the engine torque will be reduced and the WINTER light on the instrument cluster will flash Above 145 C the transmission will neutralise until the fluid temperature falls below 120 C as a final protection Activation of the hot mode inhibits other transmi...

Page 1091: ...dy during manufacture The EMM is integrated into the input speed sensor which is mounted on the valve body in the transmission The EMM data contains transmission specific characterisation information Upon installation the TCU will upload the data from the EMM and utilise this data in the operation of the transmission Selector lever position Selected gear state Manual mode activation Output torque ...

Page 1092: ...er train of the transmission is as follow Gear States Summary Power train M 1st gear Power train D 1st gear Power train D 2nd gear Power train D 2nd gear lockup Power train D 3rd gear Power train D 4th gear D 4th gear limp home mode Power train D 5th gear Power train D 6th gear ...

Page 1093: ...03 21 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 Overall Hydraulic Circui ...

Page 1094: ...lenoids S9 is also a variable bleeding solenoid It controls Line Pressure Solenoid S10 is a variable bleeding solenoid as well and is used for controlling the application of the Torque Converter lock up clutch ON OFF Solenoids Gear States Summary S1 controls apply release of the C1 Clutch S2 controls apply release of the C2 Clutch S3 controls apply release of the C3 Clutch B2 Band S4 controls appl...

Page 1095: ...S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch S1 ON moves B2 Shift Valve to its left end position allowing an application of the B2 Band S7 must be ON as well C2 Shift Valve S2 OFF is open allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 Connecting Components Manual 1st is not achieved by moving the Manual Valv...

Page 1096: ...03 24 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Manual 1st C2 B2 ON 3 536 ...

Page 1097: ...C2 applied drives FSG Rear Planet Carrier held via 1 2 OWC Control Connecting Components S1 is ON S2 is OFF S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch C2 Shift Valve S2 OFF is open allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 ...

Page 1098: ...03 26 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Auto 1st C2 OWC ON 3 536 ...

Page 1099: ...onents S1 is ON S2 is OFF S4 is ON S1 ON moves C1 Shift Valve to its left end position not allowing the application of the C1 Clutch C2 Shift Valve is OPEN S2 OFF allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 S4 ON moves B1 Shift Valve to its left end position allowing engagement of B1 Band Drive oil that engages B1 Band is regulated by VBS S8 ...

Page 1100: ...03 28 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Auto 2nd C2 B1 ON 2 143 ...

Page 1101: ...03 29 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 4 Power Train D Drive 2nd Lockup Power flow diagram Connecting Components ...

Page 1102: ...03 30 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 2nd Lockup C2 B1 TCC ON ...

Page 1103: ...ual to the ratio of the Front Gear Set Control Connecting Components S1 ON moves C1 Shift Valve to the left end not allowing the application of the C1 Clutch C2 Shift Valve is open allowing drive oil to engage C2 Clutch S2 OFF S3 S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch Connecting Components C3 Clutch cannot be engaged without S7 being ON and supplying press...

Page 1104: ...03 32 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 3rd Gear C2 C3 ON 1 478 ...

Page 1105: ...pplied drives Rear Planet Carrier Control Connecting Components S1 is OFF S2 is OFF C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch C2 Shift Valve is OPEN S2 OFF allowing drive oil to engage C2 Clutch Drive oil that engages C1 C2 Clutches is regulated by S5 S6 VBS respectively for each clutch 4th GEAR is used as a LHM state Connecting Components ...

Page 1106: ...03 34 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 4th 4th LHM C1 C2 ON 1 156 ...

Page 1107: ...rrier C3 applied drives RSG Control Connecting Components S1 is OFF S2 is ON S3 is ON S2 ON moves C2 Shift Valve to its left end position not allowing the application of the C2 Clutch C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch S3 ON and with S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutc ...

Page 1108: ...03 36 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 5th Gear C1 C3 ON 0 866 ...

Page 1109: ...t Carrier B1 applied to hold RSG Control Connecting Components S1 is OFF S2 is ON S4 is ON S2 ON moves C2 Shift Valve to its left end position not allowing the application of the C2 Clutch C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch S4 ON moves B1 Shift Valve to its left end position allowing the engagement of B1 Band ...

Page 1110: ...03 38 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T 6th Gear C1 B1 ON 0 677 ...

Page 1111: ...ves RSG B2 applied holds Rear Planet Carrier stationary Control Connecting Components S1 is ON S2 is ON S3 is ON Line pressure is directed via Manual Valve to apply B2 Band directly S3 ON allows ramping and regulating pressure supplied to the C3 S1 S2 are ON not allowing engagement either C1 or C2 Clutch at any circumstances ...

Page 1112: ...03 40 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Reverse C3 B2 ON 3 094 ...

Page 1113: ...03 41 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 10 Power Train Reverse Limp Home Mode Power flow diagram Connecting Components ...

Page 1114: ...03 42 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Reverse at LHM C3 B2 ON ...

Page 1115: ...03 43 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 11 Power Train Parking Power flow diagram Connecting Components ...

Page 1116: ...03 44 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Park ...

Page 1117: ...03 45 DSI M78 6 SPEED A T KYRON 2008 07 3650 01 12 Power Train Neutral Power flow diagram Connecting Components ...

Page 1118: ...03 46 KYRON 2008 07 3650 01 DSI M78 6 SPEED A T Neutral ...

Page 1119: ...03 94 KYRON 2008 07 3110 01 DSI M78 6 SPEED A T 1 WIRING DIAGRAM DIAGNOSIS AND TESTING ...

Page 1120: ...03 95 DSI M78 6 SPEED A T KYRON 2008 07 3110 01 1 Transmission Control Unit 2 WIRE HARNESS CONNECTOR CHART Connector Front View 3 UNIT CONNECTOR DESCRIPTION Connector J1 A ...

Page 1121: ...03 96 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Connector J2 B Connector J3 C ...

Page 1122: ...03 97 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 2 Transmission Connector J4 Connector Front View ...

Page 1123: ...03 98 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T 3 Inhibitor Switch Connector J5 ...

Page 1124: ...03 99 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 1 DIAGNOSTIC TROUBLE CODE LIST TROUBLE CODE DIAGNOSIS ...

Page 1125: ...03 100 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T ...

Page 1126: ...rent draw typically being less than 4 amps but reaching as high as 10 amps during gear shifts As the mechanical components of the transmission change due to wear etc the TCU adapts its shift data to accommodate these changes and maintain shift quality over the life of the vehicle If a transmission component degrades to a point whereby the TCU is unable to adapt its shift data to maintain shift qua...

Page 1127: ...03 102 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Schematic Connector Details ...

Page 1128: ...03 103 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Details DTC Clearing ...

Page 1129: ...d enables reverse light operation when the TGS lever is in the reverse position The inhibitor switch has an individual circuit for each of these functions with only the gear lever position circuit being connected directly to the TCU The TCU supplies a 5 V reference signal to the gear lever position circuit inhibitor switch and measures the voltage drop in the circuit to determine the gear lever po...

Page 1130: ...03 105 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 Resistance Values DTC Details Gear Lever Position Sensor Specifications ...

Page 1131: ...03 106 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 1132: ...nable to maintain a satisfactory transmission oil temperature the TCU will take precautionary measures to prevent damage to the transmission and other vehicle components The TCU also monitors the rate of temperature change according to current operating conditions performance If the temperature sensor performance is outside a pre determined set of values DTC P0711 will set DTC Details DTC Clearing...

Page 1133: ...n the valve body harness tray The TFT sensor is a negative coefficient thermistor The transmission control unit TCU supplies a 5 V reference signal to the sensor and measures the voltage drop in the circuit When the transmission fluid is cold the sensor resistance is high with the sensor resistance decreasing as the fluid temperature increases Schematic Connector Details ...

Page 1134: ...03 109 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 Resistance Values ...

Page 1135: ...03 110 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 1136: ...e sensor and is mounted on the valve body in the transmission The EMM is matched to the transmission valve body during manufacture The EMM is integrated into the input speed sensor The hall effect sensor drives the signal low The TCU then pulls the signal up to 5 V via a resistor 36 times per revolution of the C2 cylinder ...

Page 1137: ...03 112 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Schematic Connector Details ...

Page 1138: ...03 113 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Details ...

Page 1139: ...03 114 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 1140: ...N 2008 07 3110 00 6 Transmission Gear Select Lever DTC Description The transmission gear select lever contains the mode switch manual mode active switch and up down switches These switches are connected directly to the TCU Schematic ...

Page 1141: ...03 116 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Connector Details Resistance Values Transmission Gear Select Lever Resistance Values ...

Page 1142: ...03 117 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Clearing ...

Page 1143: ...n The OSS sensor is a Hall Effect type sensor and is mounted at the rear of the transmission main case The hall effect sensor drives the signal low The TCU then pulls the signal up to 5 V via a resistor 22 times per revolution of the transmission output shaft Schematic Connector Details ...

Page 1144: ...03 119 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Details DTC Details ...

Page 1145: ...Engagement DTC Description Transmission gear change is controlled by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change ...

Page 1146: ...03 121 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Details ...

Page 1147: ...03 122 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 1148: ...raulic control system Pressure at the torque converter lock up clutch piston is determined by an electronic variable bleed solenoid VBS During operation the TCU evaluates torque converter slip speed and compares this against what is expected If torque converter slip is not within predefined parameters a DTC will set to indicate a torque converter lock up problem ...

Page 1149: ...03 124 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 1150: ...10 00 10 Steering Wheel DTC Description The steering wheel contains transmission gear select TGS up down switches and are directly connected to the TCU These switches operate in parallel with the TGS lever switches directly to the TCU Schematic ...

Page 1151: ...03 126 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Connector Details Resistance Values DTC Details ...

Page 1152: ...03 127 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Clearing ...

Page 1153: ...CU is able to vary the amount of torque applied to the clutch elements by controlling the current to the variable bleed solenoid windings The clutch element torque transfer is directly related to the current applied to the solenoids During operation the TCU evaluates the actual current delivered to the solenoid and compares this against what is expected If the current is not within predefined para...

Page 1154: ...03 129 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Description Schematic Connector Details ...

Page 1155: ...03 130 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 1156: ...03 131 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 ...

Page 1157: ...03 132 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T ...

Page 1158: ...03 133 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Clearing ...

Page 1159: ...ween different clutch elements within the transmission During operation the TCU evaluates the actual current delivered to the on off solenoid and compares this against what is expected If the current is not within predefined parameters a DTC will be set to indicate the load on the TCU is abnormal DTC Description ...

Page 1160: ...03 135 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 Schematic Connector Details ...

Page 1161: ...03 136 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 1162: ...03 137 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 ...

Page 1163: ...03 138 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 1164: ...share vehicle system information between the control units connected to the bus The TCU obtains the majority if its information via this network If the TCU does not receive information at regular intervals from the electronic control units connected to the bus the TCU will set a communication DTC DTC Description ...

Page 1165: ...03 140 KYRON 2008 07 3110 00 DSI M78 6 SPEED A T Schematic Connector Details DTC Details ...

Page 1166: ...03 141 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Clearing ...

Page 1167: ...TCU software or calibration may be upgraded at service These DTC뭩 protect the TCU against corrupted files being loaded into the TCU They also ensure only the correct calibration parameters are used with the software version currently loaded into the TCU DTC Description ...

Page 1168: ...03 143 DSI M78 6 SPEED A T KYRON 2008 07 3110 00 DTC Details DTC Clearing ...

Page 1169: ...of driving power Replenish oil if the engine is completely warmed up and there is no loss of driving power but there is still a problem with the vehicle speed Oil Check and Replenishment When replenishing or changing transmission oil a genuine recommended oil must be used If non approved oil is used it will have fatal impacts on the transmission s performance and life Never use such oil Wrong oil ...

Page 1170: ...filler pump to the oil inlet After attaching the filler pump to the transmission lower this vehicle and replenish oil 1 2 3 4 When the transmission torque converter has no oil 9 5 ℓ When the transmission torque converter is filled with oil 4 5 ℓ a b Engage the parking brake start the engine while the selection lever is engaged to P and depress the foot brake Then start shifting the selection lever...

Page 1171: ...ngine torque without slipping Stall testing should be performed for a period no longer then 10 seconds Apply Hand Brake Start Engine Press Brake Pedal Shift to DRIVE Press Accelerator Pedal to 100 for 6 seconds Observe Engine speed Release Accelerator Pedal Shift To Reverse Press Accelerator Pedal to 100 for 6 seconds Observe Engine speed If engine speed is observed 3000 rpm transmission hardware ...

Page 1172: ...ting the scan tool With the transmission gear select TGS lever in Park turn the ignition key to the ON position engine not running Using the scan tool set the parameter Set Km Travelled to 0Km Run the task Activate Adaptive Green Offset Turn the ignition key to the OFF position Start the vehicle and check for normal operation 1 2 3 4 5 6 Adaptive Reset Procedure To perform an adaptive reset proced...

Page 1173: ...til fluid starts to drain from the level hole and reinstall the plug Drive the vehicle for approximately five minutes Connect the vehicle s diagnostic scan tool to the vehicles diagnostic connector Refer to the vehicle repair manual for information on connecting the scan tool With the gear select lever in the Neutral position start the engine and allow to run at idle until the transmission fluid t...

Page 1174: ... 3 Connect one end of a rubber hose to the end of the rear cooler line and place the other end in a suitable container to collect the transmission fluid as it is pumped out Start the engine and run for approximately 30 seconds at idle With ATF at 50 C temperature a minimum of 2 5litres oil flow after 30 seconds Whist the engine is running have an assistant pump transmission fluid into the transmis...

Page 1175: ...03 150 KYRON 2008 07 3680 01 DSI M78 6 SPEED A T 7 TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE NEW TRANSMISSION ...

Page 1176: ......

Page 1177: ...ience especially 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 KY...

Page 1178: ... 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 1179: ...05 3 T M LEVER KYRON 2008 07 3170 01 3170 01 T M LEVER OVERVIEW AND OPERATION PROCESS 1 CIRCUIT OF ION 4 SPEED AUTOMATIC T M ...

Page 1180: ...05 4 KYRON 2008 07 3170 01 T M LEVER 2 CIRCUIT OF SHIFT INTER LOCK ...

Page 1181: ...ft mechanism is used to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 3 4 The clutch release system is available to use CSC Concentric Slave Cylinder or Fork type according to the vehicle model 5 T...

Page 1182: ...06 4 KYRON 2008 07 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications 2 Tightening Torque ...

Page 1183: ...06 5 M T KYRON 2008 07 3170 01 Inside N Switch OVERVIEW AND OPERATION PROCESS 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch ...

Page 1184: ...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 1185: ...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 1186: ...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 1187: ... 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 1188: ... 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 1189: ......

Page 1190: ...07 3 CLUTCH KYRON 2008 07 3010 01 GENERAL 1 CLUTCH SPECIFICATIONS 2 TIGHTTENING TORQUE ...

Page 1191: ...d into a clutch steel cover which is bolted to the flywheel The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consi...

Page 1192: ...07 5 CLUTCH KYRON 2008 07 3010 01 3 Functions Components of Clutch Assembly Adapter Pipe Assembly Clutch Assembly Concentric Slave Cylinder ...

Page 1193: ...07 6 KYRON 2008 07 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 1194: ...08 3 AXLE KYRON 2008 07 4120 01 GENERAL 1 AXLE SPECIFICATIONS Specification Torque Gear ratio Type Size Offset Housing Specification Capacity Length Width Weight ...

Page 1195: ...s models in addition to existing 5 link suspension the IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle The below figures for rear axle show the rear axle with the independent type suspension 4WD A T Front Axle Rear Axle IRDA Independent Rear Drive Axle ...

Page 1196: ...OCESS 1 OVERVIEW 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 1197: ...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 1198: ...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 1199: ...conventional part time transfer case but the changes in comparison to the conventional transfer case are as follows No additional coding is required when replacing TCCU Delete the devices tone wheel speed sensor wiring etc related to the speed sensor in the transfer case This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 through the CAN communic...

Page 1200: ...KYRON 2008 07 3240 01 T C OVERVIEW AND OPERATION PROCESS 1 STRUCTURE Rear propeller shaft Part time transfer case Rear axle IRS type Transmission Front propeller shaft Front locking hub system IWE Front axle ...

Page 1201: ...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 1202: ...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 1203: ... 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 1204: ...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 1205: ...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 1206: ...10 10 KYRON 2008 07 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 1207: ...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 1208: ... 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 1209: ... 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 1210: ......

Page 1211: ...11 3 PROPELLER SHAFT KYRON 2008 07 3310 00 3310 00 PROPELLER SHAFT GENERAL 1 SPECIFICATION ...

Page 1212: ...duction gear It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and ...

Page 1213: ...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 1214: ...11 6 KYRON 2008 07 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 1215: ...ROPELLER SHAFT Manual Transmission Automatic Transmission For Gasoline Engine Remove the flange yoke mounting bolt on the transfer case side of the front propeller shaft 1 Put installation marks on the yoke to the propeller and the flange to the transfer case ...

Page 1216: ...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 1217: ... 07 3310 06 3310 06 REAR PROPELLER SHAFT Remove the yoke mounting bolt and nut on the transfer case side of the rear propeller shaft 1 Put installation marks on the yoke of the rear propeller shaft and the flange of the transfer case ...

Page 1218: ...08 07 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 1219: ...er shaft Place an alignment on the spiders before removing 1 2 Remove the snap ring with snap ring pliers 3 Tap the yoke shoulder on shaft with copper hammer to remove the roller bearing Remove the other bearings with same manner 4 If it cannot be removed hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer 5 ...

Page 1220: ...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 1221: ...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 1222: ...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 1223: ...12 3 SUSPENSION KYRON 2008 07 4411 01 GENERAL 1 FRONT SUSPENSION SPECIFICATIONS 2 REAR SUSPENSION SPECIFICATIONS 4411 01 SUSPENSION ...

Page 1224: ... internal Cylinders ABS ESP 5Link Suspension solid type disc ABS ESP Independent suspension ventilated disc 2 REAR BRAKE Rear Disc and Caliper 1 Internal Cylinder For the rear brake system specifications differ between ABS ESP system equipped vehicles and non ABS ESP system equipped vehicles The drum type brake is installed on non ABS equipped vehicles When ABS ESP is installed on the 5 link type ...

Page 1225: ...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 1226: ...13 5 ESP KYRON 2008 07 4890 01 3 SECTIONAL DRAWING Front Disc Brake Rear Disc Brake ...

Page 1227: ... 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 1228: ...13 7 ESP KYRON 2008 07 4890 01 2 BRAKE SYSTEM SPECIFICATIONS ...

Page 1229: ...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 1230: ...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 1231: ... 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 1232: ...ehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 about 5 71 degree ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Br...

Page 1233: ...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 1234: ...13 13 ESP KYRON 2008 07 4890 01 New T C Without speed sensor ...

Page 1235: ...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 1236: ... 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 1237: ...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 1238: ......

Page 1239: ...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 1240: ...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 1241: ...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 1242: ...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 1243: ...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 1244: ... 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 1245: ...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 1246: ...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 1247: ...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 1248: ......

Page 1249: ...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 1250: ...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 1251: ...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 1252: ...13 31 ESP KYRON 2008 07 4890 01 4 Input Output Signals for HDC Operation ...

Page 1253: ...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 1254: ......

Page 1255: ...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 1256: ...13 35 ESP KYRON 2008 07 4890 01 Comparison with ABS System ABS ESP Indicator ESP OFF Switch HDC Indicator HDC Switch ActiveWheelSpeedSensor ...

Page 1257: ...13 36 KYRON 2008 07 4890 01 ESP 7 INPUT OUTPUT SIGNALS FOR HDC OPERATION Input Output of ESP System ...

Page 1258: ...13 37 ESP KYRON 2008 07 4890 01 8 ESP HYDRAULIC CIRCUIT DIAGRAM ...

Page 1259: ...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 1260: ...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 1261: ...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 1262: ...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 1263: ...13 42 KYRON 2008 07 4890 01 ESP New Transfer Case Without Speed Sensor ...

Page 1264: ...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 1265: ... 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 1266: ...7 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 1267: ...13 46 KYRON 2008 07 4890 01 ESP 13 INPUT AND OUTPUT DIAGRAM OF ABS Input Output of ABS without TPMS ...

Page 1268: ...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 1269: ...tlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually No Hydraulic Pressure Circuit when ABS is Operating As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increas...

Page 1270: ...es again The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber ...

Page 1271: ...ief valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydraulic press...

Page 1272: ... Power steering return pipe 5 Power steering gear box pipe 3 Power steering high pressure hose and pipe 6 Power steering gear box assembly OVERVIEW AND OPERATION PROCESS 1 POWER STEERING SYSTEM LAYOUT 40 50 Nm Feed pipe nut Steering gear box mounting bracket bolts 14 mm 2EA 30 40 Nm ...

Page 1273: ...14 5 STEERING KYRON 2008 07 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 1274: ...14 6 KYRON 2008 07 4610 00 STEERING Installation Drawing of SSPS Pipe bracket bolt 10 mm Pipe mounting nut Pipe bracket bolt 10 mm 9 14 Nm 9 14 Nm 20 26 Nm Gear box mounting bolt ...

Page 1275: ...14 7 STEERING KYRON 2008 07 4610 00 Components 20 25 Nm 40 60 Nm 7 11 Nm 18 25 Nm 35 45 Nm 45 50 Nm 70 90 Nm 20 25 Nm 30 40 Nm Tie rod end Steering gear box Lower shaft Steering wheel Column shaft ...

Page 1276: ...14 8 KYRON 2008 07 4610 00 STEERING Steering wheel Column shaft Lower shaft Steering gear box ...

Page 1277: ...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 1278: ...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 1279: ...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 1280: ...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 1281: ...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 1282: ...14 14 KYRON 2008 07 4610 00 STEERING 3 CIRCUIT DIAGRAM ...

Page 1283: ...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 1284: ...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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SSANGYONG KYRON 2008.07, Manual

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