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SSANGYONG KYRON 2010.01 Manual Download Page 1

GENERAL

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GENERAL

1. DIMENSIONS........................................
2. SPECIFICATIONS.................................
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

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Summary of Contents for KYRON 2010.01

Page 1: ...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 2: ...01 2 undefined 0000 00 GENERAL ...

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

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

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

Page 6: ...ea 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 4 Vin Label ...

Page 7: ... 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 8: ...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 9: ...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 10: ... 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 11: ...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 12: ...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 13: ...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 14: ...01 14 undefined 0000 00 GENERAL 6 JACK UP POINTS 1 IRS Lifting Point Dotted Circles ...

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

Page 16: ...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 17: ...01 17 GENERAL undefined 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

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

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

Page 20: ... 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 21: ...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 22: ......

Page 23: ...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 24: ...01 4 undefined 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 25: ...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 26: ...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 27: ...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 28: ... 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 29: ...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 30: ... 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 31: ...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 32: ...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 33: ...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 34: ... 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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...01 19 ENGINE GENERAL undefined 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ... 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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ... 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 57: ...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 58: ... 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 59: ... 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 60: ...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 61: ...01 41 ENGINE GENERAL undefined 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 62: ...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 63: ...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 64: ...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 65: ... 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 66: ...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 67: ...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 68: ... 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 69: ...02 8 undefined 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 70: ...02 9 ENGINE ASSEMBLY undefined 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 71: ...02 10 undefined 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 72: ...02 11 ENGINE ASSEMBLY undefined 1212 01 ...

Page 73: ...02 12 undefined 1212 01 ENGINE ASSEMBLY ...

Page 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...03 13 ENGINE FUEL SYSTEM undefined 1881 01 6 CIRCUIT DIAGRAM ...

Page 85: ...03 14 undefined 1881 01 ENGINE FUEL SYSTEM ...

Page 86: ...03 15 ENGINE FUEL SYSTEM undefined 1881 01 ...

Page 87: ......

Page 88: ... 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 89: ... 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 90: ...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 91: ...04 6 undefined 2321 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 92: ...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 93: ... 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 94: ...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 95: ...04 10 undefined 2321 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 96: ...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 97: ... 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 98: ...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 99: ...05 6 undefined 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...07 3 COOLING SYSTEM undefined 9210 05 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 106: ...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 107: ...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 108: ... 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 109: ...08 3 ENGINE ELECTRIC DEVICES undefined 1461 01 1461 01 ENGINE ELECTRICAL SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 110: ...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 111: ...NGINE ELECTRIC DEVICES undefined 1451 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGINE Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 112: ...08 6 undefined 1461 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 113: ...08 7 ENGINE ELECTRIC DEVICES undefined 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ... 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 122: ... 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 123: ...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 124: ...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 125: ...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 126: ... 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 127: ...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 128: ... 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 129: ...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 130: ... 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 131: ...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 132: ...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 133: ...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 134: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 135: ... 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 136: ...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 137: ... 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 138: ...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 139: ... 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 140: ...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 141: ...01 4 undefined 1114 00 ENGINE ASSEMBLY 1 Engine Assembly Structure Front View Top View Touch idler equipped for A T ...

Page 142: ...01 5 ENGINE ASSEMBLY undefined 1114 00 Right Side View Left Side View ...

Page 143: ...01 6 undefined 1114 00 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 144: ...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 145: ...01 8 undefined 1114 00 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 146: ...01 9 ENGINE ASSEMBLY undefined 1114 00 ...

Page 147: ...01 10 undefined 1114 00 ENGINE ASSEMBLY ...

Page 148: ... 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 149: ...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 150: ... 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 151: ... 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 152: ...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 153: ...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 154: ...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 155: ......

Page 156: ...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 157: ...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 158: ...02 8 undefined 1881 09 ENGINE FUEL SYSTEM 2 FUEL FLOW OF D20DT EU IV ENGINE ...

Page 159: ...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 160: ... 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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ... 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 173: ...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 174: ...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 175: ...07 2 undefined 2112 00 ENGINE COOLING SYSTEM ...

Page 176: ...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 177: ...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 178: ...07 5 ENGINE COOLING SYSTEM undefined 1520 00 1 Structure of Water Pump for D20DT Engine ...

Page 179: ......

Page 180: ...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 181: ...08 4 undefined 1491 01 ENGINE ELECTRICAL SYSTEM 2 D20DT EU IV ENGINE S ECU CIRCUIT ...

Page 182: ...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 183: ...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 184: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 185: ... 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 186: ...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 187: ... 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 188: ...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 189: ... 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 190: ...NO DATA ...

Page 191: ...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 192: ......

Page 193: ...01 3 ENGINE D20DT undefined 0000 00 GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH Side View D20DT D27DT 0000 00 ENGINE GENERAL ...

Page 194: ...01 4 undefined 0000 00 ENGINE D20DT 2 RH side view D20DT D27DT ...

Page 195: ...01 5 ENGINE D20DT undefined 0000 00 3 Front view D20DT D27DT ...

Page 196: ...01 6 undefined 0000 00 ENGINE D20DT 4 Fan belt D20DT D27DT ...

Page 197: ...01 7 ENGINE D20DT undefined 0000 00 2 COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ...

Page 198: ...01 8 undefined 0000 00 ENGINE D20DT ...

Page 199: ...01 9 ENGINE D20DT undefined 0000 00 ...

Page 200: ...01 10 undefined 0000 00 ENGINE D20DT ...

Page 201: ...01 11 ENGINE D20DT undefined 0000 00 3 ENGINE CONTROLS LAYOUT 1 Ecu related componets 1 D20DT Engine ...

Page 202: ...01 12 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 203: ...01 13 ENGINE D20DT undefined 0000 00 2 ENGINE AND SENSORS 1 D20DT Engine ...

Page 204: ...01 14 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 205: ...01 15 ENGINE D20DT undefined 0000 00 4 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1 D20DT Engine ...

Page 206: ...01 16 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 207: ...01 17 ENGINE D20DT undefined 0000 00 5 INTAKE SYSTEM LAYOUT 1 D20DT Engine ...

Page 208: ...01 18 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 209: ...01 19 ENGINE D20DT undefined 0000 00 6 EXHAUST SYSTEM LAYOUT 1 D20DT Engine ...

Page 210: ...01 20 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 211: ...01 21 ENGINE D20DT undefined 0000 00 7 LUBRICATION SYSTEM LAYOUT 1 D20DT Engine ...

Page 212: ...01 22 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 213: ...01 23 ENGINE D20DT undefined 0000 00 8 COOLING SYSTEM LAYOUT 1 D20DT Engine ...

Page 214: ...01 24 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 215: ...01 25 ENGINE D20DT undefined 0000 00 9 FUEL SYSTEM LAYOUT 1 D20DT Engine ...

Page 216: ...01 26 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 217: ...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 218: ...01 28 undefined 0000 00 ENGINE D20DT 2 D27DT Engine ...

Page 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ......

Page 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...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 236: ...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 237: ...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 238: ...01 48 undefined 0000 00 ENGINE D20DT 17 STANDARD BOLTS SPECIFICATIONS Diameter X pitch in millimeters ...

Page 239: ...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 240: ......

Page 241: ...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 242: ...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 243: ... 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 244: ...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 245: ...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 246: ...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 247: ...02 9 ENGINE D20DT undefined 1114 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 248: ...02 10 undefined 1114 01 ENGINE D20DT 2 Engine Performance Curve 1 Vehicle with A T Output and Torque D20DT engine D27DT engine ...

Page 249: ...02 11 ENGINE D20DT undefined 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 250: ...02 12 undefined 1114 01 ENGINE D20DT Output and Torque 2 Vehicle with M T D20DT engine D27DT engine ...

Page 251: ...02 13 ENGINE D20DT undefined 1114 01 Oil Temperature Pressure and Boost Pressure D20DT engine D27DT engine ...

Page 252: ...02 14 undefined 1114 01 ENGINE D20DT 4 TIGHTENING TORQUE ...

Page 253: ...02 15 ENGINE D20DT undefined 1114 01 ...

Page 254: ...02 16 undefined 1114 01 ENGINE D20DT ...

Page 255: ...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 256: ... 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 257: ...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 258: ...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 259: ...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 260: ...03 8 undefined 1881 01 ENGINE D20DT 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Page 261: ...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 262: ...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 263: ...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 264: ... 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 265: ...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 266: ...03 14 undefined 1881 01 ENGINE D20DT 7 Circuit Diagram ...

Page 267: ...03 15 ENGINE D20DT undefined 1881 01 ...

Page 268: ...03 16 undefined 1881 01 ENGINE D20DT ...

Page 269: ...ge every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2 Special Tools and Equipment Special Tools and Equipment Application Y99220112B Intake manifold guide pin Installation of intake manifold 2321 01 INTAKE SYSTEM ...

Page 270: ...04 4 undefined 2321 01 ENGINE D20DT OVERVIEW AND OPERATION PROCESS 1 ENGINE INTAKE COMPONENTS LOCATOR 1 D20DT Engine Air Cleaner Cover Elemen t Housing Intake Manifold HFM Sensor Intercooler ...

Page 271: ...04 5 ENGINE D20DT undefined 2321 01 2 D27DT Engine Air Cleaner Intake Manifold HFM Sensor Intercooler Cover Element Housing ...

Page 272: ...04 6 undefined 2321 01 ENGINE D20DT 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 273: ...lows to engine combustion chamber and intake air temperature And intake temperature sensor built in the sensor detects intake temperature Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the heating resistance Rh to 160 C that is higher temperature than intake air temperature that is measured by resistance RI Temperature sens...

Page 274: ...this sensor is most proper in controlling accurate air fuel ratio to meet the legal emission regulations This sensor measures actual intake air mass into engine very accurately during specific instant acceleration and deceleration and determines engine loads and detects intake air pulsation and air flows Main functions of HFM sensor are 1 Using for EGR feedback control 2 Using for turbocharger boo...

Page 275: ...04 9 ENGINE D20DT undefined 2321 01 Circuit Diagram of HFM Sensor ...

Page 276: ...en into the engine However the intake air is heated 100 110 C during the compression process in turbo charger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine Cold air has more oxygen molecules than warm air Thus cooler air gives more power and better fuel economy 1 Intercooler ...

Page 277: ...ort 2 Optimized EGR gas mixture in inlet chamber 3 Maximized intake efficiency with helical and tangential inlet port 1 Improving the swirl ratio in low and mid operating range 2 Improving the acceleration fuel economy and reducing the maintenance in low and mid operating range 4 Integrated inlet port and coolant outlet port D20DT D27DT 1 System Characteristics ...

Page 278: ... 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 279: ...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 280: ...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 281: ...05 6 undefined 1913 01 ENGINE D20DT Turbo Charger EGR Valve Muffler Exhaust Manifold Catalytic Converter DOC EGR Pipe Vacuum Modulator ...

Page 282: ...05 7 ENGINE D20DT undefined 1913 01 2 EXHAUST GAS FLOWS ...

Page 283: ... 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 284: ...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 285: ...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 286: ... 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 287: ...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 288: ...07 3 ENGINE D20DT undefined 2112 01 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 289: ...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 290: ...07 5 ENGINE D20DT undefined 2112 01 Coolant Reservoir FFH Coolant Temperature Sensor Radiator Water Pump Cooling Fan 2 D27DT Engine ...

Page 291: ... 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 292: ... 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 293: ...08 3 ENGINE D20DT undefined 1461 01 1461 01 ENGINE ELECTRIC SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 294: ...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 295: ... 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 296: ...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 297: ...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 298: ...08 8 undefined 1461 01 ENGINE D20DT 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 299: ...08 9 ENGINE D20DT undefined 1461 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 300: ...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 301: ...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 302: ...10 5 ENGINE D20DT undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 303: ...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 304: ...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 305: ... 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 306: ...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 307: ...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 308: ... 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 309: ......

Page 310: ...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 311: ...01 4 undefined 0000 00 ENGINE GENERAL D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Page 312: ...01 5 ENGINE GENERAL undefined 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Page 313: ...01 6 undefined 0000 00 ENGINE GENERAL D27DT Engine General Side View D27DT Engine General Left Side View ...

Page 314: ...01 7 ENGINE GENERAL undefined 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 315: ...01 8 undefined 0000 00 ENGINE GENERAL 2 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 316: ...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 317: ...01 10 undefined 0000 00 ENGINE GENERAL ...

Page 318: ...01 11 ENGINE GENERAL undefined 0000 00 ...

Page 319: ... 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 320: ...01 13 ENGINE GENERAL undefined 0000 00 2 Major Changes and Summary ...

Page 321: ...01 14 undefined 0000 00 ENGINE GENERAL ...

Page 322: ...01 15 ENGINE GENERAL undefined 0000 00 ...

Page 323: ...01 16 undefined 0000 00 ENGINE GENERAL ...

Page 324: ...01 17 ENGINE GENERAL undefined 0000 00 ...

Page 325: ...01 18 undefined 0000 00 ENGINE GENERAL ...

Page 326: ...01 19 ENGINE GENERAL undefined 0000 00 ...

Page 327: ...01 20 undefined 0000 00 ENGINE GENERAL ...

Page 328: ...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 329: ...01 22 undefined 0000 00 ENGINE GENERAL ...

Page 330: ...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 331: ...01 24 undefined 0000 00 ENGINE GENERAL Major Sensors and Components ...

Page 332: ...01 25 ENGINE GENERAL undefined 0000 00 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Page 333: ...01 26 undefined 0000 00 ENGINE GENERAL ...

Page 334: ...01 27 ENGINE GENERAL undefined 0000 00 2 Preheat System ...

Page 335: ...01 28 undefined 0000 00 ENGINE GENERAL 3 Fuel System ...

Page 336: ...01 29 ENGINE GENERAL undefined 0000 00 Fuel Supply System ...

Page 337: ...01 30 undefined 0000 00 ENGINE GENERAL 4 Lubrication System ...

Page 338: ...01 31 ENGINE GENERAL undefined 0000 00 5 Cooling System ...

Page 339: ...01 32 undefined 0000 00 ENGINE GENERAL 6 Intake System ...

Page 340: ...01 33 ENGINE GENERAL undefined 0000 00 7 Exhaust System ...

Page 341: ...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 342: ...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 343: ...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 344: ...02 6 undefined 1881 09 ENGINE FUEL SYSTEM 2 COMPONENTS OF FUEL SYSTEM ...

Page 345: ...02 7 ENGINE FUEL SYSTEM undefined 1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 346: ...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 347: ...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 348: ... 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 349: ...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 350: ...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 351: ...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 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ...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 359: ...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 360: ...NO DATA ...

Page 361: ...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 362: ...07 4 undefined 1520 01 ENGINE COOLING SYSTEM D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 363: ...NO DATA ...

Page 364: ...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 365: ...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 366: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 367: ... 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 368: ...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 369: ... 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 370: ...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 371: ... 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 372: ...NO DATA ...

Page 373: ...NO DATA ...

Page 374: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 375: ......

Page 376: ......

Page 377: ...01 4 KYRON 2010 01 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 378: ... 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 379: ... 01 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 380: ...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 381: ......

Page 382: ...02 3 ENGINE ASSEMBLY KYRON 2010 01 1113 01 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 383: ...02 4 KYRON 2010 01 1113 01 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 384: ...02 5 ENGINE ASSEMBLY KYRON 2010 01 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 385: ...02 6 KYRON 2010 01 1113 01 ENGINE ASSEMBLY ...

Page 386: ...02 7 ENGINE ASSEMBLY KYRON 2010 01 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 387: ...02 8 KYRON 2010 01 1113 01 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 388: ...02 9 ENGINE ASSEMBLY KYRON 2010 01 1113 01 4 FASTENER TIGHTENING SPECIFICATIONS CONT D ...

Page 389: ...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 390: ...03 4 KYRON 2010 01 2211 22 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 391: ...NO DATA ...

Page 392: ...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 393: ...05 4 KYRON 2010 01 2420 01 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 394: ...06 3 LUBRICATION SYSTEM KYRON 2010 01 9210 01 9210 01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1 OIL CIRCULATION ...

Page 395: ...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 396: ...07 3 COOLING SYSTEM KYRON 2010 01 2110 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 397: ...07 4 KYRON 2010 01 2110 01 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 398: ...07 5 COOLING SYSTEM KYRON 2010 01 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 399: ...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 400: ...07 7 COOLING SYSTEM KYRON 2010 01 2110 01 2 COMPONENT LOCATOR ...

Page 401: ... 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 402: ...08 3 ENGINE ELECTRIC DEVICES KYRON 2010 01 1452 01 1452 01 ENGINE ELECTRIC DEVICES GENERAL 1 GENERAL SPECIFICATIONS ...

Page 403: ...08 4 KYRON 2010 01 1452 01 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 404: ...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 405: ... 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 406: ...08 7 ENGINE ELECTRIC DEVICES KYRON 2010 01 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 407: ...09 3 ENGINE CONTROL SYSTEM KYRON 2010 01 1522 16 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE GENERAL ...

Page 408: ...09 4 KYRON 2010 01 1522 16 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 409: ... 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 410: ...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 411: ...10 5 CRUISE CONTROL SYSTEM KYRON 2010 01 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 412: ...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 413: ...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 414: ...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 415: ...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 416: ...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 417: ...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 418: ...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 419: ...01 5 ENGINE ASSEMBLY KYRON 2010 01 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 420: ...01 6 KYRON 2010 01 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 421: ...01 7 ENGINE ASSEMBLY KYRON 2010 01 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 422: ...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 423: ...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 424: ...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 425: ... 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 426: ...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 427: ... 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 428: ...01 14 KYRON 2010 01 1113 01 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 429: ...01 15 ENGINE ASSEMBLY KYRON 2010 01 1113 01 General Diagnosis Cont d ...

Page 430: ...01 16 KYRON 2010 01 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 431: ...01 17 ENGINE ASSEMBLY KYRON 2010 01 1113 01 General Diagnosis Cont d ...

Page 432: ...01 18 KYRON 2010 01 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 433: ...01 19 ENGINE ASSEMBLY KYRON 2010 01 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 434: ...01 20 KYRON 2010 01 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 435: ...01 21 ENGINE ASSEMBLY KYRON 2010 01 1113 01 Fastener Tightening Specifications Cont d ...

Page 436: ...01 22 KYRON 2010 01 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 437: ......

Page 438: ...02 3 ENGINE INTAKE SYSTEM KYRON 2010 01 1713 08 1713 08 ENGINE INTAKE SYSTEM GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 439: ...ENGINE EXHAUST SYSTEM 2420 01 ENGINE EXHAUST SYSTEM GENERAL 1 SPECIFICATION OVERVIEW AND OPERATION PROCESS 1 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION 2420 01 EXHAUST LINE 3 4 7 ...

Page 440: ......

Page 441: ...03 3 ENGINE EXHAUST SYSTEM KYRON 2010 01 2420 01 2420 01 ENGINE EXHAUST SYSTEM GENERAL 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 442: ...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 443: ...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 444: ... 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 445: ...04 3 ENGINE COOLING SYSTEM KYRON 2010 01 2112 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 446: ...04 4 KYRON 2010 01 2112 01 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 447: ...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 448: ...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 449: ...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 450: ... 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 451: ...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 452: ...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 453: ... 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 454: ...05 3 ENGINE ELECTRICAL SYSTEM KYRON 2010 01 1452 01 0000 00 ENGINE ELECTRIC DEVICES GENERAL 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 455: ...05 4 KYRON 2010 01 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 456: ...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 457: ...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 458: ...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 459: ...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 460: ...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 461: ... 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 462: ... 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 463: ...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 464: ...06 5 CRUISE CONTROL SYSTEM KYRON 2010 01 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 465: ...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 466: ...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 467: ...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 468: ...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 469: ...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 470: ... 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 471: ...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 472: ...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 473: ...ON 2010 01 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 474: ... ELECTRIC SYSTEM KYRON 2010 01 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 475: ...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 476: ...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 477: ...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 478: ...2010 01 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 479: ...01 10 KYRON 2010 01 0000 00 ELECTRIC SYSTEM Wiring Harness Arrangement 5 ELECTRIC COMPONENTS AND LAYOUT ...

Page 480: ...01 11 ELECTRIC SYSTEM KYRON 2010 01 0000 00 Components Locator ...

Page 481: ......

Page 482: ... 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 483: ...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 484: ...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 485: ...02 6 KYRON 2010 01 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 486: ...02 7 FUSE AND RELAY KYRON 2010 01 8410 02 2 Interior Fuse and Relay Box On the Passenger Side ...

Page 487: ...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 488: ...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 489: ...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 490: ...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 491: ...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 492: ...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 493: ...03 5 STICS KYRON 2010 01 8710 01 Rated Load ...

Page 494: ...03 6 KYRON 2010 01 8710 01 STICS Input Signals ...

Page 495: ...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 496: ......

Page 497: ...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 498: ...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 499: ......

Page 500: ...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 501: ... 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 502: ...06 4 KYRON 2010 01 8010 01 CLUSTER ...

Page 503: ......

Page 504: ...06 6 KYRON 2010 01 8010 01 CLUSTER 2 WARNING INDICATOR PANE ...

Page 505: ...06 7 CLUSTER KYRON 2010 01 8010 01 ...

Page 506: ...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 507: ...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 508: ...07 4 KYRON 2010 01 8310 01 LAMP BULB SPECIFICATIONS ...

Page 509: ......

Page 510: ... 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 511: ...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 512: ...oors Lock Unlock with this switch unit The position memory is available for up to three drivers Each driver can set his her own driver s seat and outside rearview mirrors positions and it will be separately stored in the integrated computer If somebody has moved the seat the memory positions can be recalled automatically by pressing the position button When this button is pressed once HDC is ready...

Page 513: ...ore than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer fluid will be sprayed onto the rear window glass once during rear wiper operation Auto Washer Switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid ...

Page 514: ...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 515: ...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 516: ...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 517: ...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 518: ...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 519: ...09 8 KYRON 2010 01 7810 01 WIPER 2 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 520: ...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 521: ...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 522: ...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 523: ...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 524: ...09 13 WIPER KYRON 2010 01 7810 01 3 WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS ...

Page 525: ...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 526: ...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 527: ...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 528: ...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 529: ...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 530: ...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 531: ... 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 532: ...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 533: ...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 534: ...10 11 RAIN SENSOR KYRON 2010 01 8610 09 3 ELECTRICAL WIRING DIAGRAM ...

Page 535: ...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 536: ...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 537: ...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 538: ...11 6 KYRON 2010 01 8790 00 PAS When failed ...

Page 539: ...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 540: ...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 541: ... 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 542: ...12 4 KYRON 2010 01 8930 14 AV OVERVIEW AND OPERATION PROCESS 1 AV SYSTEM CONFIGURATION AV System DVD Head Unit DVD Changer Audio System 6 Speakers ...

Page 543: ...12 5 AV KYRON 2010 01 8930 14 6 DISC changer TAPE RADIO CD RADIO DISC changer CD slot Tape ...

Page 544: ...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 545: ...12 7 AV KYRON 2010 01 8930 14 ...

Page 546: ...0 01 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 547: ...12 9 AV KYRON 2010 01 8930 14 4 AV SYSTEM SPECIFICATIONS AND CONTROL ...

Page 548: ...12 10 KYRON 2010 01 8930 14 AV Function Settings on Touch Panel Example ...

Page 549: ...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 550: ...13 3 AUDIO SYSTEM KYRON 2010 01 8930 01 8930 01 AUDIO SYSTEM OVERVIEW AND INSTALLATION 1 AUDIO SYSTEM OVERVIEW Audio System 6 Speakers ...

Page 551: ...01 3 ION 4 SPEED KYRON 2010 01 3410 01 3410 01 ION 4 SPEED GENERAL 1 SPECIFICATIONS ...

Page 552: ...01 4 KYRON 2010 01 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 553: ...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 554: ...01 6 KYRON 2010 01 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 555: ...01 7 ION 4 SPEED KYRON 2010 01 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 556: ...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 557: ...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 558: ... 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 559: ...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 560: ...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 561: ...01 13 ION 4 SPEED KYRON 2010 01 3410 01 ...

Page 562: ...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 563: ...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 564: ...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 565: ...01 17 ION 4 SPEED KYRON 2010 01 3410 01 Solenoid Operation during Gearshifts ...

Page 566: ...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 567: ...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 568: ...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 569: ...01 21 ION 4 SPEED KYRON 2010 01 3410 01 1 Hydraulic Control Circuit ...

Page 570: ...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 571: ...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 572: ...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 573: ...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 574: ...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 575: ...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 576: ...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 577: ... 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 578: ...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 579: ...01 31 ION 4 SPEED KYRON 2010 01 3410 01 ...

Page 580: ...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 581: ... 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 582: ...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 583: ...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 584: ...01 36 KYRON 2010 01 3410 01 ION 4 SPEED 1 Park and Neutral ...

Page 585: ...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 586: ...01 38 KYRON 2010 01 3410 01 ION 4 SPEED 2 Reverse ...

Page 587: ...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 588: ...01 40 KYRON 2010 01 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 589: ...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 590: ...01 42 KYRON 2010 01 3410 01 ION 4 SPEED 4 Drive 1 ...

Page 591: ...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 592: ...01 44 KYRON 2010 01 3410 01 ION 4 SPEED 5 Drive 2 and Manual 2 ...

Page 593: ...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 594: ...01 46 KYRON 2010 01 3410 01 ION 4 SPEED 6 Drive 3 and Manual 3 ...

Page 595: ... 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 596: ...01 48 KYRON 2010 01 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 597: ...01 49 ION 4 SPEED KYRON 2010 01 3410 01 7 Drive 3 Lock Up and Manual 3 Lock Up ...

Page 598: ... 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 599: ...01 51 ION 4 SPEED KYRON 2010 01 3410 01 8 Drive 4 Overdrive ...

Page 600: ...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 601: ...01 53 ION 4 SPEED KYRON 2010 01 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 602: ...01 54 KYRON 2010 01 3410 01 ION 4 SPEED 9 Drive 4 Lock Up ...

Page 603: ... 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 604: ... 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 605: ...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 606: ...02 6 KYRON 2010 01 3650 01 DC 5 SPEED 2 AUTOMATIC TRANSMISSION DC 5 SPEED APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View ...

Page 607: ... 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 608: ...02 8 KYRON 2010 01 3650 01 DC 5 SPEED Specifications ...

Page 609: ...02 9 DC 5 SPEED KYRON 2010 01 3650 01 ...

Page 610: ... 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 611: ... 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 612: ...02 12 KYRON 2010 01 3650 01 DC 5 SPEED General Characteristics ...

Page 613: ...SPEED KYRON 2010 01 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 614: ...02 14 KYRON 2010 01 3650 01 DC 5 SPEED Shifting Elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 615: ...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 616: ...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 617: ...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 618: ...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 619: ...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 620: ...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 621: ...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 622: ...ATION 9210 01 FLUID LEVEL INSPECTION 3650 01 TRANSMISSION RESET PROCEDURE REPLACEMENT TRANSMISSION DIAGNOSIS AND TESTING 1 WIRING DIAGRAM 2 WIRE HARNESS CONNECTOR CHART 3 UNIT CONNECTOR DESCRIPTION TROUBLE CODE EIAGNOSIS 1 DIAGNOSTIC TROUBLE CODE LIST 2 SYSTEM DIAGNOSIS MAINTENANCE OPERATIONS 1 OIL TEST 2 STALL TEST 3 TRANSMISSION RESET PROCEDURE REPLACEMENT TRANSMISSION 4 FLUID LEVEL INSPECTION 5...

Page 623: ... 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 624: ...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 625: ...03 4 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 1 Specifications 2 STRUCTURE CHARACTERISTICS AND SPECIFICATIONS ...

Page 626: ... 5 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 4WD Automatic Transmission 2 Appearance 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Adapter housing Inhibiter switch ...

Page 627: ...03 6 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 3 Internal Assembly Figure 2WD 4WD ...

Page 628: ...03 7 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 4 Shift Pattern ...

Page 629: ...03 8 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 3 TIGHTENING TORQUE ...

Page 630: ...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 631: ...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 632: ...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 633: ...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 634: ... 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 635: ...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 636: ...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 637: ... 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 638: ...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 639: ...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 640: ...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 641: ...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 642: ...03 21 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 Overall Hydraulic Circui ...

Page 643: ...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 644: ...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 645: ...03 24 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Manual 1st C2 B2 ON 3 536 ...

Page 646: ...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 647: ...03 26 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Auto 1st C2 OWC ON 3 536 ...

Page 648: ...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 649: ...03 28 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Auto 2nd C2 B1 ON 2 143 ...

Page 650: ...03 29 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 4 Power Train D Drive 2nd Lockup Power flow diagram Connecting Components ...

Page 651: ...03 30 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 2nd Lockup C2 B1 TCC ON ...

Page 652: ...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 653: ...03 32 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 3rd Gear C2 C3 ON 1 478 ...

Page 654: ...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 655: ...03 34 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 4th 4th LHM C1 C2 ON 1 156 ...

Page 656: ...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 657: ...03 36 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 5th Gear C1 C3 ON 0 866 ...

Page 658: ...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 659: ...03 38 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T 6th Gear C1 B1 ON 0 677 ...

Page 660: ...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 661: ...03 40 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Reverse C3 B2 ON 3 094 ...

Page 662: ...03 41 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 10 Power Train Reverse Limp Home Mode Power flow diagram Connecting Components ...

Page 663: ...03 42 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Reverse at LHM C3 B2 ON ...

Page 664: ...03 43 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 11 Power Train Parking Power flow diagram Connecting Components ...

Page 665: ...03 44 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Park ...

Page 666: ...03 45 DSI M78 6 SPEED A T KYRON 2010 01 3650 01 12 Power Train Neutral Power flow diagram Connecting Components ...

Page 667: ...03 46 KYRON 2010 01 3650 01 DSI M78 6 SPEED A T Neutral ...

Page 668: ...03 94 KYRON 2010 01 3110 01 DSI M78 6 SPEED A T 1 WIRING DIAGRAM DIAGNOSIS AND TESTING ...

Page 669: ...03 95 DSI M78 6 SPEED A T KYRON 2010 01 3110 01 1 Transmission Control Unit 2 WIRE HARNESS CONNECTOR CHART Connector Front View 3 UNIT CONNECTOR DESCRIPTION Connector J1 A ...

Page 670: ...03 96 KYRON 2010 01 3110 01 DSI M78 6 SPEED A T Connector J2 B Connector J3 C ...

Page 671: ...03 97 DSI M78 6 SPEED A T KYRON 2010 01 3110 01 2 Transmission Connector J4 Connector Front View ...

Page 672: ...03 98 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T 3 Inhibitor Switch Connector J5 ...

Page 673: ...03 99 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 1 DIAGNOSTIC TROUBLE CODE LIST TROUBLE CODE DIAGNOSIS ...

Page 674: ...03 100 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T ...

Page 675: ...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 676: ...03 102 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T Schematic Connector Details ...

Page 677: ...03 103 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Details DTC Clearing ...

Page 678: ...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 679: ...03 105 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 Resistance Values DTC Details Gear Lever Position Sensor Specifications ...

Page 680: ...03 106 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 681: ...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 682: ...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 683: ...03 109 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 Resistance Values ...

Page 684: ...03 110 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 685: ...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 686: ...03 112 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T Schematic Connector Details ...

Page 687: ...03 113 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Details ...

Page 688: ...03 114 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 689: ...N 2010 01 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 690: ...03 116 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T Connector Details Resistance Values Transmission Gear Select Lever Resistance Values ...

Page 691: ...03 117 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Clearing ...

Page 692: ...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 693: ...03 119 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Details DTC Details ...

Page 694: ...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 695: ...03 121 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Details ...

Page 696: ...03 122 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 697: ...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 698: ...03 124 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 699: ...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 700: ...03 126 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T Connector Details Resistance Values DTC Details ...

Page 701: ...03 127 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Clearing ...

Page 702: ...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 703: ...03 129 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Description Schematic Connector Details ...

Page 704: ...03 130 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 705: ...03 131 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 ...

Page 706: ...03 132 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T ...

Page 707: ...03 133 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Clearing ...

Page 708: ...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 709: ...03 135 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 Schematic Connector Details ...

Page 710: ...03 136 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 711: ...03 137 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 ...

Page 712: ...03 138 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 713: ...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 714: ...03 140 KYRON 2010 01 3110 00 DSI M78 6 SPEED A T Schematic Connector Details DTC Details ...

Page 715: ...03 141 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Clearing ...

Page 716: ...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 717: ...03 143 DSI M78 6 SPEED A T KYRON 2010 01 3110 00 DTC Details DTC Clearing ...

Page 718: ...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 719: ...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 720: ...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 721: ...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 722: ...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 723: ... 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 724: ...03 150 KYRON 2010 01 3680 01 DSI M78 6 SPEED A T 7 TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE NEW TRANSMISSION ...

Page 725: ......

Page 726: ...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 727: ... 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 728: ...05 3 T M LEVER KYRON 2010 01 3721 01 3710 01 T M LEVER OVERVIEW AND OPERATION PROCESS 1 CIRCUIT OF ION 4 SPEED AUTOMATIC T M ...

Page 729: ...05 4 KYRON 2010 01 3721 01 T M LEVER 2 CIRCUIT OF SHIFT INTER LOCK ...

Page 730: ...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 731: ...06 4 KYRON 2010 01 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications 2 Tightening Torque ...

Page 732: ...06 5 M T KYRON 2010 01 3170 01 Inside N Switch OVERVIEW AND OPERATION PROCESS 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch ...

Page 733: ...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 734: ...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 735: ...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 736: ... 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 737: ... 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 738: ......

Page 739: ...07 3 CLUTCH KYRON 2010 01 3010 01 GENERAL 1 CLUTCH SPECIFICATIONS 2 TIGHTTENING TORQUE ...

Page 740: ...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 741: ...07 5 CLUTCH KYRON 2010 01 3010 01 3 Functions Components of Clutch Assembly Adapter Pipe Assembly Clutch Assembly Concentric Slave Cylinder ...

Page 742: ...07 6 KYRON 2010 01 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 743: ...08 3 AXLE KYRON 2010 01 4120 01 GENERAL 1 AXLE SPECIFICATIONS Specification Torque Gear ratio Type Size Offset Housing Specification Capacity Length Width Weight ...

Page 744: ...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 745: ...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 746: ...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 747: ...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 748: ...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 749: ...KYRON 2010 01 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 750: ...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 751: ...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 752: ... 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 753: ...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 754: ...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 755: ...10 10 KYRON 2010 01 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 756: ...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 757: ... 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 758: ... 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 759: ......

Page 760: ...11 3 PROPELLER SHAFT KYRON 2010 01 3310 00 3310 00 PROPELLER SHAFT GENERAL 1 SPECIFICATION ...

Page 761: ...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 762: ...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 763: ...11 6 KYRON 2010 01 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 764: ...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 765: ...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 766: ... 01 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 767: ...10 01 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 768: ...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 769: ...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 770: ...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 771: ...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 772: ...12 3 SUSPENSION KYRON 2010 01 4411 01 GENERAL 1 FRONT SUSPENSION SPECIFICATIONS 2 REAR SUSPENSION SPECIFICATIONS 4411 01 SUSPENSION ...

Page 773: ... 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 774: ...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 775: ...13 5 ESP KYRON 2010 01 4890 01 3 SECTIONAL DRAWING Front Disc Brake Rear Disc Brake ...

Page 776: ... 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 777: ...13 7 ESP KYRON 2010 01 4890 01 2 BRAKE SYSTEM SPECIFICATIONS ...

Page 778: ...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 779: ...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 780: ... 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 781: ...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 782: ...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 783: ...13 13 ESP KYRON 2010 01 4890 01 New T C Without speed sensor ...

Page 784: ...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 785: ... 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 786: ...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 787: ......

Page 788: ...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 789: ...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 790: ...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 791: ...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 792: ...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 793: ... 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 794: ...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 795: ...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 796: ...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 797: ......

Page 798: ...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 799: ...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 800: ...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 801: ...13 31 ESP KYRON 2010 01 4890 01 4 Input Output Signals for HDC Operation ...

Page 802: ...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 803: ......

Page 804: ...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 805: ...13 35 ESP KYRON 2010 01 4890 01 Comparison with ABS System ABS ESP Indicator ESP OFF Switch HDC Indicator HDC Switch ActiveWheelSpeedSensor ...

Page 806: ...13 36 KYRON 2010 01 4890 01 ESP 7 INPUT OUTPUT SIGNALS FOR HDC OPERATION Input Output of ESP System ...

Page 807: ...13 37 ESP KYRON 2010 01 4890 01 8 ESP HYDRAULIC CIRCUIT DIAGRAM ...

Page 808: ...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 809: ...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 810: ...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 811: ...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 812: ...13 42 KYRON 2010 01 4890 01 ESP New Transfer Case Without Speed Sensor ...

Page 813: ...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 814: ... 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 815: ...1 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 816: ...13 46 KYRON 2010 01 4890 01 ESP 13 INPUT AND OUTPUT DIAGRAM OF ABS Input Output of ABS without TPMS ...

Page 817: ...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 818: ...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 819: ...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 820: ...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 821: ... 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 822: ...14 5 STEERING KYRON 2010 01 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 823: ...14 6 KYRON 2010 01 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 824: ...14 7 STEERING KYRON 2010 01 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 825: ...14 8 KYRON 2010 01 4610 00 STEERING Steering wheel Column shaft Lower shaft Steering gear box ...

Page 826: ...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 827: ...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 828: ...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 829: ...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 830: ...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 831: ...14 14 KYRON 2010 01 4610 00 STEERING 3 CIRCUIT DIAGRAM ...

Page 832: ...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 833: ...s weak electric current to solenoid valve Then the spool located PCV moves from top to bottom and the working pressure A port from oil pump is applied to reaction plunger C port through B port As a result the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier ...

Page 834: ...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 835: ...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 836: ...01 4 KYRON 2010 01 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM COMPONENTS Locations of Vents Air Duct ...

Page 837: ...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 838: ...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 839: ...01 7 AIR CONDITIONER KYRON 2010 01 6810 15 3 Components ...

Page 840: ...01 8 KYRON 2010 01 6810 15 AIR CONDITIONER 4 PTC HEATER AND FFH HEATER LAYOUT 1 PTC HEATER ASSEMBLY LAYOUT 2 FFH HEATER ASSEMBLY LAYOUT ...

Page 841: ...010 01 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 842: ... 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 843: ...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 844: ... 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 845: ...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 846: ... 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 847: ...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 848: ...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 849: ...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 850: ...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 851: ...01 19 AIR CONDITIONER KYRON 2010 01 6810 15 2 Exploded View ...

Page 852: ...01 20 KYRON 2010 01 6810 15 AIR CONDITIONER ...

Page 853: ...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 854: ...01 22 KYRON 2010 01 6810 15 AIR CONDITIONER 3 SPECIFICATIONS ...

Page 855: ...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 856: ...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 857: ...01 25 AIR CONDITIONER KYRON 2010 01 6810 15 4 Circuit Diagram ...

Page 858: ...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 859: ...01 27 AIR CONDITIONER KYRON 2010 01 6810 15 6 Specification Water Pump 7 Characteristic Curve of Water Pump 12 V ...

Page 860: ...01 28 KYRON 2010 01 6810 15 AIR CONDITIONER 8 Function Diagram 9 Switching Diagram According to Temperature Changes ...

Page 861: ...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 862: ...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 863: ...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 864: ...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 865: ......

Page 866: ...N 2010 01 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 867: ... 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 868: ...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 869: ...02 11 AIR BAG KYRON 2010 01 8810 03 ...

Page 870: ...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 871: ...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 872: ...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 873: ...02 15 AIR BAG KYRON 2010 01 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 874: ... 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 875: ... 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 876: ...02 18 KYRON 2010 01 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 877: ...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 878: ...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 879: ...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 880: ...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 881: ...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 882: ...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 883: ...02 25 AIR BAG KYRON 2010 01 8810 03 8 AIR BAG ELECTRICAL WIRING DIAGRAM ...

Page 884: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 885: ......

Page 886: ...0 3 BRAKE KYRON 2010 01 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 887: ...0 4 KYRON 2010 01 0000 00 BRAKE ...

Page 888: ...0 5 BRAKE KYRON 2010 01 0000 00 ...

Page 889: ...0 6 KYRON 2010 01 0000 00 BRAKE ...

Page 890: ...0 7 BRAKE KYRON 2010 01 0000 00 ...

Page 891: ...0 8 KYRON 2010 01 0000 00 BRAKE ...

Page 892: ...0 9 BRAKE KYRON 2010 01 0000 00 ...

Page 893: ...0 10 KYRON 2010 01 0000 00 BRAKE ...

Page 894: ...0 11 BRAKE KYRON 2010 01 0000 00 ...

Page 895: ...0 12 KYRON 2010 01 0000 00 BRAKE ...

Page 896: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 897: ......

Page 898: ...0 3 AIR BAG KYRON 2010 01 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 899: ...0 4 KYRON 2010 01 0000 00 AIR BAG ...

Page 900: ...0 5 AIR BAG KYRON 2010 01 0000 00 ...

Page 901: ...0 6 KYRON 2010 01 0000 00 AIR BAG ...

Page 902: ...0 7 AIR BAG KYRON 2010 01 0000 00 ...

Page 903: ...0 8 KYRON 2010 01 0000 00 AIR BAG ...

Page 904: ...0 9 AIR BAG KYRON 2010 01 0000 00 ...

Page 905: ...0 10 KYRON 2010 01 0000 00 AIR BAG ...

Page 906: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 907: ......

Page 908: ...0 3 CCCS KYRON 2010 01 0000 00 0000 00 CCCS 1 CCCS ...

Page 909: ...0 4 KYRON 2010 01 0000 00 CCCS ...

Page 910: ...0 5 CCCS KYRON 2010 01 0000 00 ...

Page 911: ...0 6 KYRON 2010 01 0000 00 CCCS ...

Page 912: ...0 7 CCCS KYRON 2010 01 0000 00 ...

Page 913: ...0 8 KYRON 2010 01 0000 00 CCCS ...

Page 914: ...0 9 CCCS KYRON 2010 01 0000 00 ...

Page 915: ...0 10 KYRON 2010 01 0000 00 CCCS ...

Page 916: ...0 11 CCCS KYRON 2010 01 0000 00 ...

Page 917: ...0 12 KYRON 2010 01 0000 00 CCCS ...

Page 918: ...0 13 CCCS KYRON 2010 01 0000 00 ...

Page 919: ...0 14 KYRON 2010 01 0000 00 CCCS ...

Page 920: ...0 15 CCCS KYRON 2010 01 0000 00 ...

Page 921: ...0 16 KYRON 2010 01 0000 00 CCCS ...

Page 922: ...0 17 CCCS KYRON 2010 01 0000 00 ...

Page 923: ...0 18 KYRON 2010 01 0000 00 CCCS ...

Page 924: ...0 19 CCCS KYRON 2010 01 0000 00 ...

Page 925: ...0 20 KYRON 2010 01 0000 00 CCCS ...

Page 926: ...0 21 CCCS KYRON 2010 01 0000 00 ...

Page 927: ...0 22 KYRON 2010 01 0000 00 CCCS ...

Page 928: ...0 23 CCCS KYRON 2010 01 0000 00 ...

Page 929: ...0 24 KYRON 2010 01 0000 00 CCCS ...

Page 930: ...0 25 CCCS KYRON 2010 01 0000 00 ...

Page 931: ...0 26 KYRON 2010 01 0000 00 CCCS ...

Page 932: ...0 27 CCCS KYRON 2010 01 0000 00 ...

Page 933: ......

Page 934: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 935: ......

Page 936: ...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 937: ...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 938: ...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 939: ...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 940: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 941: ......

Page 942: ...0 3 FFH KYRON 2010 01 0000 00 0000 00 FFH 1 FFH ...

Page 943: ...0 4 KYRON 2010 01 0000 00 FFH ...

Page 944: ...0 5 FFH KYRON 2010 01 0000 00 ...

Page 945: ...0 6 KYRON 2010 01 0000 00 FFH ...

Page 946: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 947: ......

Page 948: ...0 3 P TRUNK KYRON 2010 01 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 949: ...0 4 KYRON 2010 01 0000 00 P TRUNK ...

Page 950: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 951: ......

Page 952: ...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 953: ...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 954: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 955: ......

Page 956: ...0 3 STICS KYRON 2010 01 0000 00 0000 00 STICS 1 STICS ...

Page 957: ...0 4 KYRON 2010 01 0000 00 STICS ...

Page 958: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 959: ......

Page 960: ...0 3 TC KYRON 2010 01 0000 00 0000 00 TC 1 TC ...

Page 961: ...0 4 KYRON 2010 01 0000 00 TC ...

Page 962: ...0 5 TC KYRON 2010 01 0000 00 ...

Page 963: ...0 6 KYRON 2010 01 0000 00 TC ...

Page 964: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 965: ......

Page 966: ...0 3 TCU KYRON 2010 01 0000 00 0000 00 TCU 1 TCU ...

Page 967: ...0 4 KYRON 2010 01 0000 00 TCU ...

Page 968: ...0 5 TCU KYRON 2010 01 0000 00 ...

Page 969: ...0 6 KYRON 2010 01 0000 00 TCU ...

Page 970: ...0 7 TCU KYRON 2010 01 0000 00 ...

Page 971: ...0 8 KYRON 2010 01 0000 00 TCU ...

Page 972: ...0 9 TCU KYRON 2010 01 0000 00 ...

Page 973: ...0 10 KYRON 2010 01 0000 00 TCU ...

Page 974: ...0 11 TCU KYRON 2010 01 0000 00 ...

Page 975: ...0 12 KYRON 2010 01 0000 00 TCU ...

Page 976: ...0 13 TCU KYRON 2010 01 0000 00 ...

Page 977: ...0 14 KYRON 2010 01 0000 00 TCU ...

Page 978: ...0 15 TCU KYRON 2010 01 0000 00 ...

Page 979: ...0 16 KYRON 2010 01 0000 00 TCU ...

Page 980: ...0 17 TCU KYRON 2010 01 0000 00 ...

Page 981: ...0 18 KYRON 2010 01 0000 00 TCU ...

Page 982: ...0 19 TCU KYRON 2010 01 0000 00 ...

Page 983: ......

Page 984: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 985: ......

Page 986: ...0 3 TGS LEVER KYRON 2010 01 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 987: ...0 4 KYRON 2010 01 0000 00 TGS LEVER ...

Page 988: ...0 5 TGS LEVER KYRON 2010 01 0000 00 ...

Page 989: ...0 6 KYRON 2010 01 0000 00 TGS LEVER ...

Page 990: ...GENERAL INFORMATION 0000 00 GENERAL INFORMATION GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 4 ...

Page 991: ......

Page 992: ...01 3 GENERAL INFORMATION KYRON 2010 01 0000 00 D 146 UPDATE DETAILS ...

Page 993: ...al No3 Refer to Major Connector Position Section 2 D S202 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 ...

Page 994: ... 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 Batter...

Page 995: ...k 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 9 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 assi...

Page 996: ......

Page 997: ...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 ...

Page 998: ......

Page 999: ...02 3 CONNECTOR GROUND KYRON 2010 01 0000 00 WIRING HARNESS 0000 00 WIRING HARNESS COMPONENTS LOCATION 1 WIRING HARNESS 2 COMPONENTS LOCATION ...

Page 1000: ...02 4 KYRON 2010 01 0000 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 1001: ...02 5 CONNECTOR GROUND KYRON 2010 01 0000 00 GROUND SPLICE PACK 4 SPLICE PACK CIRCUIT S101 S201 S202 CAN ...

Page 1002: ...02 6 KYRON 2010 01 0000 00 CONNECTOR GROUND S203 GND S204 ILL S205 GND S301 CAN S302 S206 ...

Page 1003: ...02 7 CONNECTOR GROUND KYRON 2010 01 0000 00 WIRNING CONNECTOR MODE CONNECTOR 5 CONNECTOR WIRNING CONNECTOR WIRNING CONNECTOR ...

Page 1004: ...02 8 KYRON 2010 01 0000 00 CONNECTOR GROUND UNIT CONNECTOR SENSOR CONNECTOR LAMP CONNECTOR SWITCH CONNECTOR ...

Page 1005: ...02 9 CONNECTOR GROUND KYRON 2010 01 0000 00 ETC ...

Page 1006: ......

Page 1007: ...0 18 ACTYON SPORTS 2006 03 8210 00 CONNECTOR GROUND CONNECTOR 8210 00 W H ENGINE ROOM ...

Page 1008: ...0 19 CONNECTOR GROUND ACTYON SPORTS 2006 03 8210 02 8210 02 W H MAIN ...

Page 1009: ...0 20 ACTYON SPORTS 2006 03 8210 03 CONNECTOR GROUND ...

Page 1010: ...0 21 CONNECTOR GROUND ACTYON SPORTS 2006 03 8210 03 8210 03 W H FLOOR ...

Page 1011: ...0 22 ACTYON SPORTS 2006 03 8210 03 CONNECTOR GROUND ...

Page 1012: ...0 23 CONNECTOR GROUND ACTYON SPORTS 2006 03 8210 09 8210 07 W H FRT DOOR 8210 09 W H ROOF ...

Page 1013: ...0 24 ACTYON SPORTS 2006 03 8210 10 CONNECTOR GROUND 8210 10 W H DECK 8210 08 W H RR DOOR ...

Page 1014: ...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 ...

Page 1015: ......

Page 1016: ...03 3 POWER DISTRIBUTION KYRON 2010 01 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 1017: ...03 4 KYRON 2010 01 8210 00 POWER DISTRIBUTION 5 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 6 ENGINE ROOM FUSE BOX CONNECTOR NUMBER ...

Page 1018: ...03 5 POWER DISTRIBUTION KYRON 2010 01 8410 00 8410 00 I P LH FUSE RELAY BOX 1 I P LH FUSE RELAY BOX 2 POWER SUPPLY ...

Page 1019: ...03 6 KYRON 2010 01 8410 00 POWER DISTRIBUTION 8410 00 I P RH FUSE RELAY BOX 1 I P RH FUSE RELAY BOX ...

Page 1020: ...03 7 POWER DISTRIBUTION KYRON 2010 01 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 1021: ...03 8 KYRON 2010 01 8210 00 POWER DISTRIBUTION 3 SB10 SB11 CONDENSOR FAN RELAY HI LO 4 SB12 SB16 START RELAY PTC RELAY ...

Page 1022: ...03 9 POWER DISTRIBUTION KYRON 2010 01 8210 00 5 Ef1 Ef2 Ef6 Ef7 6 Ef8 Ef10 TAIL LAMP RELAY FRT FOG LAMP RELAY ...

Page 1023: ...03 10 KYRON 2010 01 8210 00 POWER DISTRIBUTION 7 Ef12 Ef14 ENG MOUNT RELAY COMPRESSOR RELAY 8 Ef15 Ef23 ...

Page 1024: ...03 11 POWER DISTRIBUTION KYRON 2010 01 8210 00 9 WIPER MOTOR RELAY HI LO WASHER RELAY FRT RR ...

Page 1025: ...03 12 KYRON 2010 01 8410 00 POWER DISTRIBUTION 8410 00 I P LH FUSE RELAY BOX CIRCUIT 2 F29 F34 1 F24 F28 ...

Page 1026: ...03 13 POWER DISTRIBUTION KYRON 2010 01 8410 00 3 F35 F40 RR WIPER RELAY 4 F41 F48 ...

Page 1027: ...03 14 KYRON 2010 01 8410 00 POWER DISTRIBUTION 5 F49 F51 RR FOG LAMP RELAY 6 F52 F55 BURGLAR HORN RELAY RR SEAT LH RH WARMER RELAY ...

Page 1028: ...03 15 POWER DISTRIBUTION KYRON 2010 01 8410 00 7 F56 F57 HDC RELAY FLASHER UNIT ...

Page 1029: ...03 16 KYRON 2010 01 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 1030: ...03 17 POWER DISTRIBUTION KYRON 2010 01 8410 00 4 FOLD G RELAY UNFOLD G RELAY 3 BLOWER RELAY INJECTOR RELAY SNR RELAY ...

Page 1031: ...03 18 KYRON 2010 01 8410 00 POWER DISTRIBUTION 8410 00 ICM RELAY BOX CIRCUIT 1 DEICER RELAY DR LOCK UNLOCK RELAY 2 HAZARD RELAY DRL SIGNAL ...

Page 1032: ......

Page 1033: ...RROR CIRCUIT 8910 00 AUDIO CLOCK CIRCUIT 8790 00 PARKING AID CIRCUIT 6810 00 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT 6910 00 FFH FUEL FIRED HEATER 6810 00 FATC FULL AUTO TEMP CONTROL CIRCUIT 6810 00 AIR 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 00 ELECTRIC OUTSIDE ...

Page 1034: ......

Page 1035: ...04 3 CIRCUIT KYRON 2010 01 1461 00 1461 00 STARTING CHARGING 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 5 AT M T 1 ...

Page 1036: ...04 4 KYRON 2010 01 1461 00 CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 6 A T 4 A T 2 ...

Page 1037: ...04 5 CIRCUIT KYRON 2010 01 2820 00 2820 00 PREHEATING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1038: ... 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 E EGR WASTE GATE INLET METERING SENSOR HFM PEDAL ...

Page 1039: ...UIT KYRON 2010 01 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 1040: ...ATION 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 1041: ...N 2010 01 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 1042: ...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 1043: ...04 11 CIRCUIT KYRON 2010 01 1491 00 3 INJECTOR CAN LINE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1044: ...04 12 KYRON 2010 01 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 1045: ...04 13 CIRCUIT KYRON 2010 01 1490 00 2 O2 SENSOR CPS KNOCK SENSOR HFM SENSOR CANISTER PURGE VALVE 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1046: ...04 14 KYRON 2010 01 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 1047: ...04 15 CIRCUIT KYRON 2010 01 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 1048: ...04 16 KYRON 2010 01 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 1049: ...04 17 CIRCUIT KYRON 2010 01 1490 00 3 STOP LAMP CRUISE CONTROL SW FUEL PUMP IMMOBILIZER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1050: ...04 18 KYRON 2010 01 8210 00 CIRCUIT 8210 00 DIAGNOSIS CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1051: ...04 19 CIRCUIT KYRON 2010 01 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 1052: ...04 20 KYRON 2010 01 3110 00 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1053: ...04 21 CIRCUIT KYRON 2010 01 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 1054: ...04 22 KYRON 2010 01 3110 00 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1055: ...04 23 CIRCUIT KYRON 2010 01 3110 00 3110 00 TCU 4 A T 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1056: ...04 24 KYRON 2010 01 3740 00 CIRCUIT 3740 00 A T SHIFT LOCK 4 A T 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1057: ...04 25 CIRCUIT KYRON 2010 01 3410 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3410 00 TCCU ...

Page 1058: ...04 26 KYRON 2010 01 4892 00 CIRCUIT 4892 00 ABS ESP W SPEED SENSOR STOP LAMP SW DIAGNOSIS WARNING LAMP ABS ESP HDC 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1059: ...04 27 CIRCUIT KYRON 2010 01 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 1060: ...04 28 KYRON 2010 01 4620 00 CIRCUIT 4620 00 S S P S SPEED SENSITIVE POWER STEERING 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1061: ...04 29 CIRCUIT KYRON 2010 01 8810 00 8810 00 AIR BAG CURTAIN AIR BAG 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1062: ...0 KYRON 2010 01 8010 00 CIRCUIT 8010 00 CLUSTER 1 GAUGE SPEED RPM FUEL TEMP WARNING LAMP FUEL FUEL FILTER ABS ESP BRAKE HDC 4WD 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1063: ...CUIT KYRON 2010 01 8010 00 2 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 1064: ...04 32 KYRON 2010 01 7410 00 CIRCUIT 7410 00 POWER SEAT DRIVER W MEMORY 1 DRIVER POWER SEAT SEAT MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1065: ...04 33 CIRCUIT KYRON 2010 01 7410 00 2 ELECTRIC OUTSIDE MIRROR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1066: ...04 34 KYRON 2010 01 7410 00 CIRCUIT 7410 00 POWER SEAT DRIVER W O MEMORY 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1067: ...04 35 CIRCUIT KYRON 2010 01 7410 00 7410 00 POWER SEAT PASSENGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1068: ...04 36 KYRON 2010 01 8510 00 CIRCUIT 8510 00 null ELECTRIC OUTSIDE MIRROR FOLDING W O MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1069: ...04 37 CIRCUIT KYRON 2010 01 8510 00 8510 00 FRT SEAT WARMER 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 1070: ...04 38 KYRON 2010 01 8610 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8610 00 RR SEAT WARMER ...

Page 1071: ...04 39 CIRCUIT KYRON 2010 01 8710 00 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 1072: ...04 40 KYRON 2010 01 8710 00 CIRCUIT 2 CENTRAL DOOR LOCK CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1073: ...04 41 CIRCUIT KYRON 2010 01 8710 00 3 TAIL LAMP HAZARD POWER WINDOW 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1074: ...04 42 KYRON 2010 01 8710 00 CIRCUIT 4 DEFOGGER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1075: ...04 43 CIRCUIT KYRON 2010 01 8710 00 5 PANIC AUTO LIGHT RAIN SENSING ROOM LAMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1076: ...04 44 KYRON 2010 01 8710 00 CIRCUIT 6 FRT WIPER WASHER RR WASHER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1077: ...04 45 CIRCUIT KYRON 2010 01 8710 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 7 MIRROR FOLD G UNFOLD G FOLD SW ...

Page 1078: ...04 46 KYRON 2010 01 7830 00 CIRCUIT 7830 00 RR WIPER CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1079: ...04 47 CIRCUIT KYRON 2010 01 8510 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8510 00 POWER WINDOW CIRCUIT ...

Page 1080: ...04 48 KYRON 2010 01 8610 00 CIRCUIT 8610 00 HORN 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1081: ...04 49 CIRCUIT KYRON 2010 01 7632 00 7632 00 CIGAR LIGHTER POWER OUTLET CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1082: ...04 50 KYRON 2010 01 7340 00 CIRCUIT 7340 00 SUN ROOF CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1083: ...04 51 CIRCUIT KYRON 2010 01 8310 00 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 1084: ...04 52 KYRON 2010 01 8510 00 CIRCUIT 8510 00 HLLD HEAD LAMP LEVEL G DEVICE CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1085: ...04 53 CIRCUIT KYRON 2010 01 8320 00 8320 00 TAIL LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1086: ...04 54 KYRON 2010 01 8410 00 CIRCUIT 8410 00 TURN SIGNAL HAZARD LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1087: ...04 55 CIRCUIT KYRON 2010 01 8210 00 8210 00 TRAILER LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1088: ...04 56 KYRON 2010 01 8310 00 CIRCUIT 8310 00 FOG LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1089: ...04 57 CIRCUIT KYRON 2010 01 4810 00 4810 00 STOP BACK UP LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1090: ...04 58 KYRON 2010 01 7770 00 CIRCUIT 7770 00 INTERIOR LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1091: ...04 59 CIRCUIT KYRON 2010 01 7770 00 7770 00 AUTO DIMMING ROOM MIRROR CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1092: ...04 60 KYRON 2010 01 8910 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8910 00 AUDIO CLOCK CIRCUIT ...

Page 1093: ...04 61 CIRCUIT KYRON 2010 01 8790 00 8790 00 PARKING AID CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1094: ...04 62 KYRON 2010 01 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6810 00 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT ...

Page 1095: ...04 63 CIRCUIT KYRON 2010 01 6910 00 6910 00 FFH FUEL FIRED HEATER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1096: ...04 64 KYRON 2010 01 6810 00 CIRCUIT 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 1097: ...04 65 CIRCUIT KYRON 2010 01 6810 00 2 PWM MOTOR AIR MIX MOTOR D27DT EU IV M T 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 1098: ...04 66 KYRON 2010 01 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3 C FAN SENSOR AIR MIX MOTOR D27DT EU Ⅲ ...

Page 1099: ...04 67 CIRCUIT KYRON 2010 01 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4 C FAN SENSOR AIR MIX MOTOR GSL 3 2 ...

Page 1100: ...04 68 KYRON 2010 01 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 5 PWM MOTOR AIR MIX MOTOR GSL 2 3 ...

Page 1101: ...04 69 CIRCUIT KYRON 2010 01 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6 BLOWER ACTUATOR MODE INTAKE AMBI SENSOR ...

Page 1102: ...04 70 KYRON 2010 01 6810 00 CIRCUIT 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 1103: ...04 71 CIRCUIT KYRON 2010 01 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 PWM MOTOR MOTOR D27DT EU IV M T ...

Page 1104: ...04 72 KYRON 2010 01 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3 COMPRESSOR MOTOR D27DT EU Ⅲ ...

Page 1105: ...04 73 CIRCUIT KYRON 2010 01 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4 COMPRESSOR MOTOR GSL 3 2 ...

Page 1106: ...04 74 KYRON 2010 01 6810 00 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 5 PWM MOTOR MOTOR GSL 2 3 ...

Page 1107: ...04 75 CIRCUIT KYRON 2010 01 6810 00 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 6 BLOWER ...

Page 1108: ......

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