SSANGYONG Rexton Y290 2012 Manual Download Page 1

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Summary of Contents for Rexton Y290 2012

Page 1: ...0000 00 ...

Page 2: ...2 Preheat System ...

Page 3: ...0000 00 3 Fuel System ...

Page 4: ...Fuel Supply System ...

Page 5: ...0000 00 4 Lubrication System ...

Page 6: ...5 Cooling System ...

Page 7: ...0000 00 6 Intake System ...

Page 8: ...7 Exhaust System ...

Page 9: ...tem has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque 1 Coolant reservoir 2 FFH device 3 Brake fluid reservoir 4 Washer fluid reservoir 5 Common rail 6 Fuse box 7 Battery 8 Fuel filter 9 Power steering pump 10 Priming pump 11 EGR valve 12 Air cleaner assembly 13 Turbo charger 14 Oil dipstick ...

Page 10: ...y 4 Idle pulley 5 Coolant pump pulley 6 Alternator 7 Viscos fan clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 Drive plate MT DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR to center pipe Front View Rear View ...

Page 11: ... Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 PCV valve and oil separator 31 Oil dipstick 32 EGR LH 1 pipe ...

Page 12: ...k 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH 3 pipe 39 PCV valve and oil separator 40 Oil dipstick 41 High pressure pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Right Side View ...

Page 13: ...1212 01 2 SPECIFICATIONS ...

Page 14: ...3 ENGINE PERFORMANCE CURVE ...

Page 15: ...1212 01 ...

Page 16: ...4 TIGHTENING TORQUE ...

Page 17: ...1212 01 ...

Page 18: ......

Page 19: ...jector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running Howev...

Page 20: ...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 21: ...7DT 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 22: ...2 COMPONENTS OF FUEL SYSTEM ...

Page 23: ...1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 24: ...ody 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 25: ...en deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more details refer to the next description The exhaust ...

Page 26: ...of CDPF System by Vehicle Model Rexton II Same CDPF system for D27DTP 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 a...

Page 27: ...t at CDPF Exhaust Gas Temperature Sensor The two temperature sensors inside the CDPF are installed in exhaust manifold front exhaust gas temperature sensor and in DOC rear exhaust gas temperature sensor and perform the following functions Front Exhaust Gas Temperature Sensor Rear Exhaust Gas Temperature Sensor Measures the exhaust gas temperature of the exhaust manifold As it is installed in front...

Page 28: ...ock 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 Front exhaust gas temperature sensor Turbocharger may become weaker if high temperature exhaust gas passes through the turbocharger for DPF regeneration process The front exhaust gas te...

Page 29: ...that the amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in the exhaust emission and the particulars of the regulations are pr...

Page 30: ...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 31: ... temperature by increasing the amount of fuel while decreasing the amount of intake air 2 Sytem composition for Soot Combustion When the engine is running in low load range the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased To burn the soot filtered in the CDPF the control system should be installed to check the operating range and increase the temperature of e...

Page 32: ...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 33: ... 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 filtered and...

Page 34: ...The engine ECU detects the amount of particulate material colected by the information from temperature sensors and differential pressure snesor When the soot is accumulated the pressure difference between the front and the rear side occurs Then the engine ECU performs the post injection to raise the exhaust gas temperature and burn the collected soot at approx When the exhaust gas enters into the ...

Page 35: ...regeneration operation However the driver is not informed 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 during the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increase the temperature of the exhaust gas The driver ma...

Page 36: ...d of 5 to 10 km h for an extended period of time the soot accumulated 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 overload of the CDPF To inform this to the driver the engine warning lamp comes on and the engine power is decreased to protect the system To so...

Page 37: ...4 COMPONENTS OF CDPF SYSTEM Engine compartment RH Differential Pressure Sensor Front Exhaust Gas Temperature Sensor Throttle Body Front exhaust gas temperature sensor ...

Page 38: ......

Page 39: ...ERUP 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 40: ...D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 41: ......

Page 42: ......

Page 43: ...dal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Page 44: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 45: ... cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 46: ...2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Page 47: ...ol lever or push down the DECEL switch for 1 second per one switching 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 cruise control system until you get used to it Improper use or not fully aware of this function could r...

Page 48: ...CCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per one...

Page 49: ...il the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is running ...

Page 50: ...le speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed 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 properly ...

Page 51: ...ng conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Page 52: ...rake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch and t...

Page 53: ...1 COMPONENT LOCATOR 1 Front View ...

Page 54: ...esonance 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 55: ...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 56: ...alled 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 when a tool or equipme...

Page 57: ...1113 01 1 SPECIFICATIONS 1 Engine Specifications ...

Page 58: ...2 Performance Curve ...

Page 59: ...1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 60: ......

Page 61: ...1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 62: ...3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 63: ...1113 01 1 Fastener Tightening Specifications Cont d ...

Page 64: ... vehicle performance and damage components of the fuel system Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly earthed Static electricity build up can occur under certain atmospheric and fuel flow conditions if unearthed hoses particularly plastic are fitted to the fuel dispens...

Page 65: ...Temperature vs resistance ...

Page 66: ......

Page 67: ...f 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 OVERVIEW OF CATALYTIC CONVERTER When jac...

Page 68: ...4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 69: ...9210 01 1 OIL CIRCULATION ...

Page 70: ...l supply to intake valve tappet 7 Oil gallery at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 30 Valve tappet 14 Oil spray nozzle timing chain a Oil gallery from oil pump ...

Page 71: ...2110 01 1 GENERAL SPECIFICATIONS ...

Page 72: ...2 SPECIAL TOOLS AND EQUIPMENT ...

Page 73: ...2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 74: ... water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to the heat core This provides for heatin...

Page 75: ...2110 01 2 COMPONENT LOCATOR ...

Page 76: ...ces 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 77: ...1452 01 1 GENERAL SPECIFICATIONS ...

Page 78: ...2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 79: ... Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted by the battery i...

Page 80: ...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 Crankshaft position Engine spee...

Page 81: ...1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 82: ...1522 16 1 ENGINE DATA DISPLAY TABLE ...

Page 83: ...2 FASTENER TIGHTENING SPECIFICATIONS 1 Temperature vs Resistance ...

Page 84: ...dal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Page 85: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 86: ... cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 87: ...2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Page 88: ...ol lever or push down the DECEL switch for 1 second per one switching 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 cruise control system until you get used to it Improper use or not fully aware of this function could r...

Page 89: ...CCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per one...

Page 90: ...il the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is running ...

Page 91: ...le speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed 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 properly ...

Page 92: ...ng conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Page 93: ...rake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch and t...

Page 94: ...on switch and other lamp switches before disconnecting or connecting the negative battery cable Otherwise semiconductor parts can be damaged Do not drop or appy excessive impact to sensors and relays If a fuse is blown replace it with a fuse which has the correct amperage rating If you use a fuse with higher capacity than the specification the component can be damaged or catch fire ...

Page 95: ... lock press it down to the direction in the below figure When checking voltage or continuity of the connector terminal with a circuit tester connect the tester probe to the terminal at the harness side For a sealed type connector connect the probe to the terminal through the hole in the rubber cap of the wiring Take care not to damage the insulation of the wires Insert the probe until it contacts ...

Page 96: ...f the terminals do not contact with vehicle body or other metal parts Check that the grounding part has continuity with mounting bolts and vehicle body Check that wires are properly routed Make sure that wires are securely fixed to avoid contact with sharp body parts and high temperature parts such as the exhaust manifold and exhaust pipes The rotating parts such as fan pulley and fan belt perturb...

Page 97: ...rved temperature Max operating humidity 95 Resistible voltage 24V Insulating resistance No heat and fire due to the current leaks Confined with PCB waterproof and coating that requires the insulation Dark current below 7 0 mA When initiating the sleep mode after removing ignition key and locking the doors Voltage drop below 1 0V A Connector Pin No 31 and A Connector 15 16 17 18 19 20 29 B Connecto...

Page 98: ...e load 9 Door unlock relay DC 12V 200mA Inductive load 10 Siren DC 12V 260W Inductive load 11 Tail lamp relay DC 12V 200mA Inductive load 12 Hazard relay DC 12V 200mA Inductive load 13 Power window relay DC 12V 200W Inductive load 14 Rear defogger relay DC 12V 200W Inductive load 15 Wiper LOW relay DC 12V 250W Inductive load 16 Wiper HIGH relay DC 12V 250W Inductive load 17 Front washer motor DC 1...

Page 99: ... switch OPEN one of rear seat GND CLOSE all rear seats OPEN 13 Tailgate lock unlock switch LOCK OPEN UNLOCK GND 14 Rear defogger switch ON GND OFF OPEN 15 Seat belt switch Unfastened GND Fastened OPEN 16 Theft deterrent alarm select switch ON GND OFF OPEN 17 Parking brake switch ON GND OFF OPEN 18 Air bag collision sensor ON 200 ms Low signal OFF OPEN 19 Wiper motor parking switch Parking BAT Rota...

Page 100: ...g processing time from switch input changing point 1 2 NO Input Signal Name Logic Status 26 Front defogger switch ON GND OFF OPEN 27 Central door lock switch ON GND OFF OPEN 28 SPWM easy access switch ON GND OFF OPEN 29 Multifunction auto light switch ON GND OFF OPEN 30 Turn signal light switch ON BAT GND OFF OPEN 5 1V 9 2V 31 SPWM Seat Position with Memory ON GND PWM OFF OPEN 32 Rain sensor ON GN...

Page 101: ...8710 08 REKES Key Old New Changed the appearance of mechanical key and the company symbol 2 MAJOR CHANGES Front Back Front Back ...

Page 102: ...e controller and other electronic units to transmit and receive the signals and data The STICS includes the following functions Wiper control Ignition key reminder Door locking unlocking Lamp control Defogger control Time lagging control for power window Theft deterrent system control REKES key ...

Page 103: ...8710 08 ICM Relay Box STICS Chime 2 LOCATION ...

Page 104: ...per switch is in AUTO position Fast Fast interval Slow Slow interval Front wiper operation When moving the wiper switch release it the windshield wipers operate one wiping cycle The wipers will operate continuously if the switch is held in this position Wipers are not in operation Operates automatically according to the vehicle speed or the amount of rain Continuous wipe slow operation Continuous ...

Page 105: ...nly the wiper will keep operating Rear wiper operation Rear wiper is not in operation Rear washer and wiper When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return wiper and washer Windshield washer operation toward you to spray washer fluid on the windshield and to operate the wipers 1 3 cyc...

Page 106: ...he ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 107: ...asher switch is turned on for more than 0 6 seconds during the wiper operation by AUTO switch the wiper operates three times When it is turned on for a certain period of time 0 1 to 0 59 seconds the wiper operates once 3 ...

Page 108: ...System Diagram Operating MIST switch for 0 1 to 0 59 second Operating MIST switch for more than 0 59 second ...

Page 109: ...nd the AUTO switch OFF the washer motor output gets ON for 2 second If the system recognizes the output signal the wiper low relay output gets ON during 4 cycles and the washer motor output gets ON for 2 second Then the wiper relay output gets OFF after 3 cycles 1 System Diagram ...

Page 110: ...n during the auto washer coupled wiper operation The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive AUTO wiper operation When the AUTO switch input is received during the auto washer operation the auto washer operation stops and the auto INT operation is activated 2 3 4 5 ...

Page 111: ...8710 08 System Diagram ...

Page 112: ...RKSTICS with rain sensing function has the system layout as shown in the figure below System layout ...

Page 113: ...in sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the auto switch from OFF to ON position regardless of communication with rain sensor while the ignition key is in the ON position When the auto switch is turned to the ON position again from the OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the ...

Page 114: ...System Diagram AUTO Mode Switch ON Ignition Switch ON ...

Page 115: ...put with the ignition switch ON and the AUTO switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 116: ...System Diagram IGN ON AUTO Mode Switch ON ...

Page 117: ...ncreased while the ignition key is in the ON position the AUTO switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle ...

Page 118: ...IGN ON AUTO Mode Switch ON IGN ON AUTO Mode Switch ON Wiper Motor Parked ...

Page 119: ...erminal is grounded while the ignition key is in ON position and the AUTO switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 The wiper motor runs only when the rain sensor requires the wiper operation System Diagram IGN ON AUTO Mode Switch ON Wiper Motor Parking Terminal Stuck in Ground ...

Page 120: ...h the ignition key and the AUTO switch in ON position the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal 2 The wiper motor runs only when the rain sensor requires the wiper operation ...

Page 121: ...ignal Received The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 1 ...

Page 122: ...l Received The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 2 ...

Page 123: ...witch Check the power supply pin number 3 Ground pin number 4 IGN to sensor Check the wiper relay 1 2 3 Symptom 3 Abrupt wiper operation 3 4 times at high speed If the wiping speed control knob is positioned at FAST position this may happen because the sensitivity in FAST mode is extremely high In that case move the knob to another position Symptom 4 Continuous operation on dry windshield Check if...

Page 124: ... it rains heavy which requires the highest AUTO speed the headlamps are turned on automatically while the light switch is in AUTO position and the wiper switch is in AUTO position 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 bu...

Page 125: ...10 08 Emitter lense The emitter lens located at bottom of rain sensing unit guides the infrared rays from the LED to the target point Auto light sensor Vertical Auto light sensor Horizon Auto light sensor ...

Page 126: ...tor started to operate from parking position The pause time is calculated by the vehicle speed and the VOLUME If the pause time is below 1 0 second the wipers operate without pause If the pause time is over 1 5 seconds the wipers operate intermittently Controls the wiper intermittent operation by the values from the vehicle speed and the volume 1 Calculates and converts the Intermittent interval a...

Page 127: ... set speed when turning ON the INT switch from OFF position with the IGN ON The wiper operates in previously set speed when turning ON the Ignition switch with the switch ON Control during Faulty Wiper Motor Parking Function The wiper system continuously outputs wiper Low relay ON when the wiper parking terminal is stuck in ground or IGN with INT switch ON or washer switch ON The relays is turned ...

Page 128: ...tch is changed to LOCK while the ignition key is in ignition switch The system outputs UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed afte...

Page 129: ... When the ignition key is inserted during the UNLOCK output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does not work if the vehicle speed is over 10 km h 1 2 3 4 5 1 LOCK switches in all doors inc...

Page 130: ...s removed The buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 Tail Lamp Left On Warning ...

Page 131: ...8710 08 System Diagram Tail Lamp Relay ON ...

Page 132: ...osing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Page 133: ...8710 08 System Diagram ...

Page 134: ...he chime bell does not sound The seat belt warning light goes off and the chime bell stops when turning the ignition switch to the OFF position The chime bell stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime bell sounds for 6 seconds again when unfastening the...

Page 135: ...g the Ignition Switch to ON after Fastening Seat Belt Seat Belt Warning Light Chime The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to ON from OFF After fastening the seat belt the chime bell stops ...

Page 136: ...vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 The warning light blinks and the chime bell sounds for 0 6 seconds and stops for 0 3 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on The warning light goes off and the chime buzzer stops when turning off the parking brak...

Page 137: ...8710 08 System Diagram ...

Page 138: ...p comes on for 30 seconds when unlocking the doors with REKES key The front room lamp stays on for additional 30 seconds during lamp operation in Step 5 when receiving the UNLOCK signal from REKES again The front room lamp stays on when opening a front door and operates as in Step 3 and 4 The front room lamp dims out when closing the opened door However it goes out immediately when getting into th...

Page 139: ...8710 08 Front Room Lamp on when pressing appropriate lamp switch 1 2 in The front in Center Room Lamp The center room lamp comes on when opening a rear door with System Diagram ...

Page 140: ...ing the driver s door or passenger s door when the ignition key is removed The ignition key hole illumination stays on for 10 seconds when closing the door after step 1 The output stops when the ignition key is turned to ON position The output stops when receiving the lock signal from the remote control key under anti theft mode 1 2 3 4 ...

Page 141: ...ay is turned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp The tail lamp relay is turned on when inserting the ignition key into the ignition switch The tail lamp relay is not turned off automatically auto cut when opening and closing the driver s door while the ignition is removed and the tail lamp is turned on 1 2 3 4 ...

Page 142: ...System Diagram ...

Page 143: ...s when pressing this 5 Defogging Function The defogger system defrosts or demists the window glass with the heated wire integrated in glass When operating the defogger switch STICS controls the operating time only in IGN2 position Windshield heated glass switch The windshield heated glass is turned on for 12 minutes when pressing this switch Circuit Diagram of Front Rear Defogger ...

Page 144: ...gnition switch is ON with engine running The output stops when turning on the front defogger heated glass switch again during its operation The output is ON only for 6 minutes when turning ON the front defogger heated glass switch within 10 minutes after completion of output for 12 minutes This can be done only once 1 2 3 System Diagram ...

Page 145: ... switch is ON with engine running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 1 2 3 4 ...

Page 146: ... or passenger s door key cylinder The door lock system outputs UNLOCK signal for 0 5 seconds when switching from UNLOCK to LOCK by the driver s or passenger s door key cylinder The alarm will not be activated when switched to UNLOCK by driver s or passenger s door key cylinder switch in theft deterrent mode It does not occur abnormal operation when reconnecting the battery after disconnecting the ...

Page 147: ...ock system outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 148: ...UNLOCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Page 149: ...ft deterrent mode briefly press Panic press for more than 2 seconds operative only when the ignition key is in key cylinder Indicator Briefly press Blinks once Press and hold Blinks twice Door LOCK Function Briefly press Locking the doors and Arming the theft deterrent mode ...

Page 150: ...ccur even if the vehicle speed falls below 50 km h and accelerates again to over 50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door system outputs five LOCK...

Page 151: ...8710 08 System Diagram Power OFF ACC ON IGN ON ...

Page 152: ...iving the air bag collision signal Even though the key is turned to OFF position during the output of UNLOCK the output continues on for remaining period The room lamps come on when receiving the collision signal from the air bag collision sensor except room lamp switch OFF The hazard warning flasher relay ON when receiving the collision signal from the air bag collision sensor This function reset...

Page 153: ...s will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or UNLOCK output is ignored if LOCK or UNLOCK output is required while performing the output of LOCK or UNLOCK If the door lock system outputs LOCK and UNLOCK simultaneously only the LOCK output can be activated ...

Page 154: ...ut is ON for 30 seconds when turning off the ignition switch The power window relay output is OFF when opening the driver s door or the passenger s door The power window relay is turned OFF when receiving the remote control key lock signal armed mode during its extended operation period of 30 seconds 1 2 3 System Diagram IGN ON OFF ...

Page 155: ...on DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 DOOR LOCK Indicates that all door lock switches including tailgate are in LOCK positions DOOR UNLOCK Indicates that any of all door lock switches including tailgate is in UNLOCK position 2 The door lock unlock operation does not affect the engine hood ...

Page 156: ...nd tailgate are locked with the above three conditions met 1 2 3 4 The sleep mode is deactivated immediately if any of them is out of the specified conditions wake up mode Also the sleep mode is deactivated when receiving the UNLOCK signal from the remote control key 2 The sleep mode in Step 1 is deactivated on following conditions Operation of room lamp key hole illumination headlamp siren tail l...

Page 157: ...ock signal with any door open the doors are locked but the theft deterrent mode is cancelled when the ignition key is inserted into key cylinder or the door lock button is placed deterrent mode is activated with two blinks of turn signal lamps and one buzzer signal If any door is not opened within 30 seconds after unlocking the doors with remote control key in theft deterrent mode all doors will b...

Page 158: ...System Diagram Ignition Key Removed Door Closed ...

Page 159: ... theft deterrent mode When a door switch is moved to unlock position When a door is open after completion of siren operation for 27 seconds 1 2 3 Alarm Buzzer and Hazard warning flasher Operation The siren sounds for 27 seconds with the interval of 1 second ON and 1 second OFF 1 Alarm Stop Conditions The alarm stops when pressing any button on REKES key When turning the ignition key to ON position...

Page 160: ...After Alarm Period The siren and hazard warning flashers will be turned off 1 System Diagram Alarm Stop Conditions are Met ...

Page 161: ...the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key the system outputs LOCK signal and activates the armed mode Installed Removed Normal Armed Warning Remark Normal O Armed Ready O Armed O Warning O Warning Completion O O O RELOCK Ready O ...

Page 162: ...ic signal with Power OFF ACC and IGN ON the siren and turn signal lamps operate for 27 seconds ignition key should be in ignition key cylinder When pressing any button on REKES key during the panic operation the panic alarm stops Other commands are overridden 1 2 ...

Page 163: ... locked and the theft deterrent mode is activated 1 Indicator Briefly press Blinks once Press and hold Blinks twice Unlock briefly press If the Unlock button is briefly presses below 0 5 sec all doors and the tailgate are unlocked and the theft deterrent mode is deactivated The front room lamp comes on for 30 seconds when unlocking doors with REKES key Panic Function press and hold When pressing t...

Page 164: ...are locked when briefly pressing the door LOCK switch on remote control key less than 0 5 seconds The theft deterrent mode is activated when locking the doors with Lock button on REKES key Hazard warning flashers blink twice 1 2 ...

Page 165: ...8710 08 System Diagram ...

Page 166: ...lock switch on the remote control key for less than 0 5 seconds The door unlock relay is ON for 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 System Diagram ...

Page 167: ...tton If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 System Diagram In Theft Deterrent Mode Any Door is Not Open in 30 Seconds after Unlocking Doors ...

Page 168: ...4 CIRCUIT DIAGRAM Power Ground Diagnostic Chime Buzzer Warning lamps Brake Seat belt Door ajar ...

Page 169: ...8710 08 Central Door Locking ...

Page 170: ...Tail Lamp Hazard Warning Flasher Power Window ...

Page 171: ...8710 08 Defogger ...

Page 172: ...Panic Auto Light Rain Sensing Room Lamp ...

Page 173: ...8710 08 FRT Wiper Washer ...

Page 174: ... Coding The ignition key should be removed from the ignition key cylinder The code can be registered only by the scan tool Up to five transmitter can be registered The received code cannot be output during registration The REKES key should be coded by the scan tool 1 2 3 ...

Page 175: ...instrument panel It consists of 16 pins The REKES key should be coded by the scan tool Connector Pin Diagnostic connector Pin No Function 1 CAN HI S203 18 2 CAN LO S203 8 3 4 Ground 5 Ground 6 CAN HI S202 14 7 8 9 10 11 TCU A18 5 A T 12 13 TCCU 21 14 CAN LO S202 4 15 STICS B21 16 B ...

Page 176: ...5 Coding Procedure The REKES key should be coded up to 5 keys by the scan tool when replacing it with new one 1 button on the REKES key for more than 2 seconds 2 ...

Page 177: ...ased all REKES keys should be coded second key coding 3 The screen below will be displayed after completion of second key coding Press 4 Exit from the diagnosis program and disconnect the scan tool from the diagnostic connector Make sure that the buttons on the REKES key operate properly 5 ...

Page 178: ...TR Unit Description Specification Immobilizer control unit Coil inductance Coil turns 95T Coil wire Rich wire TBD Modulation FSK Input Output frequency Antenna cable Twisted rich wire TBD Transponder Frequency Operating temperature ...

Page 179: ...2 MAJOR CHANGES Blanking Key Old New Changed the material of key fob Changed the key plate design ...

Page 180: ...nder integrated in the key and the engine control unit has the same code When the ignition key with the integrated transponder is turned to the ON position the ECU Engine Control Unit checks the crypto code of the key and if correct allows your vehicle to start the engine REKES Key 1 OVERVIEW Immobilizer Warning Lamp meter cluster Immobilizer Control Unit Diagnostic Connector ECU ...

Page 181: ...der inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer warning lamp Immobilizer unit Transponder for Diesel engine Transponder for gasoline engine Battery ...

Page 182: ...IAGRAM New The certification for the immobilizer is performed when turning the ignition switch to the ON position after the CAN communication between the ECU and immobilizer is established D20DTR D20DT D27DT D27DTP G32D ...

Page 183: ...lizer control unit converts the signal to crypto signal The immobilizer control unit compares the crypto signal with the signal from the transponder If two signals are identical the immobilizer control unit determines the key is valid and it sends the positive message to the ECU The ECU allows starting the engine 1 2 3 4 5 6 7 Transponder In the following cases you may be unable to start the engin...

Page 184: ...ine control unit during engine starting and goes out after starting the engine Lamp ON in communication Blinking twice for one second immobilizer system failure Blinking once for two seconds immobilizer unit is not coded The immobilizer indicator does not come on if the communication time between immobilizer key and ECU is too short ...

Page 185: ... unit The system compares the signal from transponder and the encrypted signal in immobilizer unit The transponder sends an encrypted signal to the unit as a response Transponder for DI engine Transponder for gasoline engine In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When the key is c...

Page 186: ...he authorized one and transmits the positive message to the ECU The ECU enable the engine to be started The immobilizer indicator does not come on if the communication time between immobilizer key and ECU is too short ENGINE CONTROL UNIT ECU Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or reg...

Page 187: ...4 CIRCUIT DIAGRAM D20DTR ...

Page 188: ...7010 09 D27DT D27DTP ...

Page 189: ...eft deterrent mode Panic Function press and hold 2 If you are in your vehicle and feel threatened while the ignition key is inserted into the key switch you may activate the alarm to call attention If you press this button the warning siren will sound for approx 30 seconds The panic function will stop when any of the buttons on the remote control key is pressed Briefly press blinking once Press an...

Page 190: ... Total number of pulses Sliding 1 200 Pulse Lift FRT RR 46 93 Pulse Operation speed Sliding 17 9 mm Sec Reclining Lift FRT RR 7 0 mm Sec Resolution Sliding 0 188 Pulse Lift FRT RR 0 64 Pulse Variable resistance REC SPWM memory switch Type Self return type Active low Contact current Min 10mA Chattering Max 10 msec Manual switch Type Self return type Active low Contact current Max 7A Chattering Max ...

Page 191: ...Actuator Actuator Specifications For sliding reclining raising front and rear DC motor Rated voltage DC 12V Operation current Sliding Max 2A No load Reclining REC Max 3 6A AT 1 5 Nm Max 8 0A AT 12 Nm Lift FRT RR Max 3A Limited current Sliding Max 16A Reclining Max 13A Lift Max 11A 3 Outside Rearview Mirror Manual Mode Normal 12V ...

Page 192: ...ering Max 10 msec Position Sensor and Folding Switch Inputs Specification Mirror position motor Rated voltage DC 12V Operating current Max 0 2A Limited current Max 1 5A Mirror operating speed Folding motor Rated voltage DC 12V Operating current Max 3A Limited current Max 3 4A Turn over torque by hand Manual folding min 50 kgf cm Electric folding max 100kgf cm Outputs from Mirror Position Motor Nor...

Page 193: ...sition switch ON once When pressing the position switch button twice consecutively three times When detecting a sensor error while recalling position switch ON three times No buzzer output for the easy access memory recall operations No buzzer output for the outside mirror position recall by the auto down operation when reversing Buzzer Buzzer Output Specification Buzzer Rated voltage DC 12V Rated...

Page 194: ...7410 32 2 MAJOR CHANGES Changed the memory recall logic Changed logic outside rearview mirror ...

Page 195: ...wn Left Right venter position not operative Mirror folding switch operation Folding and Unfolding Operations in step 1 2 override the memory operation and memory recall operation 2 3 4 To prevent the redundant current consumption during motor running the motor starting point in each process is delayed for 100 ms in automatic control memory recall The operation sequence is as below Rear Outside rea...

Page 196: ...on vehicle speed Meter cluster SPWM available Memory Setting driver s seat and outside rearview mirror Adjust the positions of the driver s seat and the outside rearview mirrors Press the set switch for over 200ms to enter the memory setting mode Within 5 seconds press one of the position buttons 1 2 3 for over 200 ms to complete the memory setting procedure The buzzer sounds once The buzzer sound...

Page 197: ...When driving the vehicle at speed over 1 km h When the memory setting procedure is completed the memory setting procedure is automatically cancelled and the buzzer sounds twice All the stored positions position switch 1 2 3 get erased when removing the battery Recalling the Memory Setting Press one of the position buttons for over 1 5 seconds The driver s seat and outside rear view mirrors start t...

Page 198: ...ed The seat memory stop button stop switch is pressed during the recall process If the seat position is manually adjusted during recall process the seat recall operation stops but the outside rearview mirror continues to move to the set position If the outside rearview mirror is adjusted during recall process the outside rearview mirror recall operation stop but the seat continues to move to the s...

Page 199: ... stopping during folding unfolding process this delayed operating time is extended for additional 13 seconds if pressing the switch within 30 seconds T2 after turning the ignition OFF If pressing the switch again during the additional operating time the delayed operating time is extended again for additional 13 seconds 1 2 3 Timing Chart The outside rearview mirror folding switch is supplied the p...

Page 200: ... send the return signal to SPWM unit If SPWM receives the data properly it operates the return operation The prohibit conditions for the easy access seat return operation are as follows The parking brake is released or the shift lever is in any position other than P Any of seat switch is operated during the return operation Ignition switch is cycled ON and OFF with short interval approx 1 1 5 seco...

Page 201: ...seat backwards for approx 50 mm and lowers it as far as it goes If an error is detected from the motors sliding motor cushion front motor cushion rear motor during operation after removing the ignition key the motor with error stops its operation and other motors continue to complete their operations easy access stop signal to SPWM unit The SPWM overrides all STICS data signals in one second after...

Page 202: ...rd signal and doesn t send any date to SPWM unit If an error is detected on a sensor the affected motor doesn t operate until it receives normal sensor input The vehicle speed is over 1 km h When the seat switch is operated If the shift lever is any position other than P or the parking brake is disengaged 1 2 3 4 5 6 7 LED ON Easy access operation is activated LED OFF Easy access operation is stop...

Page 203: ...seat warmer unit is not variable control type but ON OFF control type The rear seat warmer switches LH RH control the rear seat warmer relays LH RH in the ICM 2 LAYOUT Front seat warmer unit Front seat heated wire seat and seatback Rear 1st seat heated wire seat Rear seat warmer switch Front seat warmer switch ICM box Rear for rear seat warmer ...

Page 204: ...Front variable seat warmer Seat outside mirror memory 3 CIRCUIT DIAGRAM ...

Page 205: ...8611 31 Front variable seat warmer Seat outside mirror non memory ...

Page 206: ...Rear seat warmer ...

Page 207: ...ure Storage temperature Performance reserve temperature DC 10V 15V Dark current below 3 mA at stable status stand by mode after 180 seconds from IGN OFF 1 Power Voltage Current 2 Illumination Level Classification When Tail Lamp ON Illumination level Day 100 100 25 6 steps Night 40 compared to the level in daytime 40 10 6 steps 1 Black Face Model ...

Page 208: ...0V 20 mA Engine oil pressure warning lamp Red 2 0V 20 mA Front fog light indicator Green 3 3V 20 A Brake warning lamp Red 2 0V 20 mA Immobilizer indicator Yellow 2 0V 20 mA Door ajar warning lamp Red 2 0V 20 mA Hazard indicator Red 2 0V 20 mA ABS warning lamp Yellow 2 0V 20 mA Engine overheat warning lamp Red 2 0V 20 mA Glow indicator Yellow 2 0V 20 mA Water separator warning lamp Red 2 0V 20 mA A...

Page 209: ...e Speedometer 1 OVERVIEW Two types Black Face type and Clear type of meter cluster are used in this model The meter clusters uses CAN communication lines with the electric units and the LCD display window is located on the lower side of the meter cluster Coolant Temperature Gauge ...

Page 210: ...1 Black Face Type 3 WARNING LAMPS AND INDICATORS ...

Page 211: ...8010 01 Trip switch ...

Page 212: ...2 Clear Type ...

Page 213: ...8010 01 ...

Page 214: ...ption for Warning Lamps and Indicators High beam indicator Front fog light indicator Light indicator Glow indicator Water separator warning lamp This warning lamp comes on when the ignition switch is turned to When the water level inside the water separator in the fuel filter exceeds a certain level this warning lamp comes on and stays for a short time or may go off right away When the pre glow sy...

Page 215: ...n this warning lamp illuminates and then should go off to confirm that the air bag is operational If it does not come on or if it does not go off or if it flashes or illuminates continuously while driving it means that there is a malfunction in the system This warning lamp blinks and the warning buzzer sounds for 6 seconds when belt is securely fastened This warning lamp comes on when the ignition...

Page 216: ...f when the engine is started driving it means there is a malfunction in the system This warning lamp comes on when the ignition switch is turned to This indicator comes on when pressing the ESP OFF switch to deactivate the ESP function If the lamp stays on or comes on while driving some of the engine control components including sensors and devices are defective This warning lamp is blinking when ...

Page 217: ...es on when the ignition switch is turned to This warning lamp comes on when the ABS system is defective This indicator comes on when the ignition key is communicating with the engine control unit during engine starting for 0 5 seconds The time needed for communication between the immobilizer key and ECU may vary When the time is very short the immobilizer indicator does not come on If the ABS warn...

Page 218: ...sed Use this mode to drive off smoothly on an icy and slippery road This indicator blinks when the left turn signal switch is turned on Both indicators blink when the hazard warning switch is turned on This indicator blinks when the right turn signal switch is turned on Both indicators blink when the hazard warning switch is turned on This indicator blinks when the hazard warning flashers are swit...

Page 219: ... on when the global warning lamps comes on blinks for 70 seconds 0 4s ON OFF Low tire pressure warning Global warning This warning lamp comes on when the ignition switch is turned to Lamp ON over inflated over 48 psi Lamp ON under inflated 24 26 psi for more than 10 minutes Lamp ON under inflated below 24 psi This indicator illuminates in green when the ignition switch is turned to illuminates in ...

Page 220: ... TOD P TIME Yellow Green Red shifting operation is completed After completion of the mode change to 4L the indicator comes on until the shifting operation is completed After completion of the mode change to 4H the indicator comes on warning lamp stays on 4WD system is defective ...

Page 221: ...8010 01 3 Display Sequence ...

Page 222: ...amp ON The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps 4 Illumination Level Adjustment The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps in day mode and night mode ...

Page 223: ...8010 01 5 System Analysis ...

Page 224: ......

Page 225: ...Trip Meter TRIP The total driving distance 0 to 999 999 km or 0 to 999 999 miles and the trip distance 0 0 to 999 9 km or 0 0 to 9 999 9 miles are calculated by using the value of pulse per 1 km which is programmed in the EEPROM ...

Page 226: ...Function Signal Operating temperature Storage temperature Sound pressure level 70dB min 2kHz square wave 10cm Buzzer Priority Remark ON_TIME OFF_TIME 160ms 1 Non PAS outputs 610ms after Description Buzzer output R position Over speed warning ESP High temp warning Fuel filter The buzzer with lower priority outputs when the buzzer with higher priority is turned off ...

Page 227: ... HDC Indicator 8 Functions of HDC Indicator The brake system operates properly even if the HDC system is defective HDC indicator ON when Turning the ignition ON There is an error in HDC system The brake system overheats ...

Page 228: ...ed ON but it does not operate because the operating requirements road steep grade or vehicle speed are not met In operation HDC is operating Blinking 0 5s OFF HDC switch ON and the operating requirements are met System overheats High temperature of brake system over Stand by OFF OFF In operation The indicator blinks in green and red 0 5s Too high temperature of brake system OFF ON No independent t...

Page 229: ... control is activated If the activation reaches a certain limitation a beep sounds to warn the driver The ESP warning lamp goes off when ESP function is deactivated Even when the ESP is operated for a very short period of time the ESP warning lamp blinks at least four times every 175 milliseconds ...

Page 230: ...ns to normal position when the OFF switch is released The ESP system will be cancelled after approximately 150ms 1 2 3 Based on the above procedures we can see that the ESP system will be cancelled after a certain period approx 150ms from releasing the switch to the original position The ESP system does not get canceled immediately when the ESP warning lamp is turned on by pressingthe ESP OFF swit...

Page 231: ...larm or warning condition when the tire pressure in each wheel is in the specified value Tire Pressure Indicator The tire pressure indicator appears when pressing the TRIP switch for more than one second in ODO mode The tire pressure indicator returns ODO mode when pressing the TRIP switch for more than one second or wait for more than 10 seconds without any switch input The tire pressure indicato...

Page 232: ...l Warning Failure Warning ON Conditions Warning Lamp Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Error in TPMS system Defective wheel module Error in TPMS system Low tire pressure Flat Tire Yellow Comes on immediately Yellow Affected tire symbol Yellow Comes on immediately Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Yellow Affected tire symbol ...

Page 233: ... abnormal tire comes on in yellow In tire pressure display mode the symbol for abnormal tire comes on in yellow and the other symbols come on in green Tire Pressure Indicator Yellow Blinks 0 4 s ON OFF for 70 seconds and then stays on Specified tire pressure 32 psi 10 minutes of continuous driving over 20 km h The tire pressure should be measured Comes on in green 10 15 s and then goes off The tir...

Page 234: ...maining segments are ON The mode and illumination switch inputs are overridden The instrument cluster enables all functions by receiving the vehicle s variant codes through CAN lines when turning the ignition switch to ON position The verified system by variant code activates the pre warning and time out operation If not verified all data for the systems even exiting in CAN network are overridden ...

Page 235: ...ing 10 A Relay load Turn signal light switch Wiper switch Low 5 A High 7 A Motor load Relay load Fixed Max 28 A Motor load Washer switch 4A Motor load Intermittent wiper switch Max 25 mmA Horn connector 1A Relay load Description Specification Center switch cluster Hazard switch DC 12V 10A Lamp load Windshield heated glass switch DC 12V 0 1A Indicator load Tailgate and outside rearview mirror heate...

Page 236: ...2 MAJOR CHANGES Center Switch Cluster Old New Changed to independent switch type from integrated switch type Hazard Switch Old New Changed the design of hazard switch ...

Page 237: ......

Page 238: ...s all door windows Open Close Lock Unlock and doors Lock Unlock with this switch unit Auto Washer Switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be automatically operate 3 times Auto light position Rear wiper and washer coupled operation Front wiper operation range move the wiper...

Page 239: ...g Switch LH Seat warmer switch RH Seat warmer switch PAS off Switch ACCEL DECEL ON OFF Hazard Switch HDC switch ESP OFF switch Heated Tailgate Glass Outside Rearview Mirror Galss Switch Heated Windshield Glass Switch Deicer Center Switch Cluster TOD Part time ...

Page 240: ...Headlamp High beam 2 55W 55W 15W Low beam 2 55W 55W Tail Position lamp 4 LED LED Front combination lamp Front fog lamp 2 35W 35W Turn signal lamp 2 21W 21W Outside turn signal lamp supplemental turn signal lamp 10 LED LED Rear combination lamp Stop lamp Upper 32 LED LED Stop lamp Lower 24 LED Tail lamp 16 LED LED Turn signal lamp 2 21W 21W Back up lamp 2 16W 16W Rear fog lamp 2 21W High mounted st...

Page 241: ...uminescent Diode LED is a semiconductor diode that emits incoherent narrow spectrum light when electrically biased in the forward direction of the p n junction as in the common LED circuit In short it is an element that converts electric signals into light signals Yellow blue red and white LEDs are currently available The followings are the advantages of LED It is not glaring and doesn t have shor...

Page 242: ...ted the turn signal lamp and changed the tail lamp to LED type from bulb type Front Combination Lamp Old New Integrated the fog lamp and turn signal lamp 3 MAJOR CHANGES High beam Low beam Turn signal Tail lamp High beam Low beam Tail lamp Fog lamp Turn signal lamp Fog lamp ...

Page 243: ...ns of rear combination lamp Changed the stop lamp and tail lamp to LED type from bulb type Tail Stop lamp Turn signal lamp Tail lamp Back up lamp Stop lamp Tail lamp Back up lamp Turn signal lamp Stop lamp Changed the design of reflex reflector Rear fog lamp EU ...

Page 244: ...8310 00 Outside Turn Signal Lamp Old New Introduced new outside turn signal lamp LED type Side Repeater Lamp Deleted the side repeater lamp Outside turn signal lamp ...

Page 245: ...mps rear lamps and side lamps 1 EXTERIOR LAMPS Front lamps Head lamp Front combination lamp Rear lamps Rear combination lamp License plate lamp High mounted stop lamp Reflex reflector Side lamps Outside turn signal lamp 2 Layout High beam Low beam Tail lamp Turn signal lamp Fog lamp Outside turn signal lamp ...

Page 246: ...8310 00 High Mounted Stop Lamp License Plate Lamp Rear Combination Lamp Reflex Reflector Stop lamp Turn signal lamp Back up lamp Tail lamp Rear fog lamp EU ...

Page 247: ...ICS STICS controls the head lamp and tail lamp with LIN data from the auto light sensor when the light Low beam High beam DRL is the function to turn on the high beam and tail lamp without any intervention from the light switch DRL turns off the lamps when turning off the light switch This is an additional safety device to prevent the accident Tail lamp Available only for EU market ...

Page 248: ... on the tail position lamp relay when receiving the lamp on signal from the light switch Position lamp Tail lamp In vehicle for EU market the tail position lamp comes on when turning the ignition switch to ON position regardless of light switch operation ...

Page 249: ...and closing the driver s door while the ignition is removed and the tail lamp is turned on 1 2 3 4 Tail Lamp Left ON Warning The buzzer sounds with the interval of 0 3 second when opening the driver s door while the tail lamp is turned on and the ignition key is removed The buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 secon...

Page 250: ...d detects the illuminance change The STICS communicates with the auto light sensor when the ignition is turned on and turns on or off the tail lamp and headlamp automatically according to the signals from the sensor when the light switch is set to AUTO position Auto light sensor STICS controls the head lamp and tail lamp with LIN data with IGN ON and the light switch Not available for EU market ...

Page 251: ... 4 License Plate Lamp The license plate lamp comes on when the light switch is turned on Tail AUTO Low High ...

Page 252: ...8310 00 ...

Page 253: ......

Page 254: ...urned on only with the light switch ON The front fog lamp goes out when turning off the ignition or light switch Rear Fog Lamp for EU Front fog lamp Rear fog lamp Rear Fog Lamp Switch The rear fog lamp comes on when the rear fog lamp is turned on only while the front fog lamp is ON ...

Page 255: ... The turn signal lamp goes out when the steering wheel angle opposite direction with turning direction 6 Turn Signal Lamp The left or right turn signal lamp blinks when moving the light switch to appropriate direction When pressing the hazard switch both turn signal lamps come on simultaneously Outside turn signal lamp Turn signal lamp ...

Page 256: ...8310 00 ...

Page 257: ...p The stop lamp switch turns on the stop lamp when depressing the brake pedal When releasing the brake pedal the stop lamp goes out 8 Back up Lamp Back up lamp Stop lamp High mounted stop lamp Rear fog lamp for EU ...

Page 258: ...8310 00 ...

Page 259: ...ar Room Lamp Front Room Lamp 1 Overview The interior lamps consist of front room lamps 2 center room lamp rear room lamp glove box lamp sun visor lamps 2 courtesy lamps 4 and scuff lamps 4 2 INTERIOR LAMPS 2 Layout Glove Box Lamp ...

Page 260: ...8310 00 Door Courtesy Lamp One lamp in each door ...

Page 261: ...nal 30 seconds during lamp operation in Step 5 when receiving the UNLOCK signal from REKES again The front room lamp stays on when opening a front door and operates as in Step 3 and 4 The front room lamp dims out when closing the opened door However it goes out immediately when getting into the theft deterrent mode The front room lamp comes on when opening a front door with the ignition ON And it ...

Page 262: ... switch pressed in The rear room lamp comes on when opening the tailgate The rear room lamp goes out when closing the tailgate 1 2 3 Room Lamp Auto Cut When the vehicle enters into theft deterrent mode STICS sleep mode the ground circuit of room lamp is turned off Or the ground circuit of room lamp is turned off 10 minutes after power off This is to prevent the battery from discharging when the fr...

Page 263: ... box lamp comes on when opening the glove box with the tail lamp on 5 Door Courtesy Lamp and Scuff Lamp The door courtesy lamp comes on when opening the door 6 Sun Visor The sun visor lamp comes on when opening the vanity mirror ...

Page 264: ...8310 00 7 Circuit Diagram of Room Lamp ...

Page 265: ...er switch to the OFF position before any car wash to avoid unwanted operation of the wipers Wiper mist washer coupled wiper Auto washer coupled wiper Rain sensor coupled wiper operation LIN Speed sensitive intermittent wiper Wiper low high control Check if the sensor is off the position Check if the rain sensor cover is securely installed Check if the customer is familiar to how to control the wip...

Page 266: ...iper blade design and wiper arm pressure Previous Current Wiper arm pressure Wiper blade design changed blade size is same Driver side 20inch Passenger side 20inch 3 MAJOR CHANGES Windshield wiper blade ...

Page 267: ... once after the switch is turned ON and the wiper relay is turned ON for 4 cycles After that the washer motor is operated for about 1 seconds to spray the washer fluid again and the relay is turned ON for 3 cycles and then the relay is turned OFF 2 Rear Washer Fluid Supply System The front washer fluid reservoir supplies the rear washer fluid without additional washer fluid reservoir Operating par...

Page 268: ... This sensor emits infrared rays through LED and then detects the amount of rain drops by receiving the rays reflected off the sensing section rain sensor mounting section on the windshield with photodiode AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay auto speed control A position that can control the sensitivity for the amount of rains on the windshield and transmit the wi...

Page 269: ... the operating request signal to the STICS which drives the wiper directly At this moment the STICS also sends the information on whether the wiper is in operation mode or whether the multifunction wiper switch is in AUTO position to the rain sensor STICS Underhood Fuse Box ...

Page 270: ...Wahser nozzle Front Rear Rain sensor unit 3 SYSTEM LAYOUT INCLUDING RAIN SENSOR Wiper Front wiper Rear wiper Wiper and washer switch ...

Page 271: ...7810 00 STICS Wahser motor Front Rear Windshield washer reservoir tank assembly Rear wiper DPS ...

Page 272: ...ping speed control switch When turning to FAST wiping speed gets faster and when turning to SLOW wiping speed gets slower Stop the operation Wiper speed controls automatically according to the vehicle speed or amount of rain rain sensing wiper Wiping speed gets faster when placing the pointer at the HI position Wiping speed gets slower when placing the pointer at the LO position ...

Page 273: ...ith the IGN1 ON the wiper relay is turned on after 0 1 sec has passed When the wiper returns to the park position the wiper relay is turned off When the MIST switch signal is input the wiper is operated at high speed When the switch is release from the MIST position the wiper is operated at low speed 1 2 ...

Page 274: ...wiper operation The wiper relay should stay ON in low high wiper operation mode even if the parking signal for the wiper motor is not received In INT AUTO wiper operation mode the wiper relay should be turned OFF after 5 seconds if there is no parking signal for the wiper for 3 seconds and informs the driver of parking position signal abnormality While the wiper operates at low high speed the fron...

Page 275: ... switch is below 0 6 second the wipers operate only one cycle 1 2 Windshield Washer Control Function 1 Windshield washer coupled wiper Wiper and Washer Coupled Operation Pull the switch briefly for less than 0 6 sec One wiping cycle Pull and hold the switch for more than 0 6 sec Three wiping cycles with washer fluid spray ...

Page 276: ...r pulling up the washer switch to ON position with IGN ON If the washer switch is turned on for more than 0 6 seconds the wiper relay is activated three times after releasing the washer switch and then the wiper motor is set to parking position 2 ...

Page 277: ...n Auto position sensing the vehicle speed and rain drops the wiper operates three times when the washer switch is turned on for more than 0 6 seconds and it operates once when the washer switch is turned on for less than 0 6 seconds 3 ...

Page 278: ... wiper operation When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent automatic wiping mode will be started 1 2 3 4 2 AUTO washer coupled wiper Auto washer switch If pressing the switch when the wiper switch turns to the OFF position washer fluid is sprayed once and wiper operates 4 times After a while washer fl...

Page 279: ...7810 00 ...

Page 280: ...he switch is released it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the position and turn off the wiper and washer 3 Rear Wiper Control Function ...

Page 281: ...tomatic washer switch signal is received during the rear washer switch operation the washer motor stops and the front washer or automatic washer motor begins to operate 1 2 Rear washer motor control When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the position and turn off the wiper and washer ...

Page 282: ...ain Sensor Coupled Wiper Control Function AUTO Wiper operates automatically by rain sensor FAST Auto delay auto speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly ...

Page 283: ...7810 00 System layout 1 Rain sensor coupled wiper operation LIN ...

Page 284: ... wiper switch is turned on from off with the ignition switch ON the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals After then the wiper does not operate even when the INT AUTO wiper switch is turned on from off The wiper operates at low speed only when the rain sensor detects the rain drops 1 2 2 Power up reminder wiper ...

Page 285: ...tes in washer coupled wiper operation mode However if the signal from rain sensor is the continuous operation the washer relay is turned on and the wiper keeps on running when the washer switch is ON Even though the wiper system is in washer coupled wiper operation mode the operating data should be sent to rain sensor 1 2 3 Washer coupled wiper operation during rain sensor coupled operation ...

Page 286: ...e wiper motor operates one cycle at low speed Only when the rain sensor detects rain drops If the wiping speed control switch is changed more than 1 stages within 2 seconds the wiper motor operates only one cycle 1 4 Sensitivity control instant wiping ...

Page 287: ...ent signal for parking status continuously The wiper motor is operated only when there is a request from the rain sensor 2 The wiper system sends continuously the signal for current status when the wiper parking terminal is shorted to ground with IGN2 ON and intermittent wiper switch in ON position The wiper motor is operated only when there is a request from the rain sensor 1 5 For abnormal wiper...

Page 288: ...ulty sensor signal S_COMMFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal S_RSFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 1 6 For faulty rain sensor ...

Page 289: ...iper switch in ON position the wipers do not operate When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position the wipers operate one cycle The wiper s operation cycle depends on the vehicle speed CAN communication with instrument cluster and wiping speed the side fascia panel 1 2 3 7 Speed sensitive intermittent wiper ...

Page 290: ...ng position Elapsed time Total operating time after the wiper motor has started its operation from parking position The graph for pause time in previous page is generated by vehicle speed and wiping speed control switch 4 INT wiper switch ON time below 1 sec Continuous wiper operation over 1 5 sec Intermittent wiper operation ...

Page 291: ...nsing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto speed control A position that controls sensitivity against rains on the windshield and transmits wiping demand signal accordingly Emitter lens The LED which is located at bottom emits the inf...

Page 292: ... Relay Box Front wiper low relay Front wiper high relay Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the intermediate 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 lev...

Page 293: ... turned on from off with the ignition switch ON the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals After then the wiper does not operate even when the INT AUTO wiper switch is turned on from off The wiper operates at low speed only when the rain sensor detects the rain drops 1 2 1 Power up Reminder Wiper 2 FUNCTIONS OF RAIN SENSING WIPER SYSTEM ...

Page 294: ...in washer coupled wiper operation mode However if the signal from rain sensor is the continuous operation the washer relay is turned on and the wiper keeps on running when the washer switch is ON Even though the wiper system is in washer coupled wiper operation mode the operating data should be sent to rain sensor 1 2 2 Washer Coupled Wiper Operation During Rain Sensor Coupled Operation ...

Page 295: ...f the wiping speed control switch is changed more than 1 stages within 2 seconds the wiper motor operates only one cycle 1 3 Sensitivity Control Instant Wiping 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating with the rain sensor while the ignition key is in ON position 1 ...

Page 296: ... system continuously sends the signal for current status when the wiper parking terminal is stuck in ground with IGN2 ON and intermittent wiper switch in AUTO position 1 The wiper motor is operated only when there is a request from the rain sensor ...

Page 297: ...a faulty sensor signal S_COMMFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal S_RSFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 1 6 For faulty rain sensor ...

Page 298: ...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 For example the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 299: ...eceiving other ultrasonic signals metal sounds or air braking noises from heavy commercial vehicles When there is heavy rainfall or water drops When the sensor is covered with snow Sensor Cannot Detect When the sensor is frozen operate normally when it s thawed When the sensor is covered with foreign materials such as snow or condensation if the foreign materials are removed the sensor operates no...

Page 300: ...Number of Rear PAS sensors Old New PAS Unit Old New PAS sensor holding type Old New 3 MAJOR CHANGES Left Center Right Left Right Center RH Center LH ...

Page 301: ......

Page 302: ...ect the distance to any obstacle Driver can figure out the distance from the obstacle to the vehicle by the alarming sound The alarm interval becomes faster as the vehicle approaches the object 2 LAYOUT Two sensors in front bumper Operated only when the vehicle speed is below 10 km Front PAS sensor Left Right ...

Page 303: ... switch turns the front PAS sensor ON and OFF When the LED on the switch is ON PAS system is not available Rear PAS Sensor TGS Lever R D Center RH Center LH Right Left Left Center LH Center RH Right PAS Unit Controls the PAS sensor and sends the sensing signals to the instrument cluster and buzzer ...

Page 304: ...1 Detection Range Rear LH sensor Rear RH sensor Rear center RH sensor Rear center LH sensor Front Rear PAS Rear PAS Rear LH sensor Rear RH sensor Rear center RH sensor Rear center LH sensor Front RH sensor Front LH sensor ...

Page 305: ...ear sensor Detecting range and alarm interval alarm from external buzzer Level Rear sensor Center left Center right Rear Left Right Front Left Right Alarm interval 3 30 50cm 30 50cm 30 40cm Stays ON 2 50 80cm 50 80cm 40 60cm ON OFF 0 065 s 1 80 120cm ON 0 065 s OFF 0 196 s Tolerance ...

Page 306: ... 2 Vertical Detection Range Height 0 Bottom of bumper Range B From bottom of bumper Range C Detection No detectable Detection area Tolerance 3 Horizontal Detection Range Front Rear ...

Page 307: ...when the vehicle speed exceeds 15km h 1 Self Diagnosis Buzzer indication Starts the self diagnosis mode when turning the ignition on Fail conditions of self diagnosis a Sensor circuit is open short b Power circuit is open short c Sensor is defective If the sensors are working properly the buzzer sounds for 150ms Alarm interval during self diagnosis Front Rear PAS system ...

Page 308: ...Rear PAS system ...

Page 309: ...ON MODE Operation of LED Operation when detecting the obstacle Operation of front PAS OFF switch Switch Sensor P R N D OFF LED ON Front OFF ON OFF ON Rear OFF ON OFF ON ON LED OFF Front OFF ON OFF ON Rear OFF ON OFF ON ...

Page 310: ...eration of self diagnosis If the vehicle speed exceeds 15km h the front sensors are turned off If it goes below 10km h the When turning on the ignition the self diagnosis is performed but no buzzer output ...

Page 311: ...8790 04 5 CIRCUIT DIAGRAM ...

Page 312: ...6 FLOW CHART Front Rear PAS System ...

Page 313: ...8790 04 Rear PAS System ...

Page 314: ... FM 60dB LCD Type ISTN Operating voltage 9 0V VDD 3 0 3 3V Operating temperature Storage temperature Size width x height 132X36 Bluetooth Composition MD 5XR Technology Bluetooth 2 0 EDR Product name HFP A2DP AVRCP Current consumption below 5A max 10A Dark current below 3mA Unit Description Specification Frequency EU FM 87 5 108MHz MW 522 1620 KHz LW 144 290 KHz Latin America FM 87 5 108 MHz AM 520...

Page 315: ...Unit Description Specification Micro pole antenna Audio Operating current max 150mA Operating voltage DC 10 5V 16V Operating temperature Storage temperature Input Output impedance ...

Page 316: ...05 2 MAJOR CHANGES Audio Assembly Old New Changed the audio assembly added Bluetooth hands free function AVN type Audio type Audio Antenna Old New Changed the antenna from integrated type to micro pole type ...

Page 317: ...Audio Assembly 1 LAYOUT Audio CD Radio USB AUX Bluetooth hands free Audio Remote Control Switches Front Door Tweeter Speaker Front Door Speaker ...

Page 318: ...8910 05 Hands free Microphone Rear Door Speaker USB AUX Micro Pole Antenna ...

Page 319: ...tation memory button 1 6 and Audio function button 3 Bluetooth hands free CALL button 4 Bluetooth hands free END button 5 6 SCAN INFO button 7 BAND AS button 8 SETTING button 9 Display window LCD 10 RDS setup 11 Disc Play button 12 Disc Eject button 13 Disc slot ...

Page 320: ...ted voltage 12V Maximum operating current 10A Isolated resistance Return time Power outlet Rated voltage 12V Maximum operating current 10A Isolated resistance Digital clock Rated voltage 12V Operating voltage 8V 16V Operating temperature Time tolerance Current consumption IGN ON MAX 150 mA IGN OFF MAX 2 5 mA Display color Yellow green Display type LCD 1 SPECIFICATIONS ...

Page 321: ...ld New Deleted the speaker and installed new power outlet on top of center instrument panel 2 MAJOR CHANGES 1 Power Outlet Digital Clock Digital Clock Old New Deleted the multi station and installed new digital clock ...

Page 322: ...EW The electric accessories are Horn Cigarette lighter Power outlet Digital clock and Siren Theft deterrent alarm 1 Interior Electric Accessories Digital Clock Cigarette Lighter Power Outlet Tray in luggage compartment ...

Page 323: ...2 Exterior Electric Accessories LH Horn High RH Horn Low Siren Theft Deterrent Alarm ...

Page 324: ...10 00 2 OPERATING PROCESS 1 Horn 1 Operating Condition B always ON 2 Operation The horn sounds when pressing the horn switch on the steering wheel 3 Operating Process Horn switch air bag module integrated ...

Page 325: ...amp ON 2 Operation of Cigarette Lighter Press in the cigarette lighter and wait until it pops out Heating coil The barrel of the cigarette lighter becomes very hot when it is fully charged When touched by or dropped on bare skin this may cause burns Dropping the hot cigarette lighter can cause damage to a car seat or even start a fire ...

Page 326: ...button is pressed and one hour will be added to the hour indicator if this button is pressed 4 Siren Theft Deterrent Alarm 1 Operating Condition This horn sounds once when the vehicle is armed into theft deterrent mode This horn sounds for 27 seconds when there is an unauthorized access to the vehicle in theft deterrent mode For detailed information about theft deterrent ...

Page 327: ...t 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 Automatic transaxle DSI M78 the transmission TCU use the power from the ignition power supply to start and stop its operation TCU is connected to the transmission with...

Page 328: ... the P Position If you cannot move the gear select lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt Mode Switch Selection of Manual Automatic Shift Function Positions of gear select lever P Parking R Reverse N Neutral D Drive Automatic shift accordin...

Page 329: ... 1 478 1 4th 1 156 1 5th 0 866 1 6th 0 677 1 Reverse 3 094 1 Transmission fluid Fluid Fuchs ATF 3292 ATF Resistance of oil temperature sensor 20 0 20 100 Gear position sensor 1 2 3 D N R P Fluid Fuchs ATF 3292 ATF Capacity Approx 9 5 L Change interval Check the fluid at every 30 000 km or 1 year and change it if necessary ...

Page 330: ...3650 01 4WD Automatic Transmission 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Inhibiter switch Adapter housing 2 Appearance ...

Page 331: ...4WD 2WD 3 Sectional Diagram ...

Page 332: ...3650 01 4 Shift Pattern Diagram Vehicle speed Km h Output shaft speed rpm ...

Page 333: ...aft locking nut M24 x 15 100 110 Pump cover to oil pump M8 x 55 24 27 Pump cover to transmission housing M8 x 40 24 34 Pump cover to transmission housing M8 x 58 24 34 Upper valve body to lower valve body M6 x 30 15 17 Detent spring M8 x 16 20 25 Variable bleed solenoid and speed sensor M4 x 12 2 8 3 2 Transmission oil level plug 30 35 Front cooling lines to transmission cooler 25 35 Rear cooling ...

Page 334: ...irected by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications The six forward gears and one reverse gear are obtained from a single planetary set followed by a double planetary set This type of gear set arrangement is commonly known as Lepelletier type gear set The automatic transmission is electronically controlled The contro...

Page 335: ...em as there is sufficient engine strategy to protect the system However reverse gear engagement is prevented until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12 and vehicle speed is less than 10 km h Converter Clutch Lock Up In All Gears The transmission features converter clutch lock up in all gears This feature provides improved fuel economy and vehicle pe...

Page 336: ... 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 Coastdown downshifts occur at 0 accelerator pedal when the vehicle is coasting down to a stop To reduce the shift shock and to improve the shift feeling during downshift TCU electronically controls the tran...

Page 337: ... lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt 1 Gear Position 4 P Park R Reverse N Neutral D Drive 4 Mode Switch 3 W Winter mode Start off the vehicle in 2nd gear S Standard mode Use the standard mode in normal driving conditions 3 D Automatic sh...

Page 338: ...completely to the floor Then a one or two lever gear will automatically be engaged This is called the Kickdown function 4th gear position Use on a long and gentle slope 4 3 4 2 and 4 1 automatic kickdown shift is available 6th gear position 6 5 and 6 4 automatic kickdown shift is available 5th gear position 5 4 and 5 3 automatic kickdown shift is available 1st gear position Use on a rugged road mo...

Page 339: ...OBD II regulation 1 2 3 4 In case of overheated transmission 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 the tra...

Page 340: ...the signals and information analog and digital through CAN bus from the sensors Transmission input speed Transmission output speed Accelerator pedal position Gear selector position Engine torque Engine speed This information is used by the TCU to decide which shift pattern to select and for shift energy management Electro hydraulic solenoid valves and variable bleed solenoids control the transmiss...

Page 341: ...ses the torque converter clutch to activate the fail safe operation 4 Shift Energy Management This function involves reducing or increasing the engine output torque during shifting This reduces the energy which is dissipated in the friction elements of the transmission during up shift This is done by reducing the engine torque during the gear ratio change without interrupting the tractive drive Th...

Page 342: ...ossible to adapt precisely to the particular shift operation 5 Shift Mode Selection by TCU The driver can select Standard S or Winter mode W with the mode switch TCU automatically changes the shift mode according to the transmission oil temperature uphill or downhill gradient and altitude to keep the good driving conditions Standard Mode S Uphii and Downhill Mode Altitude Mode Standard Mode is sel...

Page 343: ... different shift mode to optimize the low range driving Similar to Winter mode the first gear is not available transmission Hot Mode and reduces the load to the transmission This is called Hot Mode In Hot Mode any of shift mode is not available Auto Cruise Control When the auto cruise control is activated the engine ECU requests the downshift to increase the engine brake effect PWM fan ON the engi...

Page 344: ...ded Memory Module EMM The embedded memory module EMM is matched to the transmission s valve bodies during transmission assembly to ensure refined shift quality The EMM is integrated into the input speed sensor which is mounted on the valve body in the transmission The EMM is used to store data such as valve body calibration data and valve body serial number Upon installation the TCU will download ...

Page 345: ...o Engaged element clutch band C1 C2 C3 B1 B2 1 2OWC M1 3 536 ON ON 1st 3 536 ON ON 2nd 2 143 ON ON 3rd 1 478 ON ON 4th 1 156 ON ON 5th 0 866 ON ON 6th 0 677 ON ON Reverse 3 094 ON ON Gear S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A M1 ON 1 0 1 1st ON 1 0 0 1 2nd ON ON 1 0 1 0 1 3rd ON ON 1 0 1 0 1 4th 0 0 0 1 5th ON 0 1 1 0 1 6th ON ON 0 1 1 0 1 Reverse ON ON ON 1 1 1 0 1 Gear Selection and Engaged...

Page 346: ...3650 01 Hydraulic Circuit Diagram ...

Page 347: ... C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON ON Power Flow Diagram Manual 1st gear is not engaged e...

Page 348: ...3650 01 1st Gear M 3 53 1 ...

Page 349: ...ed to the left end C1 clutch not engaged C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON Power Flow Diagr...

Page 350: ...3650 01 1st Gear D 3 53 1 ...

Page 351: ...C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 S4 ON B1 shift valve moved to the left end B1 band operated Drive oil for B1 band engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Loc...

Page 352: ...3650 01 2nd Gear D 2 14 1 ...

Page 353: ...omponents Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON ON 1 0 0 1 0 1 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 2 14 ON ON Power Flow Diagram ...

Page 354: ...3650 01 2nd Gear D Lock Up ...

Page 355: ...aged C2 shift valve open S2 OFF C2 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 48 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 48 ON ON Power Flow Diagram C3 clutch cannot b...

Page 356: ...3650 01 3rd Gear D 1 48 1 ...

Page 357: ...ed by drive oil C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C1 and C2 engagement is regulated by VBS S6 and S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 16 0 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 16 ON ON Power Flow Diagram 4th gear is used a...

Page 358: ...3650 01 4th gear D 4th gear D in Limp home mode 1 16 1 ...

Page 359: ...clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 87 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 87 ON ON Power Flow Diagram ...

Page 360: ...3650 01 5th gear D 0 87 1 ...

Page 361: ... C2 clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S4 ON B1 shift valve moved to the left end B1 Band engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 68 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 68 ON ON Power Flow Diagram ...

Page 362: ...3650 01 6th gear D 0 68 1 ...

Page 363: ...nd directly through manual valve S3 ON Pressure to C3 increased or regulated S1 and S2 ON C1 not engaged in any case Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 ON ON ON 1 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Page 364: ...3650 01 Reverse gear R 3 09 1 ...

Page 365: ...ecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 0 0 0 0 0 0 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Page 366: ...3650 01 Reverse R Limp Home Mode ...

Page 367: ...ting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Page 368: ...3650 01 Park ...

Page 369: ...omponents Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Page 370: ...3650 01 Neutral ...

Page 371: ...lever indication P R N D Mechanical D D Electrical Parking lock system Reverse lock system Selected lever indication P R N D Lever position 1 2 3 4 5 CAN Oil temperature sensor Resistance R D Resistance P N TCU EGS 52 Shift solenoid Resistance Operating distance 0 2mm Operating current 1 5 2A Item W5A330 300 W5A580 400 Input torque 330Nm 1 SPECIFICATIONS W5A580 2WD W5A400 4WD 450Nm 270mm Yes 3 595...

Page 372: ...0A Operating range 3rd to 5th gears RPM sensor Resistance HALL type Operating voltae 6V Start lockout switch Switch contact ON D position Switch contact OFF P N position Mode switch W Winter S Standard One way clutch F1 F2 Planetary gear set Plain planetary gear 3 number of pinion 3 4 3 4 4 4 Disc clutch Disc C2 C2 C3 Single plate type Disc brake Disc B1 B2 B3 Single plate type ...

Page 373: ...ue converter housing oil pump 20 Transmission rear mounting bracket left right 36 44 Transmission rear mounting bracket center 20 Torque converter mounting bolt 42 Converter housing engine 75 90 Converter housing transmission housing 20 T 45 Valve body 8 T 30 Valve body side cover 4 T 30 Solenoid valve 8 12 point collar nut 200 12 point 30 mm B2 housing bolt 16 T 45 Selector lever unit mounting bo...

Page 374: ...Converter 3 MAJOR CHANGES The torsion damped has been newly installed in the torque converter The torsion damper absorbs the shock vibration and noise when delivering the engine driving force This improves NVH performance in this vehicle ...

Page 375: ... relation to engine power This function improves shifting quality significantly And the driver can select S Standard mode or W Winter mode according to the driving conditions This automatic transmission provides two gears even during reverse driving The internal sensors and controls are connected to TCU by cylindrical 13 pin connector DCAG 5 speed automatic transmission offers the following advant...

Page 376: ......

Page 377: ...3650 01 1 Power Flow B1 C1 C2 B3 C3 B2 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun 2 POWER FLOW ...

Page 378: ...ar set M P T V Input shaft Clockwise rotation Front sun gear Locked by F1 and B1 Planetary gear carrier Rotation with reduced speed Rear ring gear Counterclockwise 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 reduced speed Output shaft Clockwise rotation Gear C1...

Page 379: ...lanetary gear set M P T V 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 Output shaft Clockwise rotation Gear C1 C2 ...

Page 380: ...r set D H L M Impeller Turbine wheel Front planetary gear set P T V 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 Gear C1 C2 C3 B1 B2 B3 F1 F2 3 ...

Page 381: ...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 ring gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring gear direct connection Output sh...

Page 382: ...ier Rotation with reduced speed Rear planetary gear carrier 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 increasedspeed Center sun gear Clockwise rotation with increased speed by C3 activation Center planetary g...

Page 383: ...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 Center planetary gear carrier Counterclockwise rotation...

Page 384: ...lockwise 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 carrier Counterclockwise rotation reduced speed Output sh...

Page 385: ...3650 01 3 CIRCUIT DIAGRAM ...

Page 386: ......

Page 387: ...K Capacity Sercive interval Inspect and replenish every 60000 km or 3 years under severe driving conditions change every 120 000 km 1 SPECIFICATION Reversing High force type Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly Taxi patrol service or delivery service extended idling and excessive driving with low speed Frequent stop and go traffic extended idling s...

Page 388: ... SPECIAL SERVICE TOOLS Install the main shaft reverse sleeve and bearing Install the main drive pinion assembly front ball bearing Install the main shaft double angular ball bearing Install the 3rd 4th synchronizer hub Install the main shaft 5th gear Install the main shaft 6th gear Install the main shaft 1st gear sleeve Install the drive pinion assembly front ball bearing Install the main shaft do...

Page 389: ... Description Part No SSM00203 001 Name Counter shaft bearing installer Install the counter shaft front roller bearing Part No T88310011A 9 Name Bearing support Support the counter shaft when removing the roller bearing with a puller ...

Page 390: ...1 1 1EA Loctite 4 Reverse shift fork retainer bolt 53 9 67 6 2EA Loctite 5 Backup lamp switch 29 4 34 3 1EA Loctite 6 Oil drain plug 58 8 78 4 1EA Loctite 7 Interlock bolt 14 7 21 5 1EA 8 Neutral switch 29 4 34 3 1EA Loctite 9 Oil filler plug 58 8 78 4 1EA Loctite 10 Extension housing bolt 42 1 53 9 12EA 11 Concentric slave cylinder bolt 9 8 15 6 3EA 12 Front bearing retainer bolt 19 6 24 5 8EA Lo...

Page 391: ...t Seal 19 6 24 5 Nm Seal Oil Bushing Spacer Gasket Plug 58 8 78 4 Nm Gasket Plug 2 3 4 5 6 7 8 9 10 11 Breather Air Pulg Seal 53 9 67 6 Nm Cylinder assembly Concentric slave Plunger Rolling Boot Guide Oil Spring Guide Bolt Flange 42 1 53 9 Nm 12 13 14 15 16 17 18 19 ...

Page 392: ...3162 00 Main shaft ...

Page 393: ...ynchronizer Sleeeve Synchronizer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Ring assembly Triple cone Gear assembly 1st speed Sleeve 1st gear Bearing Double angular ball Ring Snap Gear Main shaft 5th Spacer Gear Main shaft 6th Sleeve Reverse gear Bearing Needle roller Gear assembly Reverse speed Ring assembly Triple cone Hub Synchronizer Sleeeve Synchronizer Stopper Synchronizer key Bearing B...

Page 394: ...aring Needle roller Gear assembly 5th speed Key assembly Synchronizer Ring assembly Triple cone 1 2 3 4 5 6 7 8 9 10 Hub Synchronizer Sleeeve Synchronizer Ring Synchronizer Sleeve Speed gear Bearing Needle roller Gear assembly 6th speed Gear Counter shaft Nut Locking 156 9 186 3 Nm Bearing Needle roller 11 12 13 14 15 16 17 18 19 ...

Page 395: ...pter assembly Plate Intermediate Guide Oil Bolt 7 8 9 8 Nm Pin Dowel Retainer Bearing Magnet 1 2 3 4 5 6 Bolt Seal 19 6 26 4 Nm Shaft Reverse idler gear Bearing Needle roller Gear Reverse idler Spacer Reverse 7 8 9 10 11 ...

Page 396: ...ball Pin Spring Rail sub assembly Shaft 1st 2nd Bushing Rail sub assembly Shaft 3rd 4th Lug Shaft 5th 6th 1 2 3 4 5 6 7 8 Lug _ Reverse shaft Fork Reverse shaft Rail Shaft 5th 6th Fork Shaft 5th 6th Pin Spring Lever assembly Shaft 5th 6th Bolt Flange 14 7 21 5 Nm 9 10 11 12 13 14 15 ...

Page 397: ... mounting Pin Spring Pin Spring Adapter Case 1 3 4 5 6 7 8 9 10 13 14 15 16 17 20 Bolt Flange 42 1 53 9 Nm Seal Oil Seal Oil Pin Dowel Switch Neutral 29 4 34 3 Nm Gasket Bolt Interlock 14 7 21 5 Nm Pin Detent Switch Backup lamp 29 4 34 3 Nm Bolt Fork hinge 53 9 67 6 Nm Bearing Poppet ball 29 4 41 1 Nm Bolt Guide 14 7 21 5 Nm Bolt 2 9 4 9 Nm Bracket Wiring 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ...

Page 398: ...e improper gear shift semi remote control system has been introduced To prevent the gears from engaging improperly the synchronizer mechanisms and independent interlock systems are installed on 1 2 gears 3 4 gears 5 6 gears and reverse gear The High Force system for reverse gear shift has been introduced The synchronizer has three types Triple 1 2 3 R Double 5 Single 4 6 6 speed M T ...

Page 399: ...ssion housing Extension housing Main shaft Counter shaft Main drive gear Intermediate plate Gear Teeth Final gear ratio Input Output 1st 13 38 4 489 2nd 23 35 2 337 3rd 33 29 1 350 4th 28 43 1 000 5th 47 24 0 784 6th 52 23 0 679 R 13 36 4 253 Idle 25 ...

Page 400: ...2nd speed 1st speed 2 POWER FLOW ...

Page 401: ...3170 01 4th speed 3rd speed ...

Page 402: ...6th speed 5th speed ...

Page 403: ...3170 01 Reverse gear ...

Page 404: ...3 SHIFTING MECHANISM High Force mechanism for reverse gear shift 3rd 4th 1st 2nd 5th 6th Neutral switch Backup lamp switch Control shaft Control finger Lug arrangement ...

Page 405: ... 3rd gear 1 536 4th gear 1 000 5th gear 0 807 Reverse gear 3 591 Transmission fluid Specification ATF DEXRON II 4WD 3 6 2WD 3 4 Change interval Inspect at every 10 000km replace at every 60 000km add or replace if necessary Description Tightening torque Oil drain plug 4 5kgf m 39 22 49 03Nm Backup lamp switch 3 4kgf m 29 42 39 22Nm Extension housing bolt 4 2 5 7kgf m 41 18 55 89Nm Selector lever l...

Page 406: ...D Gasoline Features All gears use the helical type and high strength materials 1 The helical type gear prevents the axial gear missing and provides less noise The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provid...

Page 407: ...3170 01 2 SYSTEM COMPONENTS 1 Gear Combinations 2 Shift Fork and Rail Combinations ...

Page 408: ...3 Sectional View ...

Page 409: ... sleeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Needle bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5...

Page 410: ...IDI Engine equipped vehicle 4WD ...

Page 411: ...eve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5th needle b...

Page 412: ...IDI Engine equipped vehicle 2WD ...

Page 413: ...r ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5th needle bearing 53 5th ...

Page 414: ...ing torque 30 40 Nm Shift rail 3 4th Interlock bolt tightening torque 40 50 Nm 1 2 3 4 5 6 7 8 9 Shift lever 10 Interlock plate 11 Shift rail 1 2nd 12 Shift rug 1 2nd 13 Shift fork 3 4th 14 Input shaft 15 Counter shaft 16 Reverse idler assembly 17 Spring pin 6 x 25 18 Spring pin 6 x 25 Backup lamp switch Concentric slave cylinder adaptor Apply Loctite 243 Apply Loctite DRI LOC 200 19 20 8 6 ...

Page 415: ... bolt Stopper plate Air vent tightening torque 30 40 Nm Lock washer TGS bushing Outer spring pin TGS pin Lock bolt tightening torque 17 26 Nm 1 2 3 4 5 6 7 8 9 10 Offset lever Offset lever bushing Rolling plunger Return spring Spring plug tightening torque 30 35 Nm Apply Long term grease MoS2 when installing the offset lever 11 12 13 14 15 A ...

Page 416: ...6 Power Flows 1st gear Counter shaft 2nd gear ...

Page 417: ...3170 01 7 Power Flows Cont d 3rd gear 4th gear ...

Page 418: ...8 Power Flows Cont d 5th gear Reverse gear ...

Page 419: ...CHANISM 1 Interlock System Interlock system prevents the gears from meshing over two sets 2 Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward ...

Page 420: ...ext shift easier the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected 1 Offset lever 2 Shift lever 3 Shift shaft 4 Rolling plunger rolling plunger return spring and ball ...

Page 421: ...selected gear from getting out of its meshed position 1 Gear pump out locking device It prevents the shift lever is beyond the correct shift position while shifting 2 Guiding a control direction and preventing an over stroke 3 4 Backup Lamp Switch It is normal open type switch Its circuit is formed when the reverse gear is selected Sealant Loctite DRI LOC 200 Tightening torque 3 kg m 4 kg m ...

Page 422: ...er inner cone and middle cone Single cone type Double cone type 1 2 shift 3 4 shift 5 R shift 1 2 shift 3 4 shift 5 R shift 1 Synchronizer sleeve 2 Synchronizer hub 3 Synchronizer ring 4 Synchronizer key 5 Synchronizer key locking ring 6 Synchronizer inner cone 7 Synchronizer middle cone Be careful not to mix up the 1 2 shift synchronizer sleeve with 3 4 or 5 R shift synchronizer sleeve The 3 4 sy...

Page 423: ...he transmission main shaft is turning and the clutch gear is spinning Even though the clutch is disengaged the clutch gear continues to spin until friction slows it down or stops it Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at different speeds By using synchronizers the possibility of broken or damaged teeth is reduced and shifting effort is lowere...

Page 424: ... and 3 4 shift 1 2 Needle bearing for reverse gear with cut out area Needle bearing for 5th gear 3 4 7 End Play of Taper Roller Bearing 1 Taper roller bearing for input shaft 2 Taper roller bearing for counter shaft A End play A 0 85 2 28 mm B End play B 1 17 1 97 mm Use the following spacers to adjust the end play A or B between input shaft and counter shaft Specified range of end play 0 05 0 1 m...

Page 425: ... assembly receives the axial force and this force acts as a resistance to rotating gears 9 Lubrication Transmission oil SAE 75W 90 Initial installation for taper roller bearing and needle roller bearing lubrication for shift rail MoS2 Grease Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm ...

Page 426: ...1 Oil filler plug 2 Air vent Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm 4WD 2WD ...

Page 427: ...3170 01 4 CIRCUIT DIAGRAM BACKUP LAMP ...

Page 428: ...ine M T 3 73 DI engine A T 3 54 Gasoline engine A T 4 27 Description Specification Axle shaft type Semi floating Axle housing type Build up Differential Type Conventional type Gear type Hypoid Gear Final gear reduction ratio DI engine M T 3 73 DI engine A T 3 31 Gasoline engine A T 4 27 Oil Capacity 1 4L Specification SAE 80W 90 or API GL 5 Oil Capacity 2 0L Specification SAE 80W 90 or API GL 5 ...

Page 429: ...4122 01 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 430: ...3260 01 1 SPECIFICATIONS ...

Page 431: ...rs without a control unit to operate AWD function It also doesn t have the TC Transfer Case shift motor and 4WD transfer switch Since it doesn t have a control unit such as TCCU Transfer Case Control Unit it delivers the driving force to the front and rear propeller shafts according to the gear ratio based on the gear combinations The distribution ratio of driving force is 40 60 front wheels rear ...

Page 432: ...3260 01 2 LOCATION Distribution of Driving Force in AWD ...

Page 433: ...3 STRUCTURE 1 Sectional View ...

Page 434: ...Front sun gear 6 Differential carrier assembly 7 Thrust washer 8 Rear sun gear 9 Snap ring 10 Cover assembly 11 Oil seal 12 Rear output shaft assembly 13 Air breather 14 Front output shaft assembly 15 Oil seal 16 Retaining ring 17 Driven sprocket 18 Chain 19 Clip 20 Bolt 21 Plug ...

Page 435: ...4 POWER FLOW Distribution of Front Output Torque Distribution of Rear Output Torque ...

Page 436: ... while cornering the tight corner braking symptom occurs in part time transfer case However for the AWD this gap of turning radius is compensated by the differential so that the tight corner braking symptom will not occur The ESP also operates the wheel slip under control in order to keep the vehicle stable under severe conditions such as icy road ...

Page 437: ...ward the moving direction with the torque ratio of 40 60 The front wheels should rotate faster than the rear wheels while cornering including wheel slip since the front wheels turning radius is larger than the rear wheels At this moment the step pinion 19T 13T should rotate faster than the pinion 13T in relation to the carrier s movement This function is similar to the regular differential functio...

Page 438: ...3240 01 1 SPECIFICATIONS ...

Page 439: ...e and rear axle the TPS signals from engine and the operating signals from ABS control unit via CAN Based on these data TOD control unit controls the electro magnetic clutch to distribute the 3 97 44 56 of driving force to front wheels and rear wheels The conventional system uses FR driving theoretically the 100 of driving force is transferred to rear wheels on normal paved road When the system de...

Page 440: ...und grab capacity against side winds and rain Distribution ratio 15 for front wheels and 85 for rear wheels 2 When turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capacity at high ...

Page 441: ... torque into front and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set Releasing the 4L Mode When selecting 4H mode 4L drive mode is released and 4H mode is resumed 4H switch Self return type 4L switch Push lock type 3 4WD Operation Overview To make the mode shift easier stop the vehicle depr...

Page 442: ...3240 01 2 POWER FLOW System Layout 4WD Switch Instrument Panel Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output ...

Page 443: ...en turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capacity at high level Distribution ratio 30 for front wheels and 70 for rear wheels When climbing or starting off on the road wi...

Page 444: ...and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set 4H switch Self return type 4L switch Push lock type 3 4WD Operation Overview To make the mode shift easier stop the vehicle depress the brake pedal select the mode switch and move the selector lever with the sequence of N P N ...

Page 445: ...4H Mode 4WD Drive High Speed Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 446: ...3240 01 4L Mode 4WD Drive Low Speed Front Axle Front Wheel Transmission Rear Axle Rear Wheel ...

Page 447: ...3 CIRCUIT DIAGRAM ...

Page 448: ...otal length 343mm Mating surface of front flange 40mm Weight 32 4 kg including oil Oil capacity 1 4L Oil type ATF DEXRON II or III Location Transfer case Major element Housing Part time TOD Bolt 11EA M8 x 1 25 Input shaft A T outer spline M T inner spline ...

Page 449: ...2 48 of reduction gear ratio when selecting 4WD LOW The silent chain in transfer case transfers the output power to front wheels The simple operation of switches on instrument panel allows to shift between 2H and 4H easily while driving for 4L stop vehicle first The warning lamp warns the driver when the system is defective Side View Rear View ...

Page 450: ...tions due to internal resistance in the drive train when the 4WD system is properly working Mode change 2 Wheel drive Shifting is possible while driving at the speed of 70 km h or less 4L 2 Wheel drive 4 Wheel drive high speed low speed For Automatic Transmission Stop the vehicle on level ground and move the switch to the desired position For Manual Transmission Stop the vehicle on level ground an...

Page 451: ...2 LAYOUT Front axle Front locking hub system IWE Front propeller shaft Part time transfer case Rear propeller shaft Rear axle ...

Page 452: ...3240 01 3 SYSTEM LAYOUT ...

Page 453: ...stem 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 Booster Operating Process Vacuum pump Vacuum generation process in front hub actuator ...

Page 454: ...oid valve Check valve This valve allows the vacuum pressure to flow through it in only one direction This prevent the vacuum from abruptly releasing due to faulty vacuum pump The vacuum pressure is released from the hub actuator At this time the front hub end gear is engaged 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be en...

Page 455: ...5 POWER FLOW TCCU Vacuum solenoid Locking hub operation Released internal vacuum Front propeller shaft Front axle Front wheel Rear propeller shaft Rear axle Rear wheel Transfer case ...

Page 456: ...ow Output shaft of transmission Rear propeller shaft Rear wheel Rear axle Rear wheel Input shaft of transfer case Output shaft of transfer case The driving force is directly engaged 1 1 to rear axle and is transferred only to the rear wheels ...

Page 457: ...2 4H Mode 4 Wheel Drive High Speed Power Flow The driving force is pass through 4WD High magnetic clutch in transfer case and is distributed on front wheels and rear wheels 50 50 ...

Page 458: ... Wheel Drive Low Speed Power Flow The gear ratio is reduced to 2 48 1 while passing through 4WD Low range and planetary gear set in transfer case and the driving force is distributed on front wheels and rear wheels 50 50 ...

Page 459: ... re measuring Front propeller shaft length outer diameter mm A T at compressed condition Rear propeller shaft length outer diameter mm 2WD A T Front axle Rear axle at compressed condition 4WD A T Front axle Rear axle at compressed condition 2 TIGHTENING TORQUE Item Tightening torque Mounting bolt on front rear axle 66 6 73 5 Nm Mounting bolt on transfer case 79 4 87 2 Nm Center bearing mounting bo...

Page 460: ...shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration Front propeller shaft Rear propeller shaft Function of propeller shaft Transmits driving torque Compensates the angle change univ...

Page 461: ...pe Stabilizer bar type Torsion bar type Rear Suspension Suspension type 5 link type multi link type Spring type Coil spring Shock absorber type Reciprocating cylindrical type gas type Stabilizer bar type Torsion bar type 2 WHEEL ALIGNMENT LH RH Camber Caster Toe in Inspect the tire inflation pressure and underbody before checking the wheel alignment Tire inflation pressure 32 psi ...

Page 462: ...sembly Axle shaft assembly Steering knuckle Lower arm assembly Shock absorber yoke assembly 1 2 3 4 5 6 7 Shock absorber to yoke bolt 122 5 142 1 Nm Upper arm knuckle side nut 137 2 156 8 Nm Lower arm knuckle side nut 137 2 156 8 Nm Yoke lower lower arm side nut 147 0 166 6 Nm 1 2 3 4 ...

Page 463: ...4411 01 A 5 Link type B Multi link type changed lower arm ball joint In lower arm design the current mass production vehicle A is different from the new model B from July 2012 ...

Page 464: ...8 78 4Nm Stabilizer bar link upper nut Tightening torque 29 4 49 0Nm Upper arm frame side bolt nut Tightening torque 107 8 127 4Nm Stabilizer bar clamp bolt Tightening torque 39 2 58 8Nm Lower arm shock absorber yoke side nut Tightening torque 147 0 166 6Nm Lower arm frame side bolt nut Tightening torque 205 8 225 4Nm ...

Page 465: ......

Page 466: ...4 SYSTEM LAYOUT AND TIGHTENING TORQUE OF REAR SUSPENSION Lower arm link Stabilizer bar link Stabilizer bar Shock absorber Coil spring seat upper side Lateral rod Axle housing Upper arm link Top View ...

Page 467: ... 0Nm Upper arm bolt nut Tightening torque 147 0 176 4Nm Lower arm bolt nut Tightening torque 147 0 176 4Nm Stabilizer bar mounting bracket Tightening torque 39 2 58 8Nm Stabilizer bar link upper Tightening torque 29 4 44 1Nm Lateral rod Tightening torque 147 0 196 0Nm Stabilizer bar link lower Tightening torque 58 8 78 4Nm ...

Page 468: ...ue Bent or broken coil spring Replace Damaged tire Replace Worn bushing Replace Vehicle pulls to one side Deformed arm assembly Replace Worn bushing Replace Bent or broken coil spring Replace Hard steering Excessive resistance of lower arm ball joint Replace Insufficient tire pressure Replace Faulty power steering Replace Unstable steering Worn or loosened lower arm bushing Retighten or replace Ve...

Page 469: ...fortable and reasonably well isolated from road noise bumps and vibrations etc These goals are generally at odds so the tuning of suspensions involves finding the right compromise It is important for the suspension to keep the road wheel in contact with the road surface as much as possible because all the forces acting on the vehicle do so through the contact patches of the tires The design of fro...

Page 470: ...dvantage of a double wishbone suspension is that it is fairly easy to work out the effect of moving each joint so the kinematics of the suspension can be tuned easily and wheel motion can be optimized It is also easy to work out the loads that different parts will be subjected to which allows more optimized lightweight parts to be designed They also provide increasing negative camber gain all the ...

Page 471: ...type suspension is the independent suspension It provides good ride comfort and drivability by reducing the coil spring weight Also it increases the space for passenger compartment by lowering the floor This type of suspension consists of multiple links such as coil spring shock absorber upper and lower arms lateral rod and stabilizer bar ...

Page 472: ...ons to obtain a specific handling characteristic Necessity for Wheel Alignment Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other The purpose of these adjustments is maximum tire life and a vehicle that tracks straight and true when driving along a straight and level road The symptoms of a vehicle that is out of al...

Page 473: ... top When viewed from the top the distance between the tire centers is smaller in the front than in the rear Side slip protection Parallel front wheels rotation straight ahead driving is ensured by toe in to prevent the wheels from tilting outwards by the camber while driving Prevention of uneven outward tire wear Prevention of toe out from wearing of steering linkage Toe in ...

Page 474: ...sorber contracts and the restoration force is applied to the steering wheel Cornering force decreases as the positive camber increases when the vehicle makes turn The hub bearing is worn unevenly if camber is excessive Zero camber When the tire center line is perpendicular to the ground level Negative camber Better traction force due to wide load area applicable for off road vehicle Better corner ...

Page 475: ...l force to go straight following control Restoring force of the wheel restored to the straight ahead direction Prevention of wheel shimmy wheels wobble left and right Caster Caster LH RH Positive caster Advantages Negative caster Advantages Disadvantages Top of the king pin is tilted forward from the vertical line of the wheel center when viewed the tires from the side Top of the king pin is tilte...

Page 476: ......

Page 477: ...ECIFICATION Service Interval Change the brake oil at every 2 years DOT It is the quality grade of brake fluid established by US Department of Transportation Rear brake Multi Link IRS Axle Type Ventilated disc Outer diameter of disc Thickness of disc 20 mm wear limit 18 4 mm Area of brake pad Pad wear indicator Mechanical type Brake booster Type Vacuum assist type Master cylinder ype Tandem type in...

Page 478: ...epair Loosened suspension mounting bolt Retighten Pulls to one side when braking Unbalanced tire pressure between left and right Adjust Poor contact of brake pad Repair Oil or grease on brake pad Replace Scratch uneven wear distortion of brake disc Replace Improperly installed brake caliper Repair Improper operation of auto adjuster Repair Crack or distortion of brake pad Replace Poor braking Oil ...

Page 479: ... Incorrectly adjusted free play of brake pedal Adjust Faulty master cylinder Replace Lack of lubrication in sliding parts Lubricate Faulty brake booster vacuum leak Repair Poor parking brake Wear hardening or poor contact of brake pad Replace Oil or water on lining Repair or replace Fixed or broken parking brake cable Replace Excessive stroke of brake lever Adjust notch Faulty auto clearance adjus...

Page 480: ... brake during downhill driving Driving with foot on brake pedal Get off the foot from pedal Foreign materials such as dirt or sand in brake system Replace caliper wheel cylinder master cylinder return spring Broken return spring in shoe assembly Replace Incorrectly adjusted parking brake cable Adjust Incorrect wheel or wheel cover generating the heat Replace ...

Page 481: ...y any problems with the brake system Symptom 2 Slip or screech after the brake pad replacement Symptom 3 Groaning sound occurs in the automatic transmission vehicle when slightly taking the foot off the brake pedal to slowly start after waiting for the signal or slightly depressing the brake pedal This usually occurs when the bed in is not made between the disc and the pad s friction material The ...

Page 482: ...rial does not get into brake line Always work with another staff 3 AIR BLEEDING Fill up the brake fluid up to MAX line on the reservoir A Fill the reservoir with brake fluid and pump the brake pedal several times Then keep it depressed B Loosen the bleed screw and collect the bleeding brake fluid from the brake line with the order in the figure C Fill the reservoir with the brake fluid as much as ...

Page 483: ...rake D Air bleed screw at front brake E Repeat the air bleeding procedures until clear brake fluid comes out of air bleed screw F Check for oil leaks from the brake lines G Air bleeding completed Air in brake fluid Deteriorated fluid ...

Page 484: ...cified value adjust the length A B C D 4 RAKE SYSTEM CHECK Maximum Stroke of Brake Pedal Specified value A 138 mm Cause Action Worn brake pad Replace Worn brake shoe Replace Improper stroke of hand brake Adjust Air in brake line Air bleeding Oil leak Repair or replace Brake booster push rod Replace or adjust Improperly adjusted stopper bolt Adjust Cause Action Brake booster push rod Replace or adj...

Page 485: ...witch assembly Loosen the lock nut on the pedal push rod Turn the pedal push rod to adjust the pedal height Tighten the lock nut Install the stop lamp switch assembly Connect the stop lamp switch connector Check if the stop lamps come on when pressing the brake pedal around 5 mm If the stop lamp dpes not come on adjust the stop lamp switch assembly again If the stop lamps come on tighten the lock ...

Page 486: ...rmal Connect the multimeter to stop lamp switch connector N C and check if the continuity exists when pushing in the plunger If the continuity doesn t exist the stop lamp switch is normal A B If the free play is below the specified value check if the clearance between the outer case of the stop lamp and the brake pedal is within the specified range If the clearance is out of the specified range th...

Page 487: ...al If any condition is not met check the valve vacuum hose and brake booster Depress the brake pedal when the engine is running If the pedal height is not changed for 30 seconds after stopping the engine the system is normal If not the system is defective C Depress the brake pedal several times with engine off If the brake goes down when starting engine with pedal depressed the system is normal If...

Page 488: ...l leaks and refill the reservoir with the specified fluid The water in the brake fluid has an adverse effect to the brake system If the fluid contains around 3 of water the boiling point of the brake fluid goes down by 25 It will cause the vapor lock frequently Water content in fluid around 3 after 18 months around 7 10 after few years The water ib fluid makes the corrosion in the brake lines defo...

Page 489: ...eplace the brake disc with new one New disc Wear limit 28 mm 25 4 mm Disc Run Out C Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when brakin Limit 0 03 mm before installation 0 07 mm when installed If a brake pad...

Page 490: ... visually check the followings Damage and tear on boot D Uneven wear and oil contamination E Damage crack and wear on cylinder body A and guide pin B F Wear rust and damage on the cylinder and piston Scratch and bending on disc plate G H ...

Page 491: ...r limit replace the brake disc with new one Limit 0 03 mm before installation 0 07 mm when installed Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when braking New pad Wear limit 10 mm 2 mm New disc Wear limit 5 l...

Page 492: ...lue with the parking brake adjusting nut Check the parking brake force after adjustment If the parking brake force is not enough check the parking brake lever and cable Replace the components if needed A B C D Specified notches 5 Never park the vehicle only with the parking brake on the stiff hill It may cause roll down of the vehicle due to release of the parking brake Place the wheel chocks unde...

Page 493: ...nical type master cylinder booster pedal and supply lines pipes and hoses This system uses the leverage effect and Pascal s principle When depressing the brake pedal the pedal pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure The hydraulic pressure generated by the master cylinder is delivered to the brake caliper through the brake pipes or hoses T...

Page 494: ...vehicle to a complete stop This is called as stopping distance What is braking distance Tire slip occurs until the vehicle stops completely when the the brake is applied This slip is what we call a braking distance What is free running distance The free running distance is the time from the driver sees the obstacles and begins to prepare for depressing the brake pedal until the moment the brake pe...

Page 495: ......

Page 496: ...Brake Master Cylinder Booster 2 SYSTEM LAYOUT Wheel Speed Sensor 4WD A Front B Rear Front Brake Caliper Assembly Front Brake Pad HECU Assembly ...

Page 497: ...4850 01 Indicator Warning Lamp A ABS indicator warning lamp B Parking brake indicator Parking Brake Lever Brake Pedal Rear Brake Caliper Assembly Rear Brake Pad Parking Brake Assembly ...

Page 498: ...Disc Brake Tie rod end connection Lower arm connection Dust shield Knuckle Brake hose Brake caliper 2 way piston Air bleeder screw Upper arm connection Wheel bolt or hub bolt Brake disc Air bleeder screw Brake pad Brake caliper ...

Page 499: ...850 01 Rear Disc Brake Dust shield One way piston Brake hose Brake caliper Air bleeder screw Brake hub Brake disc Brake caliper Brake pad Air bleeder screw Wheel bolt or hub bolt Parking brake connection ...

Page 500: ...HYDRAULIC CIRCUIT with ABS Brake booster Brake fluid reservoir and master cylinder HECU Hydraulic Electric Control Unit 1 2 3 Front disc brake and caliper Rear disc brake and caliper 3 way connector 4 5 6 ...

Page 501: ...4850 01 5 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 502: ... Operating temperature Operating frequency 1 2 500Hz Tightening torque Front 7 8 11 7 Nm Rear 7 8 11 8 Nm Description Specification Remark ABS HECU Clock frequency 28 MHz CPU MCU60 32bit Memory 128 256 kb Switch orifice Wheel speed sensor Active type Output 7 14 mA Steering wheel angle sensor None Sensor cluster None Longitudinal G sensor 4WD only integrated in ABS HECU Pressure sensor None ...

Page 503: ...tain directional stability and control of the vehicle ABS is designed to secure more safety and increase the control of steering wheel during emergency braking situation But ABS does not guarantee perfect safety beyond its physical limit ABS in this vehicle contains EBD function In normal driving conditions the brake system operates without ABS function ABS effect according to braking conditions B...

Page 504: ......

Page 505: ...ster Cylinder and Booster ABS Warning Lamp EBD warning lamp ABS warning lamp and Brake warning lamp ON together 2 COMPONENTS AND LAYOUT Front Active Wheel Speed Sensor It is installed on the front hub assembly ...

Page 506: ...4892 01 Diagnostic Connector HECU Hydraulic Electronic Control Unit Rear Active Wheel Speed Sensor It is installed on the rear axle ...

Page 507: ...the speed information from 4 wheel speed sensors when the vehicle is being driven For example when the comparison of the reference speed with front right wheel speed shows a slip the control signal is determined according to whether it s deceleration or acceleration If the control conditions are met the brake for the front right wheel will be got under control ...

Page 508: ... on for 3 seconds for self diagnosis and goes off if the system is OK initialization mode When the system is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected the warning lamp comes on ABS is not available during lamp ON In this condition Only normal brake system without ABS function is available When the com...

Page 509: ...5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Page 510: ... process cannot be described sufficiently accurately with the brake forces calculated The values calculated only apply if the wheel is not locked In the case of a locking wheel the static friction turns into lower sliding friction with the result that the stopping distance is increased This loss of friction is termed slip in specialist literature The stopping distance depends on the vehicle weight...

Page 511: ...e is shown by the curve for freshly fallen snow for this curve increases at 100 slip In a vehicle without ABS the wheel locks on braking and therefore pushes a wedge before it This wedge of loose surface or freshly fallen snow means and increased resistance and as a result the stopping distance is shorter This reduction in stopping distance is not possible with a vehicle with ABS as the wheel does...

Page 512: ...the circle the vehicle is stable to drive If a force exceeds the circle the vehicle leaves the road Brake and cornering force Brake force When depressing the brake pedal the brake force increases to the maximum then the brake force decreases until the wheel locks Cornering force The cornering force is a maximum when the wheel is turning freely with zero slip When braking the cornering force falls ...

Page 513: ...tion Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previously determined reference speed In that case the control cycle is initiated again...

Page 514: ...e speed with each wheel speed Firstly it is determined whether the vehicle is in the deceleration or acceleration state using the wheel speed change ratio Then a signal is transmitted to the valve Finally the brake pressure is adjusted via the signal Vref Reference speed Vw Wheel speed ...

Page 515: ...f 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 6 HYDRAULIC CIRCUIT DIAGRAM ...

Page 516: ...is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This procedure hel...

Page 517: ... 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 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 circulates to the wheel by the pump and the wheel speed decreases as the...

Page 518: ...4892 01 8 ELECRTRIC CIRCUIT DIAGRAM ...

Page 519: ...m Unit Description Specification ABS ESP HECU Clock frequency 28MHz Clock frequency 33MHz CPU MCU60 32bit CPU MCU6 32bit Memory 128 256KB Memory 256 512KB Switched Orifice Switched Orifice Wheel speed sensor Active type Active type Output 7 14mA Steering wheel angle sensor None Max detection angle Operating voltage 9 12V Sensor cluster None Yaw rate sensor lateral G sensor longitudinal G sensor 4W...

Page 520: ...ing temperature Supplying voltage 9 to 16 V battery voltage Output voltage HI approx 3 50 V 3 0 to 4 1 V Output voltage LO approx 1 50 V 1 3 to 2 0 V Pulses rev 45 pulses rev 3 Specification of Sensor Cluster Description Specification Remark Supplying voltage approx 5V 4 75 5 25V Output voltage at standstill approx 2 5V IGN ON Operating range 0 2 4 8V Initial velocity 4 s ...

Page 521: ...on ESP Electronic Stability Program ABD Automatic Braking Differential ASR Acceleration Slip Regulation AYC Active Yaw Control HBA Hydraulic Brake Assistant ARP Active Rollover Protection HDC Hill Descent Control 2 Functions Function ABS EBD ESP ABS Available Available EBD Available ABD Not available ASR AYC HBA ARP HDC ...

Page 522: ...or ESP warning lamp indicator ESP OFF switch and indicator Steering wheel angle sensor 4 Operation of Components ABS ESP ARP 2WD 4WD 2WD 4WD Wheel speed sensor 4 sensors 4 sensors 4 sensors 4 sensors Sensor cluster Not applied Not applied Applied Applied G sensor Not applied Applied Not applied Not applied 2H G sensor Operable 4H G sensor Operable 4L G sensor Operable 2H sensor cluster Operable Op...

Page 523: ... operating ESP warning lamp ESP malfunctioning ABS warning lamp Amber ABS malfunctioning EBD warning lamp Amber Red EBD malfunctioning HDC indicator Red Green Red HDC operating Green HDC switched ON 3 WARNING LAMPS 1 ABS warning lamp 2 Brake warning lamp 3 ESP OFF indicator 4 ESP warning lamp indicator 5 EBD warning lamp ...

Page 524: ...e self diagnosis and when it detects the malfunction of EBD system However the brake warning lamp comes on regardless of EBD when the parking brake is applied EBD warning lamp ON When turning the ignition switch to ON position ABS warning lamp and the brake warning lamp comes on for 4 seconds for self diagnosis and goes off if the system is OK initialization mode When applying the parking brake th...

Page 525: ... meter cluster the warning lamp comes on A B C D 4 ESP OFF Switch If ESP OFF switch is pressed ESP function is deactivated and the ESP OFF indicator in the instrument cluster comes on To resume the ESP function press the switch again At this time ESP OFF indicator goes out ESP warning lamp ON 3 ESP OFF Indicator When turning the ignition switch to ON position ESP warning lamp comes on for 4 second...

Page 526: ...e ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the motor and valve operations in a very short period of time And keep in mind that the output and vehicle speed could be decreased without rpm increase due to the ASR function that controls the engine power ARP Operation During the ARP operation vehicle safety rollover prevention takes the first prio...

Page 527: ...System Controls the engine output and braking force HDC Hill DescentControl System Allows the vehicle to go down the steep hill slowly For example when the brakes are applied during cornering at the speed of 100 km h the ABS will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 degree seconds t...

Page 528: ...on of Components and Layout Brake Oil Pressure Sensor ESP only Brake Master Cylinder ESP only ABS ESP HECU ESP ABS ESP OFF indicator ESP warning lamp indicator ABS warning lamp Parking brake warning lamp HDC indicator EBD warning lamp 3 4 1 2 3 4 5 ...

Page 529: ...4892 01 ESP OFF HDC Switch ESP only ESP OFF Switch HDC Switch Rear Wheel Speed Sensor 4WD Brake Booster Assembly Front Wheel Speed Sensor 4WD Steering Wheel Angle Sensor ESP only ...

Page 530: ...centrifugal force increases the tires can easily lose the traction and the vehicle tends to slip outward when the curve angle gets bigger and the speed increases What is understeering ESP controls during understeer 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 u...

Page 531: ...aking force to the front outer wheel to compensate the yaw moment value In this way the vehicle does not lose its driving direction and the driver can steer the vehicle as intended Oversteer is a term of a condition in which the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction Compared to understeering vehicles it is hard to control the ve...

Page 532: ...ering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer understeer or cornering The ESP ECU controls against oversteer or understeer during cornering by controlling the vehicle stability using input values from these sensors and applying the braking force to the corresponding wheels independently The system also controls the engine power right before...

Page 533: ...irectional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeer with the yaw rate sensor and lateral sensor Then the ESP system applies the braking force to the rear inner wheel to compensate the yaw moment value In this way the vehicle does not lose its driving direction and the driver can steer th...

Page 534: ...4 Input and Output Diagram of ESP unit ...

Page 535: ...ary circuit and in secondary circuit When the vehicle brakes are not applied during engine running or when applying the non ABS operating brakes the normally open separation valve and the inlet valve are open whereas the normally closed shuttle valve and the outlet valve are closed When the ESP system is operating the normally open separation valve will be closed by the solenoid valve operation an...

Page 536: ...ition the separation valve and the inlet valve are open normal open the electrically operated shuttle valve and the outlet valve are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve ...

Page 537: ...ases just before the wheel speed drops and the wheels The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump operates to allow fast oil drainage ...

Page 538: ...ill be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens ...

Page 539: ...valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Page 540: ...rs under the master cylinder When the ESP ECU system determines 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 depress the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated ...

Page 541: ...ency 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 brake pressure sensor and...

Page 542: ...e value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the wheel starts to lock the HBA ...

Page 543: ...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 braking power to overcome the physical tendency of the vehicle rollover during sharp turns The...

Page 544: ...n effect Consequently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is still available even when turning off the ESP system by ESP OFF switch However if the ESP system is shut off due to a system failure the ARP system is also not available ...

Page 545: ...icator goes off When the HDC is operating on a steep downhill When the HDC is operating on a steep downhill the HDC indicator in meter cluster blinks with heavy operating sound Sensor Cluster The G sensor in sensor cluster detects the gradient of the roads When the HDC is ready by HDC switch G sensor sends the HDC request signal to ESP HECU if the vehicle is driving on a downhill with over 10 grad...

Page 546: ...ing 7 km h Reverse driving 7 km h automatic transmission 8 5 km h manual transmission A B Vehicle position control function in ESP and HBA function are not in operation The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden e The gradient of downhill should be over 10 When the gradient of down...

Page 547: ...s passed neutral N position Vehicle with automatic transmission Sensing at the selector lever unit When the vehicle speed is out of the specified values Below 7 km h When the ESP related functions e g vehicle position control HBA ARP is activated during HDC operation a steep hill with HDC operated There is no specific temperature sensor in the system but a programmed logic inside the HECU predicts...

Page 548: ...uring HDC operation If the slope level is between 10 and 20 HDC is deactivated If the slope level exceeds 20 HDC function is still activated and the brake pressure is added Longitudinal acceleration sensor When the HDC operates HECU turns on the stop lamp by supplying 12V power separate relay HECU sends the signals regarding HDC Ready Operating and other warning conditions to the meter cluster via...

Page 549: ...s 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 Initial ignition ON HDC system error occurs Brake system overheat Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning ...

Page 550: ...fore avoid using the HDC system on level roads If the HDC system is used frequently the internal components of ESP HECU and related parts could be damaged Place the HDC switch at OFF position while the vehicle is driving on level roads As mentioned earlier the HDC system is operable even when the vehicle is driving on level roads This could cause the driver to lose control of the vehicle resulting...

Page 551: ...4892 01 5 CIRCUIT DIAGRAM ABS ESP ...

Page 552: ...ESP OFF switch ...

Page 553: ...ering oil Type PSF 3 Capacity L 1 1 Service interval Daily check and add if necessary Type Double cardan CV joint type Components CV joint upper Hook joint lower Elastic sleeve 1 SPECIFICATIONS Lower shaft Description Specification Steering wheel Type 4 spoke type Outer diameter mm 390 Steering gear box Type Rack and pinion type Steering angle Inner Outer ...

Page 554: ...box and gear box cross member mounting bolt 98 0 127 4 Steering gear box and lower shaft connection bolt 24 5 29 4 Steering gear box and lower shaft connection nut 34 3 44 1 Tie rod end lock nut 63 7 78 4 Steering gear box and pressure hose connection nut 11 8 17 6 Steering gear box and return line connection nut 11 8 17 6 Power steering pump Eye bolt for oil supply pipe to power steering pump 19 ...

Page 555: ...CE TOOLS Part Number Name Description 661 589 00 33 00 L 99 46 001 0A Steering wheel puller Removing the steering wheel 661 589 13 33 00 W 99 44 002 0A Ball joint puller Removing the upper and lower end from front suspension ...

Page 556: ...belt Adjust or replace Clogging of fluid line Repair or replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace Steering wheel pulls to one side Damaged steering linkage Replace Damaged wheel or tire Repair or replace Defective brake system Repair or replace Defective suspension Repair or replace Excessive free play of steering wheel Worn steering gear Replace the st...

Page 557: ...umn and parts Repair Looseness of steering linkage Retighten Loosened or damaged oil pump drive belt Repair or replace Looseness of oil pump bracket Retighten Looseness of oil pump Retighten Air insertion into system Bleed air Defective oil pump Replace Abnormal noise when turning steering wheel Looseness of steering column Retighten Worn or damaged steering shaft bearing Replace the steering colu...

Page 558: ... vehicle with a lift Unscrew the adjusting plug lock nut Measure the torque of the adjusting plug A B C D If the torque is excessive or too low adjust to the specified torque E Place the rack gear to the center position Tighten the adjusting plug to 10 2 Nm Turn the pinion gear so that the rack gear is turned to lock to lock 5 times Unscrew the adjusting plug Tighten the adjusting plug to 4 6 to 5...

Page 559: ...n a paved and flat ground and place the front wheels at straight ahead direction Start the engine and let it run around 1 000 rpm Install the spring scale on the circumference of the steering wheel and measure the steering effort in both directions A B C Steering effort in standstill below 3 0 kg The difference between both sides should be within 0 6 kg Steering Angle Check Place the front wheel o...

Page 560: ...d direction Check the oil level in the power steering oil reservoir Adjust the oil level between MAX and MIN A B C D Oil Change If the difference between two measurements is below 5 mm and the level is between MAX and MIN level it s normal If it is over 5 mm bleed air from the system Open the power fluid reservoir cap and drain the fluid completely with oil suction device To make it easy turn the ...

Page 561: ...eriodically crank the starting motor and turn the steering wheel to its both ends without any interruption Check the oil level again If the oil level is fluctuated repeat the procedures from step 3 to step 5 Start the engine Turn the steering wheel to its both ends until any bubble can be found in the steering oil reservoir Perform the test drive and check the steering wheel for normal operation a...

Page 562: ... gauge between the power steering pump and the power steering oil pressure line Place the shift lever to neutral position Apply the parking brake Open the valve in pressure gauge Start the engine and let it run at idle speed Turn the steering wheel several times so that the oil temperature reaches to normal operating level A B C D E Fully close the valve in pressure gauge and measure the oil press...

Page 563: ...ly open G Pressure at no load 3 5bar If the pump pressure is in specified range the pump is normal If not replace the power steering pump H Turn the steering wheel righ or left until it stops with the engine idling ans valve fully open I Oil pressure 78 83Bar ...

Page 564: ...relief 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 pr...

Page 565: ...oil from the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Linkage gear box Power steering pump tank Return hose tube High pressure hose Column shaft Steering wheel Lower shaft Return line High pressure line Steering pump Steering return pipe Steering cylinder ...

Page 566: ...Oil Flows during Right Turn Steering pump Oil reservoir in To piston pipe From piston pipe Piston Piston pipe ...

Page 567: ...4620 01 1 SPECIFICATIONS 1 Specifications Description Specification Voltage Rating DC 12V Current Rating 1 0A Resistance ...

Page 568: ...driving pressure of drivers No matter for steering parking or reversing it becomes much easier The adjustable safety steering column attached possesses the functions of electrically adjusting height and transverse position has brought much more abundant and comfortable spaces for legs and has provided the great convenience to get in or out the car The Speed Sensitive Power Steering SSPS unit contr...

Page 569: ...4620 01 SSPS Warning Lamp SSPS Control Unit Location of Power Steering Pump Location of SSPS Solenoid Valve Location of SSPS Control Uni SSPS Solenoid Valve 2 COMPONENTS Power Steering Pump ...

Page 570: ...Steering Gear Box SSPS Solenoid Valve Tie rod end Tie rod Bellows SSPS solenoid valve Valve assembly Feed tube Mounting bracket Cylinder tube Rack housing Adjusting plug 1 2 3 4 5 6 7 8 9 10 ...

Page 571: ...01 3 OPERATING PROCESS 1 Input Output of ECPS Control Unit Meter Cluster Vehicle Speed SSPS Control Unit Solenoid Valve Meter cluster SSPS warning lamp Trouble Diagnosis 2 ECPS Configuration Ground IG Power ...

Page 572: ...Solenoid Valve SSPS control unit controls the current to solenoid valve according to the vehicle speed Based on this current the solenoid valve changes the position of valve spool to control the hydraulic pressure to the reaction plunger Accordingly the SSPS system can get the desired steering force according to the vehicle speed SSPS control unit outputs nearly maximum electrical current The sole...

Page 573: ... 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 reaction plunger At this time the reaction plunger transmits the reaction force to V groove in input shaft to provide heavy steerability 1 2 3 4 ...

Page 574: ... heavy steerability with low current as the vehicle speed increases And it provides light steerability with high current as the vehicle speed decreases During parking and driving in low speed the control unit supplies approx 1 A of electric current to solenoid valve Then the spool located in PCV compresses the upper spring and elevates upward and the working pressure from oil pump A port is not ab...

Page 575: ...olenoid 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 576: ...4 CIRCUIT DIAGRAM ...

Page 577: ... bar approx 14 5 psi Pressure measuring tolerance Temperature measuring range Temperature measuring tolerance Transmit frequency 433 92 MHz Battery life Lithium battery approx 3 0 3 2V 160 000 km or 10 years Subject to operating conditions Tire pressure 32psi 1 SPECIFICATIONS 1 Wheel Module ...

Page 578: ...Installing Valve Body 2 SPECIAL SERVICE TOOLS The tightening torque for wheel module is 1 4 Nm To tighten the bolts for wheel module without any damage you must use the special service tool as below Torque wrench 0 1 5 0 Nm Torx socket T 10 Tire valve remover installer ...

Page 579: ...r Tire Pressures Front Tire Pressures Rear Tire Pressures If the vehicle is moving around electric power supply cable or radio transmitter which can interferewith normal operation of TPMS the TPMS may not work properly After replacing the low pressure tirewith the spare tire without TPMS the TPMSmalfunction indicator will illuminate afterrestarting and about 20 minutes ofcontinuous driving because...

Page 580: ...t wheel has same size with factory installed wheel TPMA may not be usable due to interference on rim External View for Wheel Module Internal View for Wheel Module Do not use any tire sealant if the vehicle is equipped with a TPMS The liquid sealant can damagethe tire pressure sensors ...

Page 581: ......

Page 582: ...nificantly under inflatedtire causes the tire to overheat and canlead to tire failure Under inflation alsoreduces fuel efficiency and tire The wheel module is located under valve body in each tire and periodically sends the data to TPMS ECU with radio frequency TPMS ECU converts the signals and sends them to the meter cluster through CAN line so that the driver can recognize the tire conditions TP...

Page 583: ...4190 00 Location of TPMS ECU Location of Wheel Module Wheel Module Sensor Wheel Module Assembly TPMS ECU ...

Page 584: ...3 BLOCK DIAGRAM ...

Page 585: ...he ignition switch is turned This warning lamp comes on and stays on when there is a problem with the TPMS This warning lamp comes on when the ignition switch is turned This warning lamp blinks 0 4s ON OFF for 70 seconds and then stays on when one or more tires is significantly under inflated or flat tire This warning lamp comes on when the ignition switch is turned This indicator illuminates in g...

Page 586: ...l Warning Failure Warning ON Conditions Warning Lamp Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Error in TPMS system Defective wheel module Error in TPMS system Low tire pressure Flat Tire Yellow Comes on immediately Yellow Affected tire symbol Yellow Comes on immediately Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Yellow Affected tire symbol ...

Page 587: ... abnormal tire comes on in yellow In tire pressure display mode the symbol for abnormal tire comes on in yellow and the other symbols come on in green Tire Pressure Indicator Yellow Blinks 0 4 s ON OFF for 70 seconds and then stays on Specified tire pressure 32 psi 10 minutes of continuous driving over 20 km h The tire pressure should be measured Comes on in green 10 15 s and then goes off The tir...

Page 588: ...sure Meets the warning lamp ON condition 1 P3 Warning lamp ON P4 Warning lamp OFF Hysteresis range Condition 1 continuous driving for 10 minutes tire pressure 24 26 psi low vehicle speed 20 km h or higher A C B B Blinks 0 4 s ON OFF for 70 seconds and then stays on ...

Page 589: ...4190 00 6 TIRE PRESSURE DISPLAY LCD display Trip switch A B ...

Page 590: ... own ID Identification to TPMS ECU at every 30 seconds However in emergency situation e g pressure drop of 1 psi a second it sends the data to TPMS ECU at every one second In this case the batter current consumption increases dramatically Have the system check immediately Tire Pressure Indication Procedure Simultaneously processed Wheel module check Auto Learning TPMS ECU identifies ID for each wh...

Page 591: ...he vehicle A Carefully explain the TPMS system and its usage to customers The tire pressure can be changed frequently due to driving conditions passengers internal temperature changes and loads If there is another vehicle equipped with the TPMS keep the distance from this vehicle at least 5 m to prevent interference of wheel module transmitting Unload the cargo if not necessary Even though you adj...

Page 592: ...essure B Inflate the air into the tire according to the specified procedure Inflate the air into tire 32 psi Drive the vehicle for more than 10 minutes over 20 km h Normal Abnormal Check if TPMS warning lamp or Global warning lamp comes on If there is no indication and adjust the tire pressure to the specified value Normal tire pressure Completed ...

Page 593: ...00 Caution When Inflating If the tire pressure is 10 psi lower than the specified value remove the valve insert from the wheel module valve body and replace it with new one Then inflate the air into the tire ...

Page 594: ...type Tightening torque of wheel bolt 127 4 156 8 Nm Description Specification Tire EU GEN 16inch 18inch EU GEN 235 75R 16 255 70R 16 255 60R18 255 60R18 BR Tire inflation pressure 32psi Wheel EU GEN 16inch 18inch EU GEN 7 0J 16 7 5J 18 TYPE A 7 5J 18 DIAMOND CUT 1 SPECIFICATIONS 2 WHHEL DESIGNS 18 inch 255 60R 18 18 inch 255 60R 18 18 inch 255 60R 18 Type A Sputtering Diamond cut ...

Page 595: ...interval Incorrect toe adjustmen Adjust Incorrect wheel bearing preload adjustment Adjust Malfunction of brake syste Replace Tire squeal vibration Too low tire pressure Adjust Unbalanced wheel or tire Adjust Heavy vibration of wheel or tire Replace Uneven tire wear Check and adjust Premature tire wear Too high tire pressure Adjust Fast driving with low pressure tire Adjust Overload Adjust ...

Page 596: ... tread center Excessive tire inflation pressure Excessive wear in the outer side of the tread than in the inner side Excessive camber or deflection of knuckle arm Excessive wear in the inner side of the tread than in the outer side Insufficient camber or deflection of knuckle arm Inside Outside Inside Inside Inside Outside Outside Outside ...

Page 597: ...in tie rod length between left and right sides Blade type wear from inner side toward outer side of the tread Excessive toe in Deflection of knuckle arm Difference in tie rod length between left and right sides Corrugation wear of tread Poor wheel balance Loose wheel bearing poor wheel alignment Inside Outside Inside Outside Inside Outside ...

Page 598: ...e the protruded part in the is the indicator of the tread wear limit The limit of the tread wear for all season tires are 1 6 mm which is the same as the general tires but the wear limit mark Higher than recommended pressure can cause hard ride tire bruising or damage and rapid tread wear at the center of the tire Excessive tire wear over the limit of the tread wear 1 6 mm can cause lower sliding ...

Page 599: ...t on the tire tread Specified value 2 03mm If any measurement exceeds the above specifications replace the applicable tires or wheels Tire inflation pressure 3 Specified value 32psi Maintaining the specified tire ressure is essential for comfortable riding driving safety and long tire life Incorrect inflation pressures will increase tire wear and will impair safety vehicle handling comfortable dri...

Page 600: ...5 g There are two types of weight balance tape type and adhesion type Make sure to read the manual of the manufacturer thoroughly before using wheel balance tester Change tire location To avoid uneven wear of tires and to prolong tire life inspect and rotate your tires every 5 000 km 6 Mixing tires could cause the driver to lose control while driving Be sure to use the same size and type tires of ...

Page 601: ...e weight of the vehicle reduces the impact from the road and at the same time transmits the power to propel brake and steer on the road It also functions to maintain a vessel of air There is wear limit mark on the tire which protrudes as a strip shape located approximately 1 6 mm from the groove bottom This wear limit mark is not seen from the outside so there is groove depth measure at any point ...

Page 602: ...4170 34 Tools Location of Components Spare Tire Jack Jack connection Wheel wrench Warning Triangle ...

Page 603: ...he flexible sidewall protects the carcass and enhances characters are indicated here Bead The bead attaches the tire to the rim and wraps the end of the cord fabric Comprised of the bead wire core flipper and other parts the bead is generally designed to be slightly tight around the rim so that in the case of a sudden drop in inflation pressure the tire will not fall off the rim Carcass As the mos...

Page 604: ...ssive so a lot of heat is generated and the tire is worn out unevenly and abnormally The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire faces the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly res...

Page 605: ... a short period of time If the standing wave symptom occurs on the tire rubber on the tread comes off and eventually the tire can be blown out which is very dangerous When driving at high speed the inflation pressure should be increased to decrease heat generation due to extension and contraction motion to decrease hydroplaning and to prevent standing wave To prevent this symptom it is recommended...

Page 606: ... on a thin film of water It causes brake failure lower traction force and losing the steering performance To prevent this increase the tire inflation pressure use tires with leaf shape tread which is not worn However it is a best measure to drive slowly Hydro Planing No Hydro planning Vehicle speed 80 km h Partial Hydro planning Full Hydro planing ...

Page 607: ...dd the balance weight of a weight corresponding to unbalanced weight from B to A to maintain the static balance If the static balance is not maintained tramping up and down vibration of the wheels occurs Dynamic Balance The static unbalance of the wheel creates the vibration in the vertical direction but the dynamic unbalance creates the vibration in the lateral direction As shown in the figure 2 ...

Page 608: ...ther out than the top it is called negative camber Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground thus maximizing tire life and ensures straight and true tracking along a straight and level road Camber angle alters the handling qualities of a particular suspension design in particular negative camber improves g...

Page 609: ...raight line stability The mechanism that causes this tendency is clearly illustrated by the castering front wheels of a vehicle The steering axis of a vehicle wheel is set forward of where the wheel contacts the ground As the vehicle is driving forward the steering axis pulls the wheel along and since the wheel drags along the ground it falls directly in line behind the steering axis The force tha...

Page 610: ...ONS OF TIRE Supporting the Vehicle Weight Even friction coefficient road Uneven friction coefficient road Driving Force Braking Force Transferring the Driving Force Braking Force to Road Absorbing the Impact from Road ...

Page 611: ...ntrol panel Rated voltage DC 12V Operating voltage DC 9 16V Current consumption 2A Operating temperature Output current from air mix door motor 0 4A Output current from high relay 0 5 Base current for power transistor 1A Output current from air source motor 0 55A Output current from mode motor 0 55A Dark current Below 2 mA Below 1 1 mA Compressor Pulley diameter 120mm Maximum speed 8000RPM Rated v...

Page 612: ...Description FATC PTC Heating type Air heating type Material BaTiO3 Weight 500g ...

Page 613: ......

Page 614: ...alve Controls the refrigerant volume and sends it to evaporator Condenser Installed on the front of vehicle and converts the gaseous refrigerant to liquid refrigerant by condensing it PWM Electric Fan Cools the radiator and condenser down ...

Page 615: ...or Absorbs the moisture from the refrigerant and accumulates it for supplying AQS Sensor Ambient Temperature Sensor Measures the air contamination value and ambient temperature and sends the data to FATC controller A C Compressor A C Hose Pipe Lines ...

Page 616: ...Mode Door Actuator Air Mix Actuator Heater A C Module Sun Sensor A C Control Automatic Control 2 SYSTEM LAYOUT INTERNAL ...

Page 617: ...6822 11 Duct Temperature Sensor Thermo Amplifier A C Filter Blower Motor Power Transistor Air Source Actuator PTC ECU ...

Page 618: ...3 VENTILATION SYSTEM 1 Location 2 Duct Layout ...

Page 619: ...ram shows the input output mapping between the components of FATC A C and A C controller briefly A C Compressor OFF Conditions For approx 4 seconds after starting the engine Engine speed 650 rpm or lower Engine speed 4 500 rpm or higher ...

Page 620: ...essure and temperature for easier evaporation Condition Gas Liquid Function Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure Condition Gas Liquid Function Keeps the refrigerant free from moisture by separating collecting the moisture from it Condition Liquid Liquefied gas Function Performs adiabatic expansion and flow control for easier evaporation ...

Page 621: ...aporation easily takes place before the liquid refrigerant is sent to the evaporator is called Adiabatic Expansion During adiabatic expansion the expansion valve lowers the pressure of the refrigerant and determines the correct amount of refrigerant going into the air conditioning evaporator That is the amount of heat which is needed to stop the evaporation is determined according to the cooling l...

Page 622: ...Air Conditioner Compressor PWM Electric Fan Air Mix Motor Sun Sensor Coolant Temperature Sensor AQS Sensor Thermo Amplifier ...

Page 623: ...6810 18 2 2 Motor Mode Fresh Recirculation ...

Page 624: ......

Page 625: ...air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation The seat belt and air the bags are the most effective when you are sitting well back and upright in the seat A child restraint system must not be placed on the front seat The infant or child can be severely injured by an air bag inflation in case of an accident Do not carry your child on your lap while...

Page 626: ...o not place your face or chest near the steering wheel and dashboard Also do not allow anyone to place their hands leg or face on the dashboard The air bag cannot work properly Do not hold and operate the steering wheel by crossing your arms You could get seriously injured when the air bag deploys When the air bag inflates it makes a loud noise and smoke However the smoke is a non toxic nitrogen g...

Page 627: ......

Page 628: ...The front air bag module side air bag module and seat belt pretensioner are installed for each seat The pretensioner operates with the front seat The side air bag operates according to the signal from the lateral G sensor longitudinal G sensor and side air bag sensor The front air bags operate independently 2 COMPONENTS STICS Air Bag Unit SDM ...

Page 629: ...8810 00 Air Bag Warning Lamp Meter Cluster Seat Belt Pretensioner Side Air Bag Sensor Assembly Side Air Bag Module ...

Page 630: ...e occurs The vehicle falls into a drainage or a puddle The front of the vehicle crashes into high impact point vehicle such as a truck The hood is hit by falling stones The air bag warning lamp is on The vehicle rolls over or tips over sideward or a side rear collision occurs the impact of the collision is low enough for the seat belt to protect the occupant properly Underbody impact from the road...

Page 631: ...n occurs with low speed A rear collision occurs The impact of the collision is low enough for the seat belt to protect the occupant properly the vehicle rolls over or tips over sideward with a severe impact The vehicle is stationary or a front collision occurs with low speed A rear collision occurs The impact of the collision is low enough for the seat belt to protect the occupant properly a sever...

Page 632: ...1 Air Bag System Block Diagram 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 ...

Page 633: ...8810 00 ...

Page 634: ...river side Ignite Air bag module Passenger side Ignite Seat belt pretensioner Driver side Ignite Seat belt pretensioner Passenger side Ignite Side air bag module Driver side Ignite Side air bag module Passenger side Ignite Impact to Left direction Right direction Side air bag module Driver side Ignite Not ignite Side air bag module Passenger side Not ignite Ignite Seat belt pretensioner Driver sid...

Page 635: ...nt signal to STICS to unlock the doors automatically Automatic Door Unlock Crash unlock unlock when colliding The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to ON position After this period the door lock system outputs UNLOCK for all doors for 5 seconds from 40 ms after receiving the air bag collision signal Even though the key is turned to OF...

Page 636: ... Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF ...

Page 637: ...ve been detected When the Air Bag Unit Detects Any Malfunctions in Unit When the Air Bag Unit Detects Any Intermittent Failure When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second Then the waning lamp stays on When due to an error from outside the system the intermittent failure signal is...

Page 638: ...8 CIRCUIT DIAGRAM 8810 01 Air Bag including Side Air Bag ...

Page 639: ...tes against the heat such as a blanket or cushion Make sure that the head restraints are in place and secured properly Never drive the vehicle with the head restraint removed To minimize the injuries in a collision or an abrupt stop make sure the seatback is in the upright position before driving If the seatback is reclined too much the occupant could slide under the seat belt in a collision or an...

Page 640: ...drest 2 Front Seat Assembly Front Seat Assembly Old New Changed the design of seatback and seat cushion Changed the design of headrest Front Headrest Old New Swing type tilting Sliding type tilting Changed the design of headrest ...

Page 641: ...ack Board 4 Front Seat Cover Shield Front Seat Cover Shield Old New Integrated type Split type Changed the design of seat cover shield Front Seat Back Board Old New Changed the design of seat back board and seat back pocket ...

Page 642: ...Seat Frame Cover Front Seat Frame Cover Old New Changed the design of seat frame covers front rear 6 Rear Center Armrest Assembly Rear Center Armrest Old New Changed the location and appearance of armrest band ...

Page 643: ...headrest down The headrest can be adjusted forward to three different positions by pulling the headrest forward To adjust the headrest backward pull it fully forward to the farthest position and release it Adjust the headrest so that it properly supports the head and neck How to operate How to operate Height Adjustment of Headrest Forward and Backward Adjustment of Headrest ...

Page 644: ... move the seat as desired Then release the lever To change the seatback angle lean forward slightly and push the seatback reclining switch to desired direction To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever After adjusting make sure the lever is returned to its original position and the seatback is locked How to oper...

Page 645: ...terclockwise To adjust the seat cushion angle raise or lower the seat cushion angle adjusting switch to desired direction Turn the lever forward to increase the amount of lumbar support To decrease it turn the lever backward How to operate How to operate How to operate How to operate Seat Cushion Angle Adjustment Power Seat Seat Height Cushion Angle Adjustment Manual Seat Lumbar Support Adjustment...

Page 646: ... heater stops the operation for cranking period How to operate The seat heater has 5 heating levels Turning clockwise Higher heating level Turning counterclockwise Lower heating level Operating process the signals from the seat heater switch The unit turns ON and OFF the seat heating element to keep the set heating level ...

Page 647: ...n the memory setting is completed a buzzer sounds twice Operating process rearview mirror position sensor to recall the set position appointed to respective button To recall the memory settings Press and hold one of the position buttons you want until the buzzer sounds drive off during this recalling process this automatic memory setting stops operating Wait until they stop moving When the process...

Page 648: ...ON and OFF with the Easy Access switch pressed in The SPWM The moving distance of the seat is based on when the seat is located at its front end It varies according to the initial position There could be some differences when the seat moves back to its original position The difference of the passenger weights and electrical loads can cause the differences in its distance and this is normal not def...

Page 649: ... of the seatback and push the headrest down The headrest can be adjusted forward to three different positions by pulling the headrest forward To adjust the headrest backward pull it fully forward to the farthest position and release it Adjust the headrest so that it properly supports the head and neck How to operate How to operate Forward and Backward Adjustment of Headrest ...

Page 650: ...forward slightly and push the seatback reclining switch to desired direction To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever After adjusting make sure the lever is returned to its original position and the seatback is locked How to operate How to operate How to operate How to operate Seat Slide Adjustment Power Seat S...

Page 651: ...seat heater stops the operation for cranking period How to operate The seat heater has 5 heating levels Turning clockwise Higher heating level Turning counterclockwise Lower heating level Operating process the signals from the seat heater switch The unit turns ON and OFF the seat heating element to keep the set heating level ...

Page 652: ...rned to its original position and the setback is securely locked Second Row Seat Heating switch The heating switches for the rear seats are located on the rear door trims During heating the seats the seat heater indicator comes on Headrest Adjustment To raise the headrest pull it up without pressing the release button To lower the headrest press the release button A on top of seatback and push the...

Page 653: ...est Adjustment To raise the headrest pull it up without pressing the release button To lower the headrest press the release button A on top of seatback and push the headrest down Seatback Folding Pull up the folding lever to fold down the third row seat ...

Page 654: ...5 CIRCUIT DIAGRAM Power Seat Seat Position Memory ...

Page 655: ...4170 00 Outside Rearview Mirror Folding ...

Page 656: ......

Page 657: ...4170 00 ...

Page 658: ......

Page 659: ...4170 00 ...

Page 660: ......

Page 661: ...leted release the switch Keeping pressing the switch can result in malfunction Especially in winter never operate the sunroof if operation areas are iced Wait until melted To prevent a theft make sure that the sunroof is completely closed when leaving the vehicle In addition rain or snow can get into the vehicle through the open sunroof When the sunroof is fully open wind buffeting symptom can be ...

Page 662: ...3 MAJOR CHANGES 1 Sunroof Switch Sunroof Switch Old New Changed the appearance of sunroof switch ...

Page 663: ...7340 01 Sunroof Assembly 1 COMPONENTS AND LAYOUT OPEN TILT Overhead Console Assembly Sunroof Switch Sunroof Motor Assembly Sunroof Control Unit ...

Page 664: ...ded in the overhead console assembly CLOSE Closes the sunroof OPEN Opens the sunroof Sunroof glass The sunroof glass can be opened automatically and can be tilted by the switch operation Sun shade blind The sun shade blind can be closed or opened manually to block sunlight when the sunroof function is not in use ...

Page 665: ...mpletely When the switch is operated while the sunroof is moving the sunroof stops sliding open Push up and hold the switch manual sliding open The sunroof is opened only as long as pushing up the switch Pull down the switch briefly auto sliding close When pulling down the switch briefly the sunroof is automatically closed To stop the closing sunroof operate the switch to either direction Pull dow...

Page 666: ...l down the switch The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof closed Push up the switch The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted up ...

Page 667: ...peration mode and then resume its function 5 Emergency Operation If the sunroof becomes out of order while it is open or tilted the sunroof can be operated through the motor operating hole of the sunroof motor When you drive this vehicle with the window or sunroof open at a certain position you may feel some pressure upon your ears or hear some noises similar to those from a helicopter This happen...

Page 668: ...3 CIRCUIT DIAGRAM 7304 03 Sunroof ...

Page 669: ...7610 00 1 MAJOR CHANGES 1 Center Fascia Panel 2 Sun Visor Retainer Sun Visor Retainer Old model New model Changed design Center fascia panel Old model New model Changed design ...

Page 670: ...gate Type Gas lifter type Thickness of glass Windshield 5mm Front door glass 4mm Tailgate glass 4mm Tailgate Fixed glass 4mm Flip up glass 5mm Requirements for leak test stand Nozzle type Nozzle height 1 600 mm from ground Displacement 14 liters per minute Nozzle injection pressure 155 kPa 22 5 PSI Location of windshield A pillar test stand windshield corner Location of B pillar test stand door Lo...

Page 671: ...2 MAJOR CHANGES Hood Insulator Changed the design to eliminate the interference Hood Panel Changed the design 1 Hood Panel Old New Old New ...

Page 672: ...5110 00 Front Bumper Old New Changed the design Radiator Grille Changed the design and location 2 Radiator Grille 3 Front Bumper Old New ...

Page 673: ...Door Garnish Deleted the front and rear garnish 4 Outside Rearview Mirror Outside Rearview Mirror Introduced the LED side repeater and changed the design Old New 5 Door Garnish Old New ...

Page 674: ...5110 00 Wheel Arch Garnish Changed the design 6 Wheel Arch Garnish Old Rear New Rear Old Front New Front Center Lower Step Changed the design 7 Center Lower Step Old New ...

Page 675: ...Side Sill Garnish Old Split type New Integrated type 8 Side Sill Garnish 9 Side Outer Rear Panel Side Outer Rear Panel Changed the design of rear combination lamp Old New ...

Page 676: ...0 00 Tailgate Glass Added the window open lever for flip up glass and changed the location of rear wiper 10 Tailgate Glass Old New Rear Spoiler Introduced the wing type rear spoiler 11 Rear Spoiler Old New ...

Page 677: ...Tailgate Lower Garnish Changed the design 12 Tailgate Lower Garnish Old New Rear Bumper Old New Changed the design 13 Rear Bumper ...

Page 678: ...5110 01 Top view Side view Front view Rear view 1 MAJOR EXTERNAL DIMENSIONS Unit mm General dimensions ...

Page 679: ...ad lamp low Head lamp high Tail lamp Turn signal lamp Front fog lamp Stop lamp Tail lamp 1 2 3 4 5 6 7 Side repeater License plate lamp Turn signal lamp rear lamp Backup lamp Extra stop lamp Reflex reflector 8 9 10 11 12 13 ...

Page 680: ...5110 01 ...

Page 681: ...Front Double wishbone Rear 5 link 2 JACK POINTS ...

Page 682: ...5110 01 3 UNDER COATING APPLICATIONS ...

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SSANGYONG Rexton Y290 2012, Manual

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