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SSANGYONG Rodius 2012.07, Manual

The SSANGYONG Rodius 2012.07 comes with an extensive user manual to help you get the most out of your vehicle. This comprehensive manual covers all aspects of the Rodius, and you can download it for free from manualshive.com, ensuring you have all the necessary information at your fingertips.

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07-8

Radiator

Electric fan

Shroud

Deaeration tube

Clamp

Deaeration hose (radiator)

Electric fan mounting bracket

Bolt (M6, 8 pieces)

Bolt (M6, 4 pieces)

Bolt (M6, 4 pieces)

Upper radiator insulator

Lower radiator insulator

Plate

Clip

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Inlet hose

Outlet hose

3 way hose

Deaeration hose (reserver tank)

Clamp

Clamp

Make up hose holder

Reserver tank

Bolt (M6, 2 piece)

Cooling fan

Viscous clutch

Bolt (M6, 1 piece)

Bolt (M6, 3 piece)

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Summary of Contents for Rodius 2012.07

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Page 118: ...01 3 0000 00 Top View Side View Front View Rear View Optional Unit mm 1 DIMENSIONS ...

Page 119: ...01 4 2 SPECIFICATIONS Optional 2WD ...

Page 120: ...01 5 0000 00 Specifications Cont d ...

Page 121: ...al VIN Label Engine Number Gasoline Engine The engine number is stamped on the lower area of cylinder block in exhaust manifold side Chassis Number The chassis number is stamped on the frame behind the front right tire Certification Label The certification label is located on the driver s door sill 3 VEHICLE IDENTIFICATION ...

Page 122: ...01 7 0000 00 4 MAINTENANCE 1 Scheduled Maintenance Services EU Diesel Engine D20DTR ...

Page 123: ...01 8 ...

Page 124: ...01 9 0000 00 ...

Page 125: ...01 10 2 Scheduled Maintenance Services GEN Diesel Engine D20DTR ...

Page 126: ...01 11 0000 00 ...

Page 127: ...01 12 ...

Page 128: ...01 13 0000 00 3 Scheduled Maintenance Services Gasoline Engine ...

Page 129: ...01 14 ...

Page 130: ...01 15 0000 00 ...

Page 131: ...D FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Keep the specified levels when adding or replacing the fluids Do not mix any different types or brands of oils or fluids This may cause damages ...

Page 132: ...01 17 0000 00 Front Double wishbone Rear Multi Link 6 JACK POINTS ...

Page 133: ...key should be coded by the scan tool Connector Pin Diagnostic connector Pin No Function 1 2 3 STICS A2 Coding 4 Ground 5 Ground 6 CAN HI S205 12 7 GSL ECU 58 8 ABS ESP unit 2 9 Air bag unit 9 10 11 TCU A18 12 13 TCCU 21 14 CAN LO S205 5 15 STICS B16 Diagnosis 16 B 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR ...

Page 134: ...01 19 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 135: ...01 20 2 Components Locator ...

Page 136: ...tandard tightening torque during bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so 1 2 Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 3 4 Aluminum alloy Tighten to 80 of above torque table...

Page 137: ......

Page 138: ...ENGINE De aeration port HFM6 HFM7 1115 00 Engine Deleted D27DT Euro4 engine and introduced D20DTR Euro5 engine 2330 08 HFM Hot Film Air Mass Sensor Changed HFM sensor 2130 02 Air Cleaner Changed the material of air cleaner element paper filer to felt 2313 01 Air cleaner Housing and Snorke Changed design according to installation of new engine ...

Page 139: ...been introduced Newly Installed Equipment Water detection sensor Priming pump Front RH Front LH Electric fan Front RH Front LH PWM electric fan 1990 01 Engine Mounting Insulator Changed design according to installation of new engine 2330 01 Intercooler To increase the cooling performance made the cooling capacity bigger and changed the design ...

Page 140: ...nstalled Equipment 2412 02 CDPF Catalyst Diesel Particulate Filter Installed CDPF according to Euro 5 regulation Sub frame bushing Engine side Mounting bracket assembly Stabilizer link Stabilizer bar Stabilizer bar Mounting bracket assembly Stabilizer link Changed stabilizer mounting Changed front axle mounting height ...

Page 141: ...hanged TOD type T C to Part Time T C 4411 01 Front Suspension Changed components Coil spring assembly Upper arm assembly Stabilizer bar assembly Lower arm assembly Stabilizer bar assembly Knuckle assembly Upper arm assembly Lower arm assembly Shock absorber assembly Knuckle assembly ...

Page 142: ...acity 2 CHASSIS II 4115 01 Knuckle and Hub Assembly 4WD Changed components hub knuckle hub actuator and front axle shaft according to new part time T C Torsional damper Turbine wheel Stator Impeller 1 2 3 4 Front axle shaft Hub Knuckle Knuckle Front axle shaft Hub assembly Locking hub actuator ...

Page 143: ...arter trim Repair kit Sealant Front Front 2WD A T M T 4WD A T 2WD A T M T Wheel and Tire Repair Kit 4170 07 Wheel For 4WD vehicle installed new wheel New wheel Installed tire repair kit 3170 01 Manual Transmission Installed 6 speed manual transmission 1990 10 Transmission Cross Member Changed cross member ...

Page 144: ...0 10 Warning Lamp Indicator Cluster Changed some warning lamps and indicators 8410 14 4WD Switch Changed 4WD switch according to newly installed part time T C 8910 05 Audio Assembly Bluetooth 2 DIN CDP 3 OTHERS ...

Page 145: ...01 3 0000 00 Left view Right view Rear view Front view 1 ENGINE LAYOUT ...

Page 146: ...steering pump pulley Oil pressure switch Water pump pulley Idler pulley No 22 Alternator pulley Auto tensioner Idler pulley No 1 A C compressor pulley Rear view E EGR valve Fuel temperature sensor Fuel HP pump assembly Coolant temperature sensor Crankshaft position sensor IMV valve Isolation damper ...

Page 147: ...sensor Oil dipstick tube gauge assembly E VGT actuator E VGT turbocharger Coolant screw plug Oil drain plug Left view Thermostat assembly Variable swirl valve assembly EGR cooler E EGR valve E EGR solenoid valve Oil cooler assembly Electronic throttle body ...

Page 148: ...level and add Ssangyong genuine engine oil if necessary Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine Power steering fluid reservoir Brake fluid reservoir Engine oil dipstick gauge Washer fluid reservoir cap Engine oil filler cap Air cleaner Operating vehicle with insuffi cient amount of oil can damage the engine Make sure the engine oil level is corr...

Page 149: ...ery 200 000 km or 5 years Air cleaner element Inspection Diesel EU Change every 20 000 km The service interval should be shortened under severe conditions General Change every 15 000 km The service interval should be shortened under severe conditions Gasoline Clean every 15 000 km replace every 60 000 km The service interval should be shortened under severe conditions Fuel filter EU Change every 4...

Page 150: ...gyong genuine coolant Anti Freeze SYC 1025 Capacity approx 11 5 litter Severe condition Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended ...

Page 151: ... Otherwise some electric or electronic components could be damaged 2 Servicing Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short To prevent the foreign material from getting into engine cylinder cover the inlet of air cleaner if the air cleaner has been removed 1 Lifting up the vehicle Always keep the safety precautions To prevent the vehi...

Page 152: ...rts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system When working on the fuel line between priming pump and injector including return line always plug the openings with caps to prevent foreign materials or dust from entering to the openings and connections The HP fuel supply pipe HP pump to fuel rail and HP fuel pipe Fuel rail to injector sh...

Page 153: ...ue during bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20...

Page 154: ... 20Nm 180 20 660 720Nm Not reusable Oil pan M6 20 18 10 1Nm M6 35 2 10 1Nm M6 85 2 10 1Nm M6 120 2 10 1Nm M8 40 2 25 2 5Nm Mounting nut for high pressure pump M14 1 5 8 1 1 65 5Nm Mounting bolt for high pressure pump M8 30 3 25 2 5Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1Nm M8 60 4 25 2 5Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket M11 40 1 30 3Nm Chain tensioner scre...

Page 155: ...orque Nm Note total tightening torque Hot water inlet pipe M6 12 2 10 1Nm Alternator M10 90 1 LO 25 2 5Nm M10 116 1 HI 46 4 6Nm Air conditioner compressor M8 85 4 25 2 5Nm Air conditioner bracket M6 25 4 10 1Nm Intake manifold M8 35 2 25 2 5Nm M8 110 6 25 2 5Nm Oil filter module M8 40 6 25 2 5Nm M8 20 1 25 2 5Nm M8 140 2 25 2 5Nm Knock sensor M8 28 2 20 5Nm Camshaft position sensor M8 14 1 10 14Nm...

Page 156: ...stick gauge cover M6 16 1 10 1Nm Oil filter cap 1 25 2 5Nm Fuel rail M8 25 2 25 2 5Nm Injector clamp bolt M6 44 2 9 1 0Nm 130 10 High pressure pipe between high pressure pump and fuel rail assembly M17 1 30 3Nm High pressure pipe between fuel rail assembly and injector M17 4 30 3Nm Crankshaft position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8 25 3 25 2 5Nm Power steering pum...

Page 157: ...C 5AT AT 6 speed DSI 6AT AT 7 speed DC 7AT Pressure sensor forA C refrigerant NO Select Refrigerant pressure sensor Refrigerant Pressure Sensor Immobilizer NO Select YES if the vehicle has immobilizer YES Vehicle speed input type CAN Select CAN if the vehicle has ABS or ESP WIRE Cooling fan Relay Select PWM PWM Auto cruise NO Select YES if the vehicle hascruise control YES Engine level control NO ...

Page 158: ...r EAS 4 corner EPB NO Select NO YES Telematics NO Select NO YES T M shift lever DC lever CAN A T Select DURA lever CAN M T Select M T DURA lever CAN M T DSI lever NO CAN Brake system NO Select ABS or ESP ABS TCS ESP EPS NO Select NO YES 4WD 2WD Select 2WD or P T 4WD TOD P T 4WD AWD Transmission M T Select M T or DC AT DC AT DSI AT ...

Page 159: ...atform Rodius Select Rodius Rexton Korando C Kyron Korando Sport Vehicle code Engine D32DT A T Select DURA lever CAN M T Select M T D27DT D27DTP D20DT D20DTR D20DT LOW Brake system NO Select D20DTR ABS TCS ESP Coding process Coding uncompleted Select Coding completed Coding completed Coding error Not defined ...

Page 160: ...1 4t 1 ENGINE ASSEMBLY Unit Description Specification Remark Cylinder head Height 131 9 to 132 1 mm Flatness below 0 1 mm Valve protrusion Intake valve 0 6 to 1 0 mm Exhaust valve 0 6 to 1 0 mm Flatness on manifold side Intake manifold 0 08 mm Exhaust manifold 0 08 mm Connecting rod End play 0 5 to 0 31 mm Camshaft Axial end play Intake 0 1 to 0 35 mm Exhaust 0 1 to 0 35 mm Camshaft position senso...

Page 161: ...lt M18x50 1 200 20Nm 180 20 660 to 720 Nm Not re usable Oil pan M6 20 18 10 1Nm M6 35 2 10 1Nm M6 85 2 10 1Nm M6 120 2 10 1Nm M8 40 2 25 2 5Nm HP pump main nut M14 1 5 8 1 1 65 5Nm HP pump bolt M8x30 3 25 2 5Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1Nm M8 60 4 25 2 5Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket bolt M11 40 1 30 3Nm Chain tensioner screw plug M38 1 5 1 2...

Page 162: ... 5Nm M8 140 2 25 2 5Nm Knock sensor M8 28 2 20 5Nm Cam position sensor M8 14 1 10 14Nm T MAP pressure sensor M6 20 1 10 1Nm Exhaust manifold M8 10 40 4Nm Turbocharger M8 3 25 2 5Nm T C support bolt 1 25 2 5Nm T C support nut M8 1 25 2 5Nm T C oil supply pipe M6 block side 1 10 1 0Nm M6 turbo side 1 17 2 0Nm T C oil return pipe M6 16 turbo side 2 10 1Nm M6 16 block side 2 10 1Nm EGR valve M8 22 3 2...

Page 163: ...sure pipe between fuel rail and injector M17 4 30 3Nm Crank position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8 25 3 25 2 5Nm Power steering pump M8 100 3 25 2 5Nm Cylinder head front cover M6 10 5 10 1Nm Ladder frame M8x16 5 30 3Nm Component Size Bolt Quantity Specified torque Nm Remark Total torque Glow plug M5 4 20 2Nm Vacuum pump M8 25 3 10 1Nm Timing gear case cover M6 4...

Page 164: ... gasket This test provides current engine operating status Measurement Warm the engine up to normal operating temperature 80 C Disconnect the fuel rail pressure sensor connector to cut off the fuel injection Remove the air cleaner duct and glow plugs Place the diagram sheet to compression pressure tester and install it into the plug hole 1 Before cranking the engine make sure that the test wiring ...

Page 165: ...e test procedure do not inject the engine oil into the combustion chamber Test condition normal engine operating temperature 80 C Specified value Whole engine below 25 at valve and cylinder head gasket below 10 at piston ring below 20 Crank the engine for approx 10 seconds by using the start motor 2 Record the test result and measure the compression pressure of other cylinders with same manner 3 I...

Page 166: ...02 9 0000 00 Position the piston at TDC and measure the piston protrusion from crank case mating surface 3 Piston protrusion check Specified value 0 475 0 745mm Measure it at both ends of crankshaft ...

Page 167: ...e with compressed air to 2 bar If the height is less than the limit the cylinder head must be replaced If the measured value is out of the specified range machine the valve seat as much as necessary until the specified value is achieved Total height A 131 9 to 132 1 mm Minimum height after machining 131 9 mm Flatness Longitudinal direction 0 1 150 Transverse direction 0 15 Parallel deviation of cy...

Page 168: ...n the vehicle while servicing in engine compartment Before work on engine and each electrical equipment be sure to disconnect battery negative terminal Before service works be sure to prepare the works by cleaning and aligning work areas Do not allow the foreign material get into the fuel injection system When removing the engine use only the safety hook on engine and engine hanger Do not support ...

Page 169: ... not allow the fluid and engine oil to make contact with the body paintwork and hoses If work on the fluid system such as fuel and oil working area should be well ventilated and smoking should be prohibited Gasket or seal on the fuel lubrication system should be replaced with new ones and bolts and nuts should be tightened as specified After removal installation works be sure to check whether ther...

Page 170: ... Accessories Drive design to make a compact layout Components HPS Hydraulic Power Steering 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 Idle pulley 1 9 Idle pulley 2 10 Power steering pump pulley ...

Page 171: ...lity and durability for the system And the belt tension is decreased to minimize the friction loss and improve the belt operating noise 1 Crankshaft Pulley Isolation Damper 1 Overview 2 Sectional drawing Axial radial bearing Sleeve Hub Isolation pulley rubber Pulley Damper rubber Inertia ring ...

Page 172: ... Decrease crankshaft torsion Improve belt NHV Reduce unbalance speed to crankshaft due to irregular combustion Minimize noise Anti vibration from crankshaft and belt Post bonded type rubber damper Improve durability of rubber damper 1 2 3 4 ...

Page 173: ...this deviation automatically In D20DTR engine one of the mechanical tensioner pivot damped tensioner is used to keep the damping force system reliability and durability The single belt drive system needs to use the automatic belt tensioning device to transfer the power to pulleys effectively To get this the tensioner uses the spring and damping unit 2 Location Belt tensioner ...

Page 174: ... ECU When the engine is cooled the exhaust gas goes to combustion chamber without passing through EGR cooler because the valve is closed by vacuum pressure 2 VACUUM PUMP Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid This pump is single vane type and displacement is 210 cc rev The lubrication oil is supplied through the hole in hollow shaft Components Brake...

Page 175: ...02 18 1 Location 2 Operation The vacuum pump is engaged to the exhaust camshaft Connection between vacuum pump and exhaust camshaft Oil supply and driving Vacuum pump Exhaust camshaft ...

Page 176: ...21M20 P N 31900 21A20 P N 31900 21A40 3 ENGINE MOUNTING D20DTR engine uses 3 point mounting type that supports the engine and transmission simultaneously Components Front mounting insulator Left side Location Insulator Front mounting insulator Right side Location Insulator ...

Page 177: ...insulator Left side Type Rubber mounting Function Supports the powertrain Front mounting insulator Right side Type Rubber mounting Function Supports the powertrain Rear mounting insulato Type Rubber mounting Function Supports the powertrain 1 Functions ...

Page 178: ... the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas 2 Exhaust Manifold Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts EGR port is integrated in cylinder head Components Components For detailes refer to Chapter Intake System For detailes refer to Chapter Exhaust System Exhaust manifold Intake manifold ...

Page 179: ...VER AND OIL SEPARATOR The cylinder head cover is made by high strength plastic to reduce the weight The multi twist type oil separator improves the oil consumption Components 1 Cylinder Head Cover Cylinder head cover Cylinder head cover ...

Page 180: ... the particle in blow by gas to minimize the engine oil consumption and reduces the inflow oil from intake system into the combustion chamber The separated oil returns to oil pan through cylinder head Oil separator Blow by outlet hose 1 Overview 2 Layout ...

Page 181: ...ins cam position sensor vacuum pump intake manifold exhaust manifold and valve assembly Vacuum pump and the high pressure HP pump are driven by Camshaft and valves are install in vertical direction This enables the compact layout in cylinder head assembly 6 CYLINDER HEAD Finger follower HLA Camshaft sprocket Intake exhaust Camshafts ...

Page 182: ...e by gravity casting and the water jacket is integrated type The cylinder oil passage is drilled and sealed by cap The Camshaft bearing cap is also made by casting and installed on the cylinder head 2 Features Front Oil gallery expansion plug M10 Coolant expansion plug M21 Intake side Rear ...

Page 183: ...ears Camshaft operates the intake exhaust valves vacuum pump and HP pump and transfers the engine oil to vacuum pump through the internal oil passage 2 Location Exhaust Camshaft Exhaust Camshaft Thrust journal Intake Camshaft Closed flow type water jacket improving cooling performance Octagon cam for tooling Connected to vacuum pump ...

Page 184: ...e clearance reduces the valve noise Roller type finger follower reduces the friction loss Vertical installation Simple and compact design reduces the moving operation improving valve following and fuel consumption at high speed 1 2 3 4 5 2 Arrangement Hydraulic lash adjuster Upper valve spring retainer Lower valve spring retainer Valve spring Exhaust valve Intake valve Finger follower ...

Page 185: ...le stopper backland stopper Material MLS Multi Layer Steel Gasket 3 layers Thickness of gasket 3 types 1 2 1 3 1 4 mm 1 2 3 4 2 Thickness of cylinder head gasket There are three types of gasket to managing the compression ratio Piston protrusion Piston protrusion Thickness 0 475 to 0 540 mm 1 2t 0 541 to 0 649 mm 1 3t 0 650 to 0 745 mm 1 4t Thickness marking Ex 1 3t ...

Page 186: ...light weight and has high durability through single bush chain Shoulder bolts are used for better NHV 7 CHAIN AND GEAR DRIVE SYSTEM D20DTR engine uses single stage chain drive system Timing chain drives the exhaust side and gear drive the intake side Timing chain is single bush type Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke and lower chain drives ...

Page 187: ...aulic pressure Crankshaft sprocket Teeth 21 EA Oil pump sprocket Teeth 33 EA Chain lower bush Chain type single bush Chains 60 EA Mechanical type tensioner Operated by internal spring Clamping rail Installed between exhaust Camshaft sprocket and crankshaft sprocket Exhaust camshaft sprocket Teeth 42 EA The brass links on timing chain are aligned with the timing marks on crankshaft sprocket and cam...

Page 188: ...bush type 112 EA Chain lower bush Single bush type 60 EA 2 Tensioner Tensioner adjusts the chain tension to keep it tight during engine running This reduces the wear in guide rail and spoke Operating principle Use the spring tension in tensioner and hydraulic pressure Tensioner type Compensation and impact absorbing Static and dynamic force Spring Hydraulic pressure 1 2 3 Plunger Housing Spring Ch...

Page 189: ...uide rail is used for optimizing the movement of chain drive system And it also prevents the chain from contacting each other when the chain is loose and reduces the chain wear The guide rail is made of plastic nylon Teflon etc The guide rail is specially required when the distance between two spokes is too great It pushes the chain with constant force so that the chain can work smoothly The guide...

Page 190: ...02 33 0000 00 Screw plug Oil seal Timing gear case cover Timing gear case cover TGCC 5 Timing gear case cover ...

Page 191: ...nd screw plug on the timing gear case cover Do not touch the inner lip of crankshaft front seal Be careful not to damage the screw thread when removing the lock pin to release the chain tensioner Be careful not to damage the O ring when installing the screw plug A671 997 01 46 Crankshaft front seal Location of chain tensioner screw plug ...

Page 192: ...02 35 0000 00 Oil pan sassembly 8 OIL PAN The oil pan in D20DTR engine improves the NVH Especially the oil draining is much easier than before Components ...

Page 193: ...the irregular speed of crankshaft due to unbalanced combustion Improving the power train NVH Improving the driving performance Reducing the clutch noise by using ball bearing Improving the durability of DMF by using strong arch spring 2 Layout Spring guide Drive plate Primary cover Primary flywheel Internal external ring Secondary flywheel Ring gear ...

Page 194: ...o transaxle by absorbing the impact 3 Operation Compensating the irregular operation of engine The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more less pulsation absorbing effect Transaxle protection function Reduces the torsional vibration to powertrain transaxle b...

Page 195: ...ange Stable revolution of the primary and secondary wheel by using planetary gear Works as auxiliary damper against spring changes Less heat generation due to no direct friction against spring surface Plastic material is covered on the spring outer surface Increased durability by using plastic bushing extends the lifetime of grease 6 Drive Plate Drive plate receives the power from the start motor ...

Page 196: ...02 39 0000 00 10 PISTON CRANKSHAFT CYLINDER BLOCK The crankshaft and the cylinder block convert the compression pressure to the rotating energy Components Cylinder block Piston Connecting rod Crankshaft ...

Page 197: ...snap ring The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy 2 Layout 1 ring Oil ring Snap ring 2 ring Material B2 Skirt coating MoS2 Piston cooling gallery for connecting rod Wide bawl type CR 16 5 Cooling jet ...

Page 198: ... cylinder bore and prevents the leaked combustion gas from 1 ring from leaking into the crank chamber Oil ring Scrapes the engine oil on the cylinder bore Piston pin Connects the piston the connecting rod and transfers the linear movement of piston to connecting rod to convert it to rotating energy Snap pin Locks the piston pin 4 Assembling the piston Install the piston rings with the Y mark on th...

Page 199: ...cting piston oversize Top of piston Top of cylinder block Engine Piston Cylinder bore Part NO Marking NO D20DTF 671 030 06 17 671 037 07 01 A A 671 037 08 01 X X 671 037 09 01 B B 671 037 10 01 5 671 037 11 01 10 ...

Page 200: ...to the rotating movement of crankshaft The big end is connected to connecting rod bearing and the crank pin journal and the small end is connected to the piston pin 2 Components Connecting rod cap bolt Connecting rod upper bearing Connecting rod Piston pin bush Connecting lower bearing Connecting rod cap ...

Page 201: ... 0 063 2 Y 1 808 Y 1 809 0 016 54 614 1 812 1 812 50 960 0 062 3 B 1 812 R 1 806 0 015 1 816 1 809 0 061 Min 0 015 Max 0 063 3 Selection of crankshaft pin journal bearing The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections Three sets in the table below have nearly same oil clearance 0 015 0 063 mm of bearing Identification Coloe mark on bearing side surface Oil clear...

Page 202: ...haft is installed on the cylinder block 2 Arrangement Crankshaft main bearing upper Crankshaft main bearing upper Upper thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower Lower thrust bearing Crank pin journal Main journal ...

Page 203: ...ction of crankshaft main bearing Mark Color Thickness of main bearing mm V Violet 0 030 0 025 W White 0 025 0 020 R Red 0 020 0 015 Y Yellow 0 015 0 010 B Blue 0 010 0 005 2 25 2 25 2 25 2 25 2 25 Selection of bearing according to pin punch color Mark Color Thickness of main bearing Blue 66 500 66 506 Yellow 66 506 66 513 Red 66 513 66 519 ...

Page 204: ...ock 1 Overview The major dimensions in D20DTR are similar to D20DTR engine It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation 2 Layout Right side Cylindrical pin Expansion plug Screw plug ...

Page 205: ...02 48 Left side Expansion plug 3 Features For simple manufacturing the crankcase blow by gas passage and the oil return hole are made by casting on the cylinder block ...

Page 206: ...sage from cylinder head to inlet port of water pump is integrated in cylinder head The engine oil from oil pump is supplied to the main oil gallery through oil channel oil filter module and cross bore in cylinder block without using external pipes This oil is supplied to main bearing cylinder head and MBU And it is sprayed to the chain through the chain tensioner connected to cross bore Crankcase ...

Page 207: ... every 20 000 km GEN every 15 000 km Water accumulating capacity 200 cc Heater capacity 250W 13 5V Injector System pressure 1800 bar High pressure fuel pump Type Eccentric cam Plunger type Operating type Gear driven type Normal operating temperature 40 125 C Operating pressure 1800 bar Operating temperature 30 120 C Low pressure fuel pump Type Vane type Gear ratio pump engine 0 5 1 Pressure 6 bar ...

Page 208: ...nt the fuzz dust and foreign materials from getting into fuel system Wash your hands and do not wear working gloves 1 2 3 Follow the below procedures before starting service works for fuel system If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in this manual At this point thoroughly clea...

Page 209: ...use damages and leaks at connections Once installed the pipes have been deformed according to the force during installation therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to specified tightening torque as well If not the injection point may be deviated from correct position and it may cause engine disorder ...

Page 210: ...k the low pressure and high pressure fuel systems before removing the components To run the system properly the electric system must be intact but for the DI engine the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device 2 Hydraulic system ...

Page 211: ... of injector Excessive injector backlea Occurs when the injector control valve is not sealed due to the entry of the foreign materials Example Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector ...

Page 212: ...ssure flow Faulty fuel supply line or damaged or worn pump causes the lack of flow pressure and flow volume Example Air in fuel supply line Excessive load on fuel supply line 400 mBar Burned out and mechanical worn pump High temperature of fuel supply 85 ...

Page 213: ...est 1 Test device Tool kit 2 Pre check Check tighten fuel supply line Check fuel level in fuel tank Check air in fuel supply line bubble in fuel supply line or fuel Check fuel supply line for leaks low pressure and high pressure Check that specified fuel is used Check fuel filter for contamination ...

Page 214: ...cedure If several DTCs are output simultaneously check the electric wiring for open or short circuit Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities Carry out the high pressure fuel system check ...

Page 215: ...03 11 2210 01 4 Fuel System Check Procedure ...

Page 216: ...d IMV connector B from the fuel rail 1 Connect the pressure tester to the fuel rail pressure sensor connector 2 Crank the engine 2 times for 5 seconds 3 Read the highest pressure value displayed on the tester display If the highest pressure value is 1 050 bar or less refer to the section Fuel System Check Process ...

Page 217: ...utton on the tester to check if the message TEST is displayed If the button is pressed again at 4 seconds after starting engine cranking the highest pressure is displayed on the tester 1 2 The fuel rail pressure value can be checked using a diagnostic device ...

Page 218: ... low pressure test and clean it thoroughly to prevent foreign materials from entering 1 2 Disconnect the key connector for fuel filter connection and connect both connectors to the fuel filter and hose 3 Start the engine and check visually for clogged low pressure fuel system excessive air or air entry If the fuel flow is not sufficient or air is in the fuel repair the leak area 4 5 ...

Page 219: ...ector prevent air entry to the low pressure line 2 Disconnect the IMV connector of the high pressure pump and then fuel pressure sensor connector 3 The connector of the injector can be easily contaminated Always keep it clean Crank the engine 2 times for 5 seconds Check the time for flow if injector backleak and confirm that it is within the specified range 4 5 If the value is out of the specified...

Page 220: ...e hose of the container for measuring backleak to the return nipple of the injector Start the engine again and let the engine idle for 30 seconds Perform backleak test of fuel system with a diagnostic device after 30 seconds 3 4 5 This test consists of 4 cycles and the engine rpm reaches 3 500 rpm for 18 seconds in each cycle Check the amount of backleak collected into the container and confirm th...

Page 221: ... rail to the fuel rail for test 3 Disconnect the return hose for HP pump and connect the clear hose and connect its the other end to the return port of the fuel rail for test 4 Connect the digital tester connector to the sensor connector of the fuel rail for test Crank the engine 2 times for 5 seconds after removing the IMV connector and fuel rail pressure sensor connector Read the pressure value ...

Page 222: ...ed to protect the system It reduces the driving force restricts the engine speed rpm and stops engine operation Refer to Diagnosis section in this manual Engine CHECK Warning Lamp 3 The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or major electronic systems of the engine are not working properly As a result the engine s power output may decrease or the engine may sta...

Page 223: ...ains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The below figure shows the clearance between internal operating elements The core elements of fuel system has very ...

Page 224: ... against water in fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating fil...

Page 225: ...ne low pressure line which supplies low pressure fuel to the low pressure pump including high pressure pump common rail which distributes and accumulates the high pressurized fuel from the fuel pump high pressure line which connected to the injector and the engine control unit ECU which calculates the accelerator pedal position and controls the overall performance of vehicle based on the input sig...

Page 226: ...ERATION 1 Layout For sensor and actuator control logic refer to Chapter Engine Control Engine ECU D20DTR Engine control by various signals Injector C3I Pre injection main injection after injection by signals from ECU HFM sensor Measuring intake air mass and temperature Crankshaft position sensor Measuring engine rpm ...

Page 227: ... to injectors High pressure pump Generating high pressurized fuel and supplying it according to engine rpm required volume required pressure Plunger type HP pump 1 800 bar Vane type LP pump 6 bar Accelerator pedal position sensor Detecting driver s intention for speed up down Fuel filter assembly Supplying clean fuel fuel heating water separation by priming pump ...

Page 228: ...y the injectors according to the injection signals The injection method is the same with the conventional method Fuel return by backleak which operates the needle valve The major difference is that the fuel return line is connected to the fuel filter inlet port not the HP pump venturi The pressure from the high pressure pump is increased to 1 800 bar from 1 600 bar and the pump is now installed to...

Page 229: ...03 25 2210 01 3 Input Output devices Refer to Chapter Engine Control ...

Page 230: ...accelerator pedal depressed driver s will by receiving the electrical signals from the accelerator pedal sensor The mass air flow sensor detects the volume of intake air and sends the value to the ECU The major function of the ECU is controlling air fuel ratio to reduce the emission level EGR valve control by detecting instantaneous air flow change with the signals from the mass air flow sensor Al...

Page 231: ...cleaner element Filter type Dry filter element Initial resistance Max 300 mmAq Service interval EU Change every 20 000 km GEN Change every 15 000 km Air cleaner assembly Weight 2 36kg Operating temperature 30 100 Intercooler Radiation over 13 000 Kcal Pressure loss at turbocharger below 90 mmHg Cooling type Air cooled type Core size 450W 130H 70T Core type C FIN ...

Page 232: ...ing the intake hoses and pipes which were disconnected to check the system or replace the air cleaner If the intake system is free of any faults check the EGR and PCV oil separator connected to the intake system The figure may be different from the actual engine Therefore read thoroughly below before replacing the parts 2 Abnormal Noise Caused by Poor Tightness of Intake System When the DI engine ...

Page 233: ...ke system is an open circuit system Therefore any malfunction may occur due to dust and dirt Most of the connections consist of hoses so the system cannot withstand high temperature and pressure Also it can be deformed or loosened easily because it is a clamp mounting system Thus when checking the engine basic inspections such as tightened status check and visual inspection for hose etc should be ...

Page 234: ...r entering to the engine when the ignition switch is turned off Because of this the shape of the intake manifold has been changed and improved HFM sensor is newly adopted to control the intake air volume more precisely 2 COMPONENT 2330 01 Intercooler assembly 2313 15 HFM sensor HFM sensor version 7 For more information refer to Chapter Engine Control 2313 01 Air cleaner assembly ...

Page 235: ... swirl valve and for intake air 1719 16 Electric throttle body For more information refer to Chapter Engine Control 1719 02 Swirl control valve Operating variably in accordance with the engine load and rpm For more information refer to Chapter Engine Control ...

Page 236: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM For more information refer to Chapter Engine Control ...

Page 237: ...04 9 1719 00 4 OPERATING PROCESS Work Flow ...

Page 238: ...eates the bowl type squish 2 Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal ...

Page 239: ...efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are dramat...

Page 240: ...05 3 1729 01 1 TROUBLESHOOTING 1 Work Flow ...

Page 241: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 242: ...embly CDPF assembly 1 OVERVIEW This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion Exhaust front pipe assembly For more information refer to Chapter Engine Control ...

Page 243: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 244: ... 1 SPECIFICATION Unit Description Specification Turbocharger Max expansion coefficient 4 0 Max turbine speed 226 000rpm Max temperature of turbine housing 790 Weight 6 5kg E VGT actuator Operation duty cycle 250Hz ...

Page 245: ...nute allowing oil to circulate to the turbocharger after the replacement When the engine is stopped abruptly after driving at high speed the turbocharger continues to rotate in condition where the oil pressure is at 0 In such condition an oil film between the journal bearing and the housing shaft journal section gets broken and this causes abrasion of the journal bearing due to the rapid contact T...

Page 246: ...uling the turbocharger Oil Leakage Followings are the reasons for oil leakage condition Problems in engine In case where the oil is smeared on inner wall section of the exhaust gas opening Problems in turbocharger In case where the oil is smeared on only at the exhaust gas outlet section Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and...

Page 247: ...or section as oil pressure within the center housing gets higher than pressure within the compressor housing Overuse of engine break especially in low gear in down hill makes significantly low exhaust gas energy compared to the time where great amount of air is required during idling conditions of the engine Therefore amount of air in the compressor inlet increases but the turbocharge pressure is ...

Page 248: ...erstand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects In case where oil pan oil pipe has been contaminated oil filter is defected and where adhesive of gaskets has been contaminated into the oil line 1 ...

Page 249: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 250: ...06 9 1914 01 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 251: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 252: ...damages as well as checking the condition of connections between pipes In case where the noise of engine is louder than usual there is possibility of dampness in the areas related with air cleaner and engine or engine block and turbocharger And it could affect the smooth supply of engine oil and discharge Check for damp condition in exhaust gas when there is sign of thermal discoloration or discha...

Page 253: ...06 12 2 Work Flow for Troubleshooting ...

Page 254: ...06 13 1914 01 ...

Page 255: ...06 14 ...

Page 256: ...06 15 1914 01 ...

Page 257: ...06 16 ...

Page 258: ...ser having a passage with big surface transforms its speed energy into the pressure energy while being supplied to the cylinder improving the volume efficiency Also the exhaust efficiency improves as the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger Diffuser With the meaning of spreading out it is a device that transforms fluid s speed energy int...

Page 259: ... system 1 1 Performance for EURO V Has a faster response time than the conventional vacuum actuator 2 Improved low speed torque high speed power and fuel economy Improved acceleration performance with rapid response time of vane 1 Features Features Benefits Folding and unfolding of the vane is controlled electrically Easy to get low speed air volume Rapid response time Electric control Improved lo...

Page 260: ...ontrol E VGT turbocharger Improves engine power Accelerator pedal position sensor Transfers driver s will to accelerate to ECU Engine ECU D20DTR E VGT duty control Coolant temperature sensor Operates the VGT according to engine warm up HFM sensor Improves the engine power T MAP sensor Booster pressure and temperature ...

Page 261: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 262: ...as and running the turbine quickly and powerfully Therefore as VGT can intake more air than normal turbocharger it can give the benefit of the increased output even in a low speed zone Turbocharger lag The turbocharger is at idle speed when there is no load or it is in the normal driving condition During this period the amount of exhaust gas passing through the turbine is not enough to turn the co...

Page 263: ...dant exhaust gas can deliver a more increased energy to the compressor The output will increase in submission to the increase of intake air volume Control range Turbocharger driving mechanism Control method Effect Improved performance At high speed Expands the flow passage for the exhaust gas by unfolding the vanes The flow rate is increased due to the expanded passage Increased turbine impeller s...

Page 264: ... as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Unit Specification Oil pump Lubrication system Gear pump forced circulation Type Inscribed gear Capacity 63 L at 4 000 rpm Relief pressure 5 8 bar 0 3 bar Oil filter Type Full flow Paper element Engine oil Specified oil SAE 5W30 approved by MB SHEET 229 51 Capacity L Min 4 5 L Max 6 0 L ...

Page 265: ...ficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary 2 Replenishment If the level gets to the lower point open the filler cap on top of the cylinder block and add the genuine oil without exceeding the level of the upper mark Recheck the oil level after 5 minutes Regularly check the engine oil level and add Ssangyong genuine engine oil if ne...

Page 266: ...In other words it creates an oil film on each sliding surface to convert solid friction to liquid friction in order to minimize wear and prevent temperature increasing on the friction part For the D20DTF engine with no oil pressure switch the engine ECU receives the low engine oil level signal from the oil level sensor and communicates with the instrument cluster through the CAN communication to t...

Page 267: ...n provide sufficient flow rate of the engine oil and effective cooling 3 Sealing It helps to seal the space between the pistons and the cylinder walls so that compression is more effective and power is not lost during combustion 4 Anti corrosion As a corrosion inhibitor oil coats internal engine parts to prevent surface rust on the inside of the engine which can be caused by blow by products and w...

Page 268: ...Flow type Cross flow Antifreeze Type Long life coolant Mixing ratio water antifreeze 50 50 Cooling fan module Motor type DC motor Motor weight 2 14 kg Control type PWM type Fan runout 3 mm Coolant reservoir Capacity over 1 5 L Circulation Closed roof type Pressure cap Screw type Pressure 1 4bar Thermostat Type Wax pallet type Opening temperature 90 Fully open temperature 100 Valve lift 8mm ...

Page 269: ...roper coolant mixture ratio Kinked coolant hose Add coolant Check the coolant concentration Anti freeze Repair or replace the hose Defective thermostat Defective water pump Defective radiator Defective coolant auxiliary tank or tank cap Change the thermostat Change the water pump Change the radiator Change the coolant auxiliary tank or tank cap Cracks on the cylinder block or cylinder head Clogged...

Page 270: ... the MAX and MIN mark on the coolant reservoir Check the coolant level If the level is below the MIN mark immediately add coolant 1 2 Scalding hot coolant and steam could be blown out under pressure which could cause serious injury Never remove the coolant reservoir cap when the engine and radiator are hot Avoid any direct contact of the coolant to the painted body of the vehicle ...

Page 271: ...n Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank Connect the tester to the tank filler and apply pressure 1 4 bar Check all the coolant hoses pipes and connections for leaks when the pressure of the tester drops and replace or tighten if necessary 2 3 4 3 Thermostat Immerse the thermostat into the water Heat the water and check the valve opening...

Page 272: ...se burns by hot steam or water To open the coolant reservoir cap wrap the cap with a wet towel or thick cloth after the engine is cooled down sufficiently If cool water is added to the heated engine the engine or radiator can be deformed The anti freeze in the coolant can damage the painted surface so avoid the contact of the coolant to the painted body The anti freeze and water should be mixed in...

Page 273: ...rmostat starts to open fully open at 100 and lets the coolant flow to the radiator to maintain the engine temperature Water pump The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine 1 SYSTEM DESCRIPTION 1 Overview Water pump Impeller vane Sealing ...

Page 274: ...perature and sends the result to the engine ECU Electric fan Circulates the fresh air forcibly to exchange heat with the radiator core fin Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core ...

Page 275: ...FICATION Alternator Crankshaft pulley Alternator pulley 1 2 94 Normal output idling 2200 rpm 70 140A Regulator voltage 14 6 V Brush Length 12 5mm Wear limit 7mm Battery Type MF Capacity 90 AH Unit Description Specification ...

Page 276: ...gear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measur...

Page 277: ...rnator Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace the ignition switch Defective ground of alternator circuit Repair Charge warning lamp is not turned off after starting engine Defective alternator voltage regulator Replace the alternator Corroded or worn battery cable Repair or replace the battery cable Loo...

Page 278: ...09 6 3 Checking Battery ...

Page 279: ...ixing current load capacity and time and varying voltage Determine battery capacity based on the amount of voltage drop when discharging a fixed load capacity 120 A for 5 seconds Connect the tester to the battery and read the display while applying a load for 5 seconds How to read display Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a batte...

Page 280: ...towing hook 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle whi...

Page 281: ...the terminals are corroded clean them with a wire brush or sandpapers Always disconnect the battery cables with the ignition key removed When disconnecting the battery cables with the ignition key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the...

Page 282: ...supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change 2 System Layout Locations Battery It converts the chemical energy to the electrical energy a...

Page 283: ...09 11 1451 01 2 OPERATING PROCESS 1 Charging Flow ...

Page 284: ...he cold battery the amount of current the battery can accept initially is very small As the battery gets warmer it can accept more current Charging capacity Charging a battery with a low capacity charger takes longer time than charging with a high capacity charger Charging status Charging a fully depleted battery takes twice or more as long as charging a half depleted battery Since the electrolyte...

Page 285: ...09 13 1451 01 3 CIRCUIT DIAGRAM ...

Page 286: ...ption Specification Glow plug Rated voltage 4 4 V Max temperature 1100 C Operating temperature 1080 C 1000 C Resistance 23 C 0 39 0 52Ω Glow plug control unit Operating voltage 6 16 V Operating temperature 40 C 110 C Dark current Max 1 mA ...

Page 287: ...ed to heat the intake air This enables the diesel fuel to be ignited in low temperature condition The ECU receives the information such as engine rpm coolant temperature engine torque etc through CAN communication during pre heating process and the pre heating control unit controls the pre heating heating during cranking and post heating by the PWM control Glow plug Engine ECU D20DTR Glow indicato...

Page 288: ...10 5 1413 00 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 289: ...10 6 3 Circuit Diagram ...

Page 290: ...CU 1 Temperature Current Properties of GCU GCU increases the temperature of glow plug very rapidly approx 2 seconds up to 1000 C FETs similar to transistor for each cylinder are integrated in GCU During the pre glow period battery voltage is supplied to the glow plugs directly to heat them rapidly After getting the desired temperature by pre glowing the temperature is controlled by duty ratio Step...

Page 291: ...t is low GCU extends the pre heating time GCU monitors the energy to glow plugs the amount of pre heating energy is always same GCU monitors the battery voltage If it is low GCU extends the pre heating time to get enough energy GCU monitors the battery voltage If it is low GCU increases PWM duty ...

Page 292: ...low plugs GCU estimates the temperature of glow plug for pre heating To avoid the power loss and overheat GCU supplies the lowest power for getting target temperature when turning ON the ignition from OFF 4 Operation Frequency 20 33Hz PWM control duty ratio 1st step 100 2 3 step 35 4th step 23 ...

Page 293: ...10 10 5 Pre glow and Post glow This shows the pre glow and post glow step as a chart ...

Page 294: ... Description Specification Capacity 12V 2 3kW Engagement Meshed type Rotating direction Clockwise Pinion gear manufacturing Cooled forging Solenoid operating voltage Max 8 V Weight 2 5 kg Bracket manufacturing Aluminum die casting ...

Page 295: ... switch or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replac Loose corroded or damaged battery cable Repair or replace Faulty starter Starter does not stop Faulty starter Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring gear Replace ...

Page 296: ...ne with rotational power by converting the electric energy to the mechanical energy When the engine is cranking the pinion gear meshes with the ring gear If the ring gear overruns the pinion gear clutch overruns to protect the pinion gear 2 OPERATING PROCESS 1 System Layout ...

Page 297: ...11 6 2 Circuit Diagram ...

Page 298: ...ehicle 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 AUTO CRUISE ...

Page 299: ...torways 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 300: ...of 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 301: ...12 6 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 302: ...trol 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...

Page 303: ... ACCEL 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 o...

Page 304: ...ntil 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 runnin...

Page 305: ...hicle 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 306: ...owing 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 307: ...t brake 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 an...

Page 308: ... motor Valve EGR gas flow rate 120 Kg h Position sensor Sensing type Hole sensor Supplied voltage 5V 10 Maximum signal range 5 95 Maximum power consumption 15mA E EGR cooler Cooling capacity 8 3 kW or more Cooling fin type Wavy fin Cooler type U shaped E EGR bypass valve Driven by Vacuum Solenoid valve ...

Page 309: ...pacity reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decresed Benefits of E EGR valve Improved accuracy and response through electr...

Page 310: ...the intake duct without passing through the EGR cooler to reduce the emission of exhaust gas before warming up the engine HFM sensor Used as a main map value to control the EGR The coolant temperature engine rpm engine load intake air temperature HFM decreased at 60 C or more atmospheric pressure atmospheric pressure sensor altitude compensation are used as auxiliary map values 2 Location and Comp...

Page 311: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 312: ...ompensation by the intake air temperature The engine ECU calculates the EGR amount by adding main map value intake air volume and auxiliary map value and directly drives the solenoid valve in the E EGR to regulate the opening extent of the EGR valve and sends the feedback to the potentiometer 1 Operating conditions Intake air temperature between 10 and 50 Atmospheric pressure 0 92 bar or more Engi...

Page 313: ...not turn off the engine while the vehicle is running Do not shift the gear selector lever to neutral when going downhill Do not use improper engine oil or fuel additives Do not drive for a long time when the warning lamp is illuminated Make sure no flammable material such as dry grass or tissue paper contacts with the catalyst filter while the vehicle is parked For the vehicles used in urban traff...

Page 314: ...ation process the soot is continuously accumulated in the CDPF When this condition continues and the CDPF is overloaded with soot the engine warning lamp blinks to inform this situation to the driver In order to solve this problem drive the vehicle at a speed of approx 80 km h for 15 to 20 minutes to perform the CDPF regeneration process If the engine warning lamp on the instrument cluster blinks ...

Page 315: ...h the oxidation process of CO and HC And the DPF Diesel Particulate Filter collects PM Particle Matter and is regenerated to reduce the quantity of particulates HC and CO But there is a limitation in reducing the emission of exhaust gas for each system so the CDPF which combines these two system is applied ...

Page 316: ... difference between pre CDPF and post CDPF Engine ECU D20DTR Post injection Electric Throttle Body Regulates the air intake rate CDPF DOC DPF Front EGT Sensor Measures the combustion temperature Rear EGT Sensor Measures the CDPF temperature 2 COMPONENTS For details refer to section Engine Control ...

Page 317: ...emperature exceeds 600 the life of CDPF can be reduced So the amount of fuel post injection is decreased If the temperature drops under 600 the rate of regeneration can be decreased So the amount of fuel post injection is increased Differential pressure sensor This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF Electric throttle va...

Page 318: ...s increased and the post injection is started for regeneration The amount of fuel post injection is controlled by the exhaust gas temperature measured by the rear temperature sensor If the temperature is less than 600 the amount of post injection is increased to increase the regeneration temperature Otherwise the fuel injection amount is decreased or the fuel is not injected When the engine is run...

Page 319: ...rced recycling of PM Front temperature sensor Measures the temperature of exhaust gas This sensor is located at the rear side of exhaust manifold and monitors the temperature of combusted gas to prevent the exhaust system from overheating When the temperature gets higher this sensor cuts off the fuel delivery and controls the EGR to lower the temperature Engine ECU D20DTR T MAP sensor Intake air m...

Page 320: ...mperature and burns the collected PM at approx 600 C Oxidation DOC When the exhaust gas enters into the CDPF assembly its CO HC and PM are reduced by the redox reaction of the DOC The remaining PM is filtered and collected in CDPF and the temperature of the exhaust gas is increased to between 450 and 500 C 5 OPERATING PROCESS Configuration and principle of operation The exhaust gas passed through ...

Page 321: ... EGT sensor detects whether the DOC can burn oxidize the post injected fuel or not and sends the signal to the ECU to maintain the DOC operating temperature between 300 and 500 The DOC reduces CO and HC of the exhaust gas by redox reaction and also reduces small amount of PM Oxygen adheres to the catalyst materials Less than 180 1 CO and HC are oxidized by the catalyst materials More than 180 2 ...

Page 322: ...s to the inlet of a channel it is released from the outlet of the adjacent channel through the porous wall because of the closed outlet of the first channel and the PM is collected in the first channel Collecting PM of CDPF Normally when the driving distance becomes approx 600 to 1 200 km enough amount of soot to be burned is filtered and accumulated in the CDPF The ECU increases the amount of fue...

Page 323: ...xhaust temperature intake air mass flow booster pressure etc The regeneration is started when the amount of the collected PM is 28 g or more The ECU commands post injection to increase the temperature of CDPF to 600 When the amount of the collected PM is not enough The DPF works as a filter 1 When enough amount of PM is collected The ECU commands post injection and increase the exhaust gas tempera...

Page 324: ...post injections are to reduce the PM and harmful exhaust gas The post injection does not make the actual output The post injection activates the fuel by injecting the fuel to the incompletely combusted gas after primary combustion Through the process the PM and smoke in the exhaust gas could be reduced There are totally 7 injections as shown in the figure However all of 7 injections are not perfor...

Page 325: ...14 15 2412 02 6 CIRCUIT DIAGRAM ...

Page 326: ...led in CDPF This smoke generates the ash resulting in clogging the filter Advantages when using the designated engine oil for CDPF 2 Reduces the amount of ash Improves the fuel economy and reduces the CO2 Increases the life span of engine oil Available for all engines diesel and gasoline Problems when using non designated engine oil for CDPF 3 Decreases the life span of engine oil due to accumulat...

Page 327: ...of DPF 3 White Smoke The white smoke can be generated when the exhaust gas is recycled in DPF There are two reasons as below Saturated vapor 1 Sulfate 2 The vehicle equipped with CDPF system may generate the white smoke when using the fuel with high sulfur content over 100 ppm This is caused by the sulfur attached and accumulated in CDPF However this is very natural situation not caused by your ve...

Page 328: ...ull Open to 78 Close Engine torque Nm varies by engine conditions Injection time ms 3 to 5ms Battery voltage V 13 5 V to 14 1 V Accelerator pedal position 1 V 0 4 to 4 8V Accelerator pedal position 2 V 0 2 to 2 4 V Throttle position 1 V 0 3 to 4 6 V Throttle position 2 V 0 3 to 4 6 V Oxygen sensor V 0 to 5 V A C compressor switch 1 ON 0 OFF Full load 1 ON 0 OFF Gear selection A T 1 ON 0 OFF Knocki...

Page 329: ...15 4 Oxygen Sensor Glow Plug 1 MAJOR COMPONENTS HFM Air mass Temperature Injector C3I IMV E VGT Actuator ...

Page 330: ...15 5 0000 00 GCU Glow Plug Control Unit EGR Bypass Valve EGR Valve Electric Throttle Body Water Sensor Variable Swirl Valve Actuator ...

Page 331: ...15 6 Fuel Rail Pressure Sensor Front EGT Sensor Differential Pressure Sensor Camshaft Position Sensor Rear EGT Sensor ...

Page 332: ...15 7 0000 00 Fuel Temperature Sensor Coolant Temperature Sensor Knock Sensor 2 T MAP Sensor D20DTR ECU ...

Page 333: ...15 8 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 334: ...tion sensor Differential pressure sensor E EGR valve position sensor Camshaft position sensor Coolant temperature sensor EGT sensor HFM sensor Oxygen sensor T MAP sensor Crankshaft position sensor Accelerator pedal sensor Throttle position sensor Knock sensor Auto cruise switch Refrigerant pressure sensor Blower switch signal Brake pedal signal ...

Page 335: ...t CAN E EGR cooler bypass valve TCU Self diagnosis Cooling fan E EGR valve Variable swirl valve E VGT actuator IMV valve A C compressor Injector Throttle position sensor ABS ESP unit GCU Indicator Warning Lamp Meter Cluster PTC heater ...

Page 336: ...ectives Operating temperature range of ECU is normally 40 to 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circu...

Page 337: ...ction All of post injections are to reduce the PM and harmful exhaust gas The post injection does not make the actual output The post injection activates the fuel by injecting the fuel to the incompletely combusted gas after primary combustion Through the process the PM and smoke in the exhaust gas could be reduced There are totally 7 injections as shown in the figure However all of 7 injections a...

Page 338: ...ted fuel volume is changed and stopped according to the coolant temperature and intake air volume Pilot injection is much earlier than main injection due to higher engine rpm Too small injection volume insufficient injection pressure insufficient fuel injection volume in main injection engine braking System failure fuel system engine control system Pilot injection Main injection Combustion pressur...

Page 339: ...ition engine rpm coolant temperature intake air temperature boost pressure boost temperature and atmospheric pressure etc d Post Injection Injection after main injection Consists of After injection Post 1 Post 2 injection Post injection reduces PM and smoke from exhaust gas No actual output is generated during these injections instead fuel is injected to the unburned gas after main injection to en...

Page 340: ...el pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined according to injected fuel and coolant temperature Open loop determines the ...

Page 341: ... cylinder temperature when EGR ratio increases 5 Main injection timing control The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow The elements are A first correction is made according to the air and coolant temperatures This correction makes it possible to adapt the timing to the operating temperature of the engine When the engine is...

Page 342: ...nt by the system in order to determine the fuel injected When the driver release the pedal the idle speed controller takes over to determine the minimum fuel which must be injected into the cylinder to prevent the enigne from stalling The driver demand is the translation of the pedal position into the fuel demand It is calculated as a function of the pedal position and of the engine speed The driv...

Page 343: ... when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the fault the system activate...

Page 344: ...f the engine speed and the coolant temperature G Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The difference between these two instantaneous speeds is then calculated Finall...

Page 345: ...ion and noise can be occur for a while This is because the fuel pressure is increased instantaneously and the exact injection value is not input so that the exact engine vibration timing can be detected 6 MDP Learning Control A MDP Learning When the pulse value that the injector starts injection is measured it is called minimum drive pulse MDP Through MDP controls can correct pilot injections effe...

Page 346: ...5 seconds 2 times for each cylinder every 5 seconds If MDP learning is not properly performed engine vibration and injection could be occurred MDP learning should be performed after replacing ECU reprogramming and replacing injector D Injector characteristic curve for rail pressure The fuel injection curve is also called injection characteristic curve as shown above The amount of injected fuel is ...

Page 347: ...sh the background noise level of the knocking control signal for each cylinder This window must therefore be positioned at a moment when there cannot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection 1 2 T...

Page 348: ...s signaled is a percentage of the maximum possible value of the ratio Because of the severity of the recovery process engine shut down the etection must be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too much Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow...

Page 349: ...g swirl there are two passages in intake manifold and one of them has the valve to open and close the passage When the valve closes the passage the air flow through the another passage will be faster and the strong swirl will be generated by the internal structure of the passage This swirl makes the better mixture of air and fuel eventually the combustion efficiency in combustion chamber could be ...

Page 350: ...15 25 0000 00 B Input Output for variable swirl valve ...

Page 351: ...to bowl type D Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal flow and the t...

Page 352: ... efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are drama...

Page 353: ... been greatly improved The EGR cooler with high capacity reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decresed B Components E EGR ...

Page 354: ...15 29 0000 00 C Input Output of E EGR system ...

Page 355: ...rpm Used as the signal for determining EGR operating range Coolant temperature When the coolant temperature is low NOx is decreased but PM could be increased So to reduce PM decrease EGR ratio when the coolant temperature is low Intake air mass and temperature HFM sensor measures the intake air mass to calculate the actual EGR volume If the air mass is larger than programmed value in map EGR ratio...

Page 356: ...rdingly the concentration of NOx is decreased The point with highest NOx is immediately after TDC As EGR temperature goes up the concentration of NOx will be higher Thus it is necessary to cool down the exhaust gas However during engine cooled it may cause large amount of PM To prevent this the exhaust gas is bypassed the EGR cooler ...

Page 357: ...e newly adopted DC motor actuator E actuator controls the E VGT system more precisely and faster To get the high operating power from turbine the ECU reduces the exhaust gas passage In low speed range and increases it in high speed range B Components HFM intake air temperature Front EGT sensor E VGT actuator Accelerator pedal module Crankshaft position sensor Oxygen sensor T MAP sensor Coolant tem...

Page 358: ...15 33 0000 00 C Input Output for E VGT system ...

Page 359: ...r operation and the boost temperature is used for calculating the precise density E VGT provides higher engine power with faster reaction speed compared to conventional VGT Operating wave Vane Control Low speed range In low speed range retract the vane to increase boost pressure The vane has low duty and the unison ring moves to retract the vane in weak PWM signal High speed range The unison ring ...

Page 360: ... the wide band oxygen sensor is used for this kind of engine and this sensor is a little different from the one that used for gasoline engine The combustion in diesel engine is controlled by fuel injection volume Therefore the wide band oxygen sensor should be used in diesel engine This sensor measures the air fuel ratio in very wide range and is also called full range oxygen sensor The wide band ...

Page 361: ...15 36 C Input Output for oxygen sensor ...

Page 362: ...en ions when there is oxygen concentration difference between exhaust gas and atmosphere If a certain voltage is applied to the sensor the movement of oxygen ions occurs regardless of the oxygen density The current generated through this flow of ions is called pumping current IP and the oxygen sensor measures this value ...

Page 363: ...s 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 The heat from automatic transmission is also cooled down through the radiator by circulating the oil through the oil pump ECU controls the electric cooling fans with ...

Page 364: ...15 39 0000 00 C Input Output for cooling fan and A C compressor ...

Page 365: ...ing to coolant temperature and vehicle speed The PWM cooling fan starts running from 89 of coolant temperature PWM cooling fan control according to transmission fluid temperature A T 1 PWM duty under 129 0 2 PWM duty over 130 94 4 PWM cooling fan control according to A C refrigerant pressure PWM duty value sharply increases when the A C refrigerant pressure goes over 10 bar And it slowly decreases...

Page 366: ...mperature below 20 or over 115 Engine rpm over 4500 rpm Engine rpm below 600 rpm When abrupt acceleration Very high load during idling Refrigerant pressure over 32 bar or below 2 bar Failure in refrigerant sensor coolant temperature sensor and cooling fan ...

Page 367: ...e is mounted in the heater air outlet and increase the temperature of air to the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required PTC does not operate during engine cranking while the battery voltage is lower than 11 V or during preheating process of glow plugs B Components HFM intake air temperature Coolant temperature sensor PTC relay 1 ...

Page 368: ...Coolant temperature 15 C PTC ON after satisfying the conditions in 2nd step 2nd step coolant temperature 15 C Coolant temperature 65 C and intake air temperature 10 C PTC ON Coolant temperature 60 65 C and intake air temperature 10 0 C PTC ON Coolant temperature 60 C and intake air temperature 0 5 C PTC ON Stop OFF conditions A C blower switch OFF Defective ambient air temperature sensor including...

Page 369: ...ansponder integrated in the key and the engine control unit have 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 the vehicle to start the engine B Components Basic components ignition key system D20DTR ECU Immobilizer antenna Indicator Warning Lamp Start motor Immobi...

Page 370: ...ECU ECU communicate with the immobilizer key to check if it is valid crypto code If it is valid ECU start to control the engine when turning the ignition switch to START position The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again ...

Page 371: ...and burn it again so that the amount of PM in the exhaust gas passed through the DOC Diesel Oxidation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxidation Catalyst and DPF Diesel Particulate Filter For details refer to Chapter CDPF B Components Oxygen sensor Front EGT sensor CDPF DOC DPF Rear EGT sensor Differential pressure sensor ...

Page 372: ...15 47 0000 00 C Input Output for CDPF control ...

Page 373: ...mount of fuel injected is determined according to the temperature of exhaust gas detected by the rear temperature sensor If the temperature is below 600 C the amount of fuel injected is increased to raise the temperature If the temperature is over 600 C the amount of fuel injected is decreased or not controlled When the engine is running in low load range the amount of post injection and the amoun...

Page 374: ...cumulating Eventually this ashes will block the filter Benefit for specified engine oil Minimized the sulfur content of engine oil which reduces the service life Improved fuel economy and emission level of CO2 with high performance and low viscosity Increased service life of engine oil with high resistance to temperature Problems when using unspecified engine oil The service life of filter may be ...

Page 375: ...15 50 3 Input Output for CAN communication ...

Page 376: ...01 4 1 COMPONENT LOCATOR 1 Front View ...

Page 377: ... Resonance flap 14 Exhaust manifold 4 Cylinder head cover 15 Crankshaft 5 Exhaust camshaft 16 Engine mounting 6 Intake camshaft 17 Starter 7 Cylinder head 18 Crankcase 8 Spark plug connector 19 Oil pump sprocket 9 Valve tappet 20 Oil strainer 10 Injector 21 Oil pan 11 Exhaust valve 22 Drain plug Front View ...

Page 378: ...01 6 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 379: ...nstalled 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 equi...

Page 380: ...02 3 1113 01 1 SPECIFICATIONS 1 Engine Specifications ...

Page 381: ...02 4 2 Performance Curve ...

Page 382: ...02 5 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 383: ...02 6 ...

Page 384: ...02 7 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 385: ...02 8 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 386: ...02 9 1113 01 1 Fastener Tightening Specifications Cont d ...

Page 387: ...uce 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 disp...

Page 388: ...03 4 Temperature vs resistance ...

Page 389: ...NO DATA ...

Page 390: ...n of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 OVERVIEW OF CATALYTIC CONVERTER When ...

Page 391: ...05 4 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 392: ...06 3 9210 01 1 OIL CIRCULATION ...

Page 393: ...ry at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chain a Oil gallery from ...

Page 394: ...07 3 2110 01 1 GENERAL SPECIFICATIONS ...

Page 395: ...07 4 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 396: ...07 5 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 397: ...The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to the heat core This provides for hea...

Page 398: ...07 7 2110 01 2 COMPONENT LOCATOR ...

Page 399: ...ieces 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 400: ...08 3 1452 01 1 GENERAL SPECIFICATIONS ...

Page 401: ...08 4 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 402: ...arms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted by t...

Page 403: ...s 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 sp...

Page 404: ...08 7 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 405: ...09 3 1522 16 1 ENGINE DATA DISPLAY TABLE ...

Page 406: ...09 4 2 FASTENER TIGHTENING SPECIFICATIONS 1 Temperature vs Resistance ...

Page 407: ...pedal 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 408: ...torways 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 409: ...of 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 410: ...10 6 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 411: ...trol 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...

Page 412: ... ACCEL 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 o...

Page 413: ...ntil 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 runnin...

Page 414: ...hicle 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 415: ...owing 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 416: ...t brake 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 an...

Page 417: ...nition 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 418: ...h a 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 contac...

Page 419: ...k 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 hightemperature parts such as the exhaust manifold and exhaust pipes The rotating parts such as fan pulley and fan belt perturbative parts and wiring should be secured tightly at regular intervals Secur...

Page 420: ...he fuse and relay boxes consist of four boxes Fuse relay box in engine room and Fuse and relay box in left side of instrument panel 2 LOCATION Engine Room Fuse and Relay Box Interior Fuse and Relay Box PTC Box Assembly ...

Page 421: ...01 7 8410 02 3 CIRCUIT DIAGRAM SB1 SB4 C FAN HI LO REALY F HEATER RELAY C FAN SUB RELAY 1 Engine Room Fuse and Relay Box ...

Page 422: ...01 8 SB5 SB8 Ef5 Ef6 2ND A PUMP RELAY ENG MAIN RELAY START RELAY ...

Page 423: ...01 9 8410 02 SB9 SB11 Ef10 Ef23 RR BLOWER RELAY DEFOGGER RELAY ...

Page 424: ...01 10 Ef2 Ef4 Ef19 Ef20 B HORN RELAY H LAMP LO HI RELAY COMP RELAY ...

Page 425: ...01 11 8410 02 Ef7 Ef9 Ef21 FRT FOG LAMP RELAY TAIL LAMP RELAY ...

Page 426: ...01 12 Ef11 Ef16 POWER WINDOW RELAY ...

Page 427: ...01 13 8410 02 Ef17 Ef18 Ef22 Ef24 Ef26 FUEL PUMP RELAY ...

Page 428: ...01 14 2 Interior Fuse and Relay Box F1 F5 ...

Page 429: ...01 15 8410 02 F6 F12 ...

Page 430: ...01 16 F13 F16 ...

Page 431: ...01 17 8410 02 F17 F24 ...

Page 432: ...01 18 F25 F31 ...

Page 433: ...01 19 8410 02 F32 F36 ...

Page 434: ...cated in each function does not include chattering processing time from switch input changing point 1 2 Item Requirement Remark Rated voltage DC 12V Operating voltage DC 9 16V Should operate normally within this range Operating temperature 30 80 Reserved temperature 40 85 Max operating humidity 95 Resistible voltage 24V Insulating resistance No heat and fire due to the current leaks Confined with ...

Page 435: ...02 4 4 Input Signals Of Rk Stics ...

Page 436: ...gnals to STICS Theft deterrent horn Installed under the battery This horn works only for the theft deterrent function panic function and remote starting SCAN tool SIW is used for REKES key coding and trouble diagnosis REKES Added the escort and panic function RK STICS ICM module This module contains various relays chime and buzzer controlled by STICS ...

Page 437: ...g ON the washer switch for 0 2 0 59 seconds T2 with the ignition key ON and it is turned off when the parking terminal is turned off 1 The wiper relay is turned on 0 3 seconds T1 after turning ON the washer switch over 0 6 seconds T2 with the ignition key ON and it is turned on three times immediately after turning off the washer switch 2 ...

Page 438: ...hile the wipers are operating in intermittent or AUTO mode the system stores the previous intermittent interval and operates the washer coupled wiper After then the wiper operation returns back to intermittent or AUTO mode with the stored operating interval 3 ...

Page 439: ...n in the system diagram the rain sensor unit does not control wiper directly The rain sensor unit sends infrared rays signal through LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly For more details refer to rain sensing wiper section in this manual ...

Page 440: ...ion The wiper relay LO is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions while the ignition key is in ON position When the wiper switch is turned to AUTO position again from other positions the system drives the wiper relay LO to run the wiper motor one cycle only when the rain sensor detects the Rain Detected signal 1 2 ...

Page 441: ...on key is in ON position the wiper switch is in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal Rain sensing sensitivity control If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle ...

Page 442: ... is in AUTO position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN HIGH the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity 2 The wiper motor runs only when the rain sensor requires Wiper operation when the wiper parking terminal is grounded ...

Page 443: ...ed to 2 from 3 during receiving the malfunction signal 1 from the rain sensor 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 Defective rain sensor ...

Page 444: ...osition 2 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the malfunction signal 3 from the rain sensor while the ignition key is in ON position and the wiper switch is in AUTO position Also the wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during...

Page 445: ...T switch positioned ON Intermittent interval at 0 km h 3 0 5 19 2 seconds 2 Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 pulses sec 60 km h x 60 sec 637 pulses 1 41 km h 3 VOLUME calculation Calculates the INT VOLUME with 5 grades as shown in the table in next page 4 Pause time calculation Pause time the duration that wipers are...

Page 446: ...sher switch while the wiper relay is operating 1 If the wiper relay ON request time is shorter than the remained ON time it is disregarded 2 Speed sensitive INT intermittent wiper The wiper relay continues to output for remaining ON time even when the INT switch is turned off IGN 2 switch ON INT switch OFF resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON resume the inter...

Page 447: ...ensor When turning the INT AUTO switch from the OFF to ON position with the ignition switch in the ON mode the LOW relay operates to drive the wiper motor for 1 cycle regardless of the rain sensor communication After that when turning the INT AUTO switch from the OFF to ON position the LOW relay operates to drive the wiper motor for 1 cycle only if data from the rain sensor indicates rain drops 1 ...

Page 448: ...n the ICM box continues when opening the driver s door while the ignition key is inserted into ignition switch When removing the ignition key or closing the driver s door during chime buzzer output the output turns off This function is not available when the ignition switch is ON 1 2 3 ...

Page 449: ...ey is in ignition switch The system outputs UNLOCK 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 T1 while the ignition key is in ignition switch 1 2 3 Key Reminder Operating conditions for 1 and 2 1 Driver s door is opened and driver s door lock switch is turned to LOCK 2 Passenger s door is opened and passenger s door ...

Page 450: ... passenger s and rear doors are locked only the driver s door generates unlock signal when trying to lock the driver s door with the driver s door opened Above operations is regardless of key positions and have priority over the ignition key reminder function When the door is closed during unlock output for 5 seconds under item 1 condition the unlock output stops 2 All doors except tailgate and ho...

Page 451: ...d 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 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 opened This function is not available when the ignition key is in ON position 1 2 3 4 ...

Page 452: ...ng the door under step 1 The warning light blinks when the vehicle speed is over 10 km h V1 for more than 2 seconds while the warning light is turned on The warning light blinks when a door is opened while the vehicle speed is over 10 km h V1 while the warning light is turned off The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed is belo...

Page 453: ... for 6 seconds however the chime buzzer does not sound The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to OFF position The chime buzzer stops and the seat belt warning light stays on for the specified duration 6 seconds when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime buzzer ...

Page 454: ...ff the parking brake switch under step 2 The warning light blinks and the chime buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h V1 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 brake switch under step 4 The warning light comes on an...

Page 455: ...y during decaying operation The front room lamp comes on for 30 seconds T3 when receiving the unlock signal from the remote control key while the door is closed 1 2 3 4 The front room lamp output period is extended by 30 seconds T3 when receiving the unlock signal from the remote control key again during output When a door is opened during its extended period the lamp stays on If closed operates a...

Page 456: ... lighting period by 5 seconds when closing the rear door The room lamp output stops immediately after turning the ignition key to ON position during the extended period The room lamp output stops immediately after receiving the lock signal from the rear door lock switch or the remote control key while the rear door is closed 1 2 3 4 Door coupled front room lamp switch Rear Room Lamp ...

Page 457: ...river s door or passenger s door while 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 armed mode 1 2 3 4 ...

Page 458: ...to cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation The tail lamp relay is turned off auto cut when opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 ...

Page 459: ...gger switch again during its operation The output is ON only for 6 minutes T3 when turning ON the rear defogger switch within 10 minutes T2 after completion of output When turning on the defogger switch again within 10 minutes T2 after completion of initial 12 minutes T1 of output the output comes on for 6 minutes T3 again once only The output stops when the IGN 2 switch is turned to OFF position ...

Page 460: ...e and outside rearview mirror heated glass The heater relay in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse 15A is located in the engine compartment fuse box Windshield rear rear glass and outside rearview mirror heated glass switch ...

Page 461: ...ock switch is ignored when outputting the LOCK or UNLOCK by other functions The door lock unlock system is not working regardless of the door lock switch positions when connecting the battery All door lock signals are UNLOCK for 0 5 seconds T4 just for once when receiving the LOCK signal within 0 5 seconds T3 after closing the driver s or passenger s door However this operation is regardless of th...

Page 462: ... LOCK for 0 5 seconds T1 when pressing LOCK button on the central door lock switch The door lock system outputs UNLOCK for 0 5 seconds T2 when pressing UNLOCK button on the central door lock switch The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored 1 2 3 ...

Page 463: ...rol Key The door lock system outputs LOCK for 0 5 seconds T2 when receiving LOCK signal from the remote control key The door lock system outputs UNLOCK signal for 0 5 seconds T3 when receiving UNLOCK signal from the remote control key 1 2 ...

Page 464: ...02 33 8710 01 ...

Page 465: ...ccelerates 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 switch The door lock system outputs UNLOCK automatically if the LOCK output condition...

Page 466: ...hen turning OFF the ignition switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or UNLOCK output is ignored if LOCK or UNLOCK output is req...

Page 467: ...osition However the power window relay stays on for 90 seconds T2 when the ignition key is turned to OFF position while the door is opened The power window relay is turned ON again for 90 seconds T2 just for once when opening the door during its extended operation period of 90 seconds T1 The power window relay is turned OFF when closing the door during its extended operation period of 90 seconds T...

Page 468: ...rrent horn and hazard warning flasher At this moment if the ignition key is in the ignition switch the door unlock switch is turned ON or the door lock switch is unlocked after 0 6 seconds cancels the armed mode and activates the normal mode However in these cases if closing the door and locking the door lock switch the theft deterrent horn outputs once and the hazard warning flasher outputs twice...

Page 469: ...arning operation The theft deterrent horn and hazard warning flasher output is ON for T3 27 seconds with the interval of T2 1second 1 Warning cancellation requirements Cancels warning by using any signal from the remote control key LOCK UNLOCK START STOP PANIC CHECK during warning operation Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position 1 2 Operat...

Page 470: ...the current vehicle conditions LOCK engine running when the PANIC warning is turned off by the remote control key 1 2 3 4 5 The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft deterrent The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning PANIC output is OFF The PANIC warning outpu...

Page 471: ...multifunction light switch is in AUTO position while the ignition key is in ON position 1 4 Auto Door Lock The doors are locked and the theft deterrent mode is activated again if any of doors is not opened after unlocking them with a REKES key Sends the message in 5 seconds after locking the doors automatically 1 2 ...

Page 472: ...02 41 8710 01 3 CIRCUIT DIAGRAM Tail lamp key reminder SW chime bell ...

Page 473: ...02 42 Power window warning lamp brake s belt ...

Page 474: ...02 43 8710 01 Wiper door SW lamp door courtesy g handle door open ...

Page 475: ...02 44 Door lock defogger ...

Page 476: ...03 3 7010 06 REKES Key Immobilizer Unit Diagnostic Connector 1 SYSTEM LAYOUT 1 Location Immobilizer Warning Lamp ECU ...

Page 477: ...03 4 2 System Diagram 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 ...

Page 478: ...ponder integrated in the key and the engine control unit have 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 the vehicle to start the engine If the verification has been failed the engine cannot be started and the immobilizer warning lamp blinks Immobilizer unit ...

Page 479: ...er unit transmits the encrypted code to the transponder 2 The transponder sends an encrypted signal to the unit as a response The transmitted code is changed to an encrypted signal in the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit 3 4 5 When two or more immobilizer keys come into contact with each other s When the key is close to any device se...

Page 480: ...sponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or register an extra key let the owner attend on the site In any case the immobilizer system cannot be removed from the vehicle If you attempt to remove it and damage the system starting will be impossible so never attempt to remove damage or modify it The remote engine starter c...

Page 481: ...03 8 2 Circuit Diagram ...

Page 482: ...C 13 5V Operating temperature 30 C 75 C while driving Storage temperature 40 C 85 C Performance guarantee voltage DC 10V 15V Dark current below 3mA 12V 25 C Stabilized conditions standby mode around 180 seconds after IGN OFF 2 LCD Display Description Specification Color of display Black Color of back light Yellow Green Running type 1 4 Duty 1 3 Bias ...

Page 483: ...of the Meter cluster and the Warning lamp Indicator cluster For 2012 Model some warning lamps and indicators have been deleted added and changed according to the changes of engineering design Deleted Warning lamps and indicators for EAS EPB and TPMS Changed EBD warning lamps Added Indicators for Part time transfer case ...

Page 484: ...05 3 8310 01 1 Exterior Lamps 1 LAYOUT ...

Page 485: ...fog lamp 12V 5W Left fog lamp 12V 5W Low beam 12V 55W Tail lamp 12V 5W High beam 12V 55W Turn signal lamp 12V 28W Connector Tail lamp Tail lamp Turn signal lamp connector Turn signal lamp Headlamp Low beam Headlamp High beam Side repeater 12V 5W ...

Page 486: ...ted stop lamp 12V 6W License plate lamp 12V 5W 2 Tail lamp assembly Rear lamp Stop lamp 12V 8W Rear turn signal lamp 12V 27W Tail lamp 12V 8W Stop lamp Rear turn signal lamp or rear fog lamp LH only Tail lamp Tail lamp assembly connector ...

Page 487: ...05 6 2 Interior Lamps ...

Page 488: ...w beam passing 0 3A Relay load Turn signal switch 6 6 0 5A Lamp load Wiper switch Low 5A High 7A Motor load Auto 0 22 0 05A Relay load Fixed max 28A Motor load Washer switch 4A Motor load Intermittent wiper switch max 25 mA Mist switch 5A Motor load Description Description Auto light sensor unit Operating voltage 9 16V Load max 200 mA Relay load Operating temperature 30 85 Storage temperature 40 1...

Page 489: ...ch Outside Rearview Mirror Adjusting Folding Switches Remote Control Switches on Steering Wheel Window switch 1 LAYOUT Volume button Seek button Manual gear shift down switch Power button Manual gear shift up switch Mode button Mute button Bluetooth switch ...

Page 490: ...g Wheel Angle Sensor Room Lamp and Sunroof Switch w multimeter Defogger switch Passenger s seat warmer switch Rear fog lamp switch Driver s seat warmer switch Front fog lamp switch Hazard warning flasher switch ESP OFF switch Door coupled room lamp switch Sunroof switch Multimeter Front room lamp switch ...

Page 491: ...07 3 7810 01 1 SPECIFICATIONS OF WIPER ...

Page 492: ... does not rain turn the wiper switch to the OFF position Turn the wiper switch to the OFF position before any car wash to avoid unwanted operation of the wipers When cleaning the windshield over the sensor with damp clothes the wiper may operate suddenly It could cause serious injury Make sure to place the wiper switch to the OFF position and ignition switch OFF when not in use Irregular operation...

Page 493: ...07 5 7810 01 1 SYSTEM LAYOUT Components ...

Page 494: ...07 6 2 CIRCUIT DIAGRAM ...

Page 495: ...tects the amount of rain drops by receiving reflected rays against 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 sensitivity against rains on the windshield and transmits wiping demand signal accordingly Emitter lens The LED which is located at botto...

Page 496: ...T Low Relay6 Wiper High STICS The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS and STICSdrives the wiper directly At this moment STICS determines the wiper operation mode washer MIST AUTO then sends the information to the rain sensor ...

Page 497: ...frared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The sensing section on the windshield is located just above the center point between LED and photodiode Components and functions of the rain sensor unit Unit latch Rain sensor unit PCB assembly and emitter lens Emitter lens The LED emits the infrared rays is located at bottom an...

Page 498: ...n in the system diagram the rain sensor unit does not control wiper directly The rain sensor unit sends infrared rays signal through LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly For more details refer to rain sensing wiper section in this manual ...

Page 499: ...ion The wiper relay LO is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions while the ignition key is in ON position When the wiper switch is turned to AUTO position again from other positions the system drives the wiper relay LO to run the wiper motor one cycle only when the rain sensor detects the Rain Detected signal 1 2 ...

Page 500: ...n key is in ON position the wiper switch is in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal Rain sensing sensitivity control If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle ...

Page 501: ... is in AUTO position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN HIGH the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity 2 The wiper motor runs only when the rain sensor requires Wiper operation when the wiper parking terminal is grounded ...

Page 502: ...ed to 2 from 3 during receiving the malfunction signal 1 from the rain sensor 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 Defective rain sensor ...

Page 503: ...osition 2 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the malfunction signal 3 from the rain sensor while the ignition key is in ON position and the wiper switch is in AUTO position Also the wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during...

Page 504: ...08 12 3 OPERATION MODE OF RAIN SENSING WIPER SYSTEM ...

Page 505: ... initial operation however the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF However the wiper operates up to 5 minutes after rain stops If this function does not occur check No 2 terminal on the rain sensor If any defective cannot be found check the wiper relay LOW for defective 1 2 3 If the installed wiper brushes ...

Page 506: ...or coming off Check the rain sensor cover installation Check that the customer is familiar to how to control the wiper sensitivity If the wiper blade cannot wipe the glass uniformly and clearly the irregular operations could be occurred And the wiper blade should be replaced with new one with same specifications Check that the customer can select the sensitivity by selecting the variable resistanc...

Page 507: ...08 15 8610 11 5 DIAGNOSIS PROCEDURES ...

Page 508: ...No 2 are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICSdrives wiper motor to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode No 2 terminal sends the wiper and washer operation information such as washer operation mode MIST mode or AUTO wiper position ...

Page 509: ...08 17 8610 11 7 RAIN SENSING WIPER ...

Page 510: ...oltage DC 12V Operating voltage DC 9V 16V Current consumption Unit below 100 mA Sensor below 20 mA for each sensor Sensor insulating resistance over 5 MΩ Operating temperature 30 C 80 C Storage temperature 40 C 85 C Relative humidity 95 RH max Weight Unit 160g 10g max Sensor 70g 10g max 25 120 cm distance between sensor and obstacle ...

Page 511: ...09 4 2 Parking Aid Sensor Type Piezo ceramic element Frequency 40 kHz 2 kHz Detecting range 13 5 V Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 cm Min 60 at 50 5 cm ...

Page 512: ...detect Thin and narrow objects such as wires ropes chains Cotton sponge clothes snow that absorb ultrasonic waves Obstacles lower than the bumper ex drain ditch or mud puddle 2 Not defective but improperly working When the sensing portion is frozen operates normally after thawed When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned When receiving other...

Page 513: ...r detect the distance to obstacle Driver can figure outthe distance from obstacle to vehicle with the alarming soundand the display in multimeter 2 LAYOUT Operates in R position Operates only when the vehicle speed is below 10 km h Mulrimeter if equipped Changed to PAS mode when moving gear selector lever to R position ICM Box Integrated buzzer sounds when detecting an obstacle behind ...

Page 514: ...8790 01 Rear PAS Sensor Location 3 sensors on rear bumper Operates only in R position PAS Unit Controls the PAS sensors and sends the sensing data to multimeter and ICM box LH sensor Center sensor RH sensor ...

Page 515: ...ultimeter displays the distance to obstacles by bar symbos RH Sensor Center Sensor LH Sensor Distance to obstacle Alarm interval Multimeter display over 1 2 m No alarm 81 120cm Long beeps 51 80cm Short beeps 25 50cm Alarm stays on ...

Page 516: ...09 9 8790 01 3 Circuit Diagram ...

Page 517: ... 저장온도 ISTN 40 85 규격 너비x높이 132X36 Bluetooth 구성요소 M 30 75 D 5XR 블루투스 멀티미디어 모듈 적용기술 블루투스 2 0 EDR Enhanced Data Rate 향상된 데이터 속도 Current consumption below 5A max 10A Dark current below 3mA Unit Description Specification 안테나 안테나 글래스 안테나 내장형 Radio Frequency EU FM 87 5 108MHz MW 522 1620 KHz LW 144 290 KHz Latin America FM 87 5 108 MHz AM 520 1620 MHz Preset FM1 6ch FM2 6ch MW 6ch LW 6ch AM 6ch Sensitivit...

Page 518: ...10 4 2 MAJOR CHANGES Audio Assembly Old New Changed the audio assembly added Bluetooth hands free function ...

Page 519: ...10 6 Front Speaker 1 LAYOUT Bluetooth Microphone Bluetooth microphone Tweeter speaker Audio head unit Audio remote control switches ...

Page 520: ...10 7 8910 05 Radio Antenna Amplifier Rear Speaker ...

Page 521: ...ory button 1 6 and Audio function button 3 Bluetooth hands free CALL button 4 Bluetooth hands free END button 5 Previous and Next button 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 522: ...Selected lever indication P R N D Mechanical D D Electrical Parking lock system Brake switch signal TGS lever Reverse lock system CAN TGS lever Selected lever indication P R N D Lever position 1 2 3 4 5 CAN Oil temperature sensor Resistance R D 0 5 2 5kΩ Resistance P N 20kΩ TCU EGS 52 Shift solenoid valve 25 Resistance 3 8 0 2Ω Operating distance 0 2mm Operating current 1 5 2A Item W5A580 2WD W5A4...

Page 523: ... 5 2 0A Operating range 3rd to 5th gears Speed 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 Item W5A580 ...

Page 524: ...ber Description W126 589 62 00 Handle Install and remove the torque converter W116 589 06 59 00 Support Support the transmission W140 589 12 15 00 Drift Install the seal ring W001 589 50 33 00 Puller Install and remove the transmission housing ball bearing ...

Page 525: ...ing plate Support the transmission W140 589 06 34 00 Collet Install and remove the transmission housing ball bearing W140 589 13 43 00 Piston puller installer Install and remove the B1 B2 B3 pistons Piston collar nut Install and remove the output shaft collar nut ...

Page 526: ...01 7 3650 01 Part Name Part Number Description 129 589 04 31 00 Straight edge Measure the distance between ball bearing shaft and parking lock gear shaft Compressor Compress the clutch brake discs ...

Page 527: ... 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 bolt...

Page 528: ... from D20DTR engine 4 MJOR CHANGES Torsional damper Introduced Torsion Damper in Torque Converter The torsional damped has been newly installed in the torque converter The torsional damper absorbs the shock vibration and noise when delivering the engine driving force This improves NVH performance in this vehicle ...

Page 529: ... electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting in 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 co...

Page 530: ...01 11 3650 01 Characteristics ...

Page 531: ...01 12 1 Power Flow Sectional View B1 C1 C2 B3 C3 B2 Shifting elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun 2 POWER FLOW ...

Page 532: ...nt planetary gear 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 reducedspeed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with reduced speed Output shaft Clockwise ro...

Page 533: ...ront planetary 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 ...

Page 534: ...r planetary gear 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 535: ...g gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center ring gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring gear direct connection Ou...

Page 536: ...etary gear carrier 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 Cen...

Page 537: ... Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locked by B3 Center planetary gear carrier Counterclockwi...

Page 538: ... T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Front planetary gear carrier Clockwise rotation by clutch C1 activation direct connection Rear ring gear Clockwise rotation Rear planetary gear carrier and center ring gear Locked by brake B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center planetary gear carrier Counterclockwise rotation reduc...

Page 539: ...01 20 3 CIRCUIT DIAGRAM Start Motor Selector Lever CAN Communication ...

Page 540: ...01 21 3650 01 Solenoid Oil temperature sensor Speed sensor N2 N3 ...

Page 541: ... 75W 85 SK Capacity 2 2 ℓ 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 What s the severe conditions 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 Fr...

Page 542: ...ize the performance of D20DTR engine new 6 speed manual transmission has been introduced for 2012 Model Rear Mounting Insulator 2WD 6M T 2WD A T 4WD A T P N 3190021M20 P N 3190021A20 P N 3190021A40 There are three types of rear mounting insulators according to the variations of transmission ...

Page 543: ...seal 3 SPECIAL SERVICE TOOLS Install the main shaft 1st gear sleeve Install the drive pinion assembly front ball bearing Install the main shaft double angular ball bearing Install the main shaft 5th gear sleeve Install the counter shaft 6th gear sleeve Install the counter shaft reverse gear Install the main shaft ball bearing Install the main shaft reverse sleeve and bearing Install the main drive...

Page 544: ...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 545: ...lt 29 4 41 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 42 1 53 9 12EA 11 Concentric slave cylinder bolt 9 8 15 6 3EA 12 Front bearing retainer bolt 19 6 24 5 8E...

Page 546: ... 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 547: ...02 9 3170 01 3162 00 Main shaft ...

Page 548: ...nchronizer 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 Ba...

Page 549: ...gear Bearing 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 550: ...ter 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 551: ...tainer 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 552: ...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 553: ...vent the 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 554: ...sion 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 555: ...02 17 3170 01 1st speed 2 POWER FLOW 2nd speed ...

Page 556: ...02 18 4th speed 3rd speed ...

Page 557: ...02 19 3170 01 6th speed 5th speed ...

Page 558: ...02 20 Reverse gear ...

Page 559: ...02 21 3170 01 Lug arrangement 3 SHIFTING MECHANISM High Force mechanism for reverse gear shift 3rd 4th 1st 2nd R 5th 6th Neutral switch Backup lamp switch Control shaft Control finger ...

Page 560: ... type single diaphragm Diameter of facing Outer Ø250 mm Inner Ø160 mm Numbers of disc 2 Thickness of disc Free 8 7 0 3 mm When loaded 8 0 0 2 mm Setting load of clutch cover assembly At least 7 800 N Clutch master cylinder Operating travel 33 0mm Inner diameter Ø 15 87 Concentric slave cylinder Maximum operating travel Max 20 mm Operating pressure Max 2 200 N Clutch fluid Type DOT 3 or DOT 4 Capac...

Page 561: ...03 4 2 TROUBLESHOOTING ...

Page 562: ...way and measure the pedal stroke A 1 2 3 Stroke A 150 3mm Pedal height B B Stop the engine Remove the floor mat from the driver s footwall Measure the pedal height B 1 2 3 Height B 95 2 3mm Adjustment Release the lock nut D on stopper bolt C Turn the stopper bolt to adjust the pedal height Tighten the lock nut to the specified tightening torque 1 2 3 ...

Page 563: ...ghtly depress the clutch pedal until you feel the resistancefrom the pedal and measure the distance 1 2 3 Free play A 5 15 mm Adjustment Release the lock nut B from the master cylinder Turn the push rod C to adjust the pedal free play Tighten the lock nut to the specified tightening torque 1 2 3 ...

Page 564: ...Clutch pipe and hose Concentric slave cylinder Pressure plate Flywheel If a driver depress the clutch pedal the hydraulic pressure is generated in the master cylinder It is transmitted to the concentric slave cylinder through the pipe resulting in the cylinder being forced out At this time the clutch disc is forced against the cylinder by pushing the cover This in turn remove the flywheel from the...

Page 565: ...ion which activates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out Unlike SAT type SATIC type does not need SST for clutch cover removal Operation Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear Disc wear Free play Diaphragm ...

Page 566: ... shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by ...

Page 567: ...03 10 Clutch cover assembly 3 Layout Clutch disc Dual mass flywheel DMF Concentric slave cylinder T M Input shaft ...

Page 568: ...smission The divided dual masses are connected to the coil spring and damping system internally The DMF has the following benefits Reducing fuel consumption by lowering engine speed Reducing rattling noise and vehicle vibration in all driving ranges Reducing synchronization wear Facilitating gear change Protecting power train parts by preventing excessive load from being delivered Primary flywheel...

Page 569: ... Gear type Hypoid Gear Final gear reduction ratio Engine M T 3 54 Engine A T 4 55 Oil Capacity 1 2L Specification SAE 80W 90 Description Specification Axle shaft type Semi floating Axle housing type Build up Differential Type Conventional type Gear type Hypoid Gear Final gear reduction ratio Engine M T 3 54 Engine A T 4 55 Oil Capacity 1 7L Specification SAE 80W 90 ...

Page 570: ... including oil Oil capacity 1 4L Oil type ATF DEXRON II or III Location Transfer case Major element Housing Part time Bolt 11EA M8 x 1 25 Input shaft A T outer spline Description Specifications Total length 343mm 1 SPECIFICATIONS ...

Page 571: ... components in front axle have been changed according to new transfer case 2 MAJOR CHANGES Adopted New Part Time Transfer Case Side View Rear View New Part Time transfer case has been introduced in 2012 Model Hub assembly Knuckle Front axle shaft Hub actuator ...

Page 572: ...hen selecting 4WD HIGH and 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 ...

Page 573: ... train when the 4WD system is properly working Mode change 2H 4H 2 Wheel drive 4 Wheel drive Shifting is possible while driving at the speed of 70 km h or less 2H 4H 4L 2 Wheel drive 4 Wheel drive high speed 4 Wheel drive low speed To make the mode change easily stop the vehicle on level ground and turn the mode switch to the desired position and move the shift lever to N R N while depressing the ...

Page 574: ...05 7 3240 01 2 LAYOUT Front axle Front locking hub Front propeller shaft Part time transfer case Rear propeller shaft Rear axle ...

Page 575: ...05 8 3 SYSTEM LAYOUT ...

Page 576: ...his system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Booster Operating Process Vacuum pump Vacuum generation process in front hub actuator ...

Page 577: ...hrough it in only one direction This prevent the vacuum from abruptly releasing due to faulty vacuum pump 4WD The vacuum pressure is released from the hub actuator At this time the front hub end gear is engaged 2WD The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear Vacuum solenoid valve To atmosphere Block the vacuum pressure Hub actuat...

Page 578: ...3240 01 5 POWER FLOW Switching 2H 4H 4L 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 579: ...w Output shaft of transmission Rear propeller shaft Rear wheel Rear axle Rear wheel The driving force is directly engaged 1 1 to rear axle and is transferred only to the rear wheels Input shaft of transfer case Output shaft of transfer case ...

Page 580: ...05 13 3240 01 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 581: ...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 582: ...t Front propeller shaft 4WD One universal joint and one CV joint Rear propeller shaft Two universal joint and one CV joint Run out below 0 4 mm Unbalance Max 18g cm 4 500rpm Length of front propeller shaft 4WD A T 531 2 1 0 mm Length of rear propeller shaft 2WD M T 1892 1 2 0 mm A T 1975 1 2 0 mm 4WD A T 1593 1 2 0 mm ...

Page 583: ... 4 Part Number Part Name Description 116 589 09 43 00 P 99 48 003 0A Installer To install the center bearing 129 589 00 34 00 P 99 33 002 0B Pulling arm To remove the center bearing 2 SPECIAL SERVICE TOOL ...

Page 584: ...nding Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration Function of propeller shaft Transmits driving torque Compensates the angle change universal joint CV...

Page 585: ...06 6 Front propeller shaft Components A Flange B CV joint C Universal joint Rear propeller shaft Components A Universal joint B Spline C Center bearing D CV joint E Universal joint ...

Page 586: ...pring type Coil spring Coil spring Shock absorber type Reciprocating cylindrical type gas type Reciprocating cylindrical type gas type Stabilizer bar type Torsion bar type Torsion bar type 2 WHEEL ALIGNMENT Front Wheel Alignment Toe in 2 2 mm 0 4mm Camber 0 0 0 3 Caster 4 5 0 5 Front Wheel Alignment Toe in 0 4 0 08 Camber 0 04 0 08 Caster ...

Page 587: ...ting insulators A have been changed according to newly equipped engine D20DTR It improves the durability and NVH Front Knuckle Assembly Old New The front knuckle assembly has been changed according to new 4WD system Part time T C Hub bearing Locking hub actuator ...

Page 588: ...bilizer Bar Assembly To reduce the rolling effect of vehicle the front stabilizer assembly has been changed Front Shock Absorber Assembly To enhance the riding comfort the coil spring rate and damping force have been changed ...

Page 589: ...07 6 1 Shock Absorber and Coil Spring 4 DIMENSIONS OF FRONT SUSPENSION ...

Page 590: ...6 7 Inner diameter mm D 1 58 3 58 3 D 2 88 3 88 3 Spring identification None Red or Blue Yellow Red or Blue Number of windings 8 49 8 49 Number of active windings 6 99 CVW Curved Vehicle Weight Height mm 256 0 256 0 Weight kg 976 9 4 834 9 4 Stress kg mm 69 53 59 42 Winding direction Clockwise Clockwise ...

Page 591: ...07 8 Shock Absorber Fully extended length 547 0 0 3 mm Fully compressed length 462 0 0 3 mm Operating distance 85 0 mm ...

Page 592: ...nce when compressed and extended Minimum length should be 10 mm longer than the fully compressed length Dimension Maximum operating length Minimum operating length Operating distance 487 0 0 3 mm 326 0 0 3 mm 160 4 mm Marking X Part number Y Lot number Ex 3 C 12 12 Day 3 Month 2003 Year ...

Page 593: ...mber 45110 21000 45110 21000 Spring rate kg mm 12 0 5 12 0 5 Coil diameter mm 15 9 15 9 Inner diameter mm 69 1 69 1 Pitch mm 85 0 85 0 Number of windings 9 55 9 55 Number of active windings 8 35 8 35 CVW Curved Vehicle Weight Height mm 250 250 Weight kg 880 880 Stress kg mm 62 1 62 1 Winding direction Clockwise Clockwise Spring length mm 323 3 323 3 Dimension ...

Page 594: ...y 2 years 1 SPECIFICATIONS Description Specification Front brake Type Ventilated disc Rear brake Type Ventilated disc Master cylinder Type Step feed bore tandem double cylinder Brake booster Type Tandem type integrated level sensor Operating type Foot operated type ...

Page 595: ...08 4 2 SPECIAL SERVICE TOOL Piston Puller Caliper Piston Compressor ...

Page 596: ...lace Dust cover missing Repair 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 ...

Page 597: ...ncorrectly 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 adjuste...

Page 598: ...y foot 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 599: ...er and piston Damage crack and wear on cylinder body and guide pin Uneven wear and oil contamination on pad Damage and tear on boot Scratch and bending on disc plate Pad Thickness Remove the front tire Measure the pad thickness and replace it if it is below the wear limit 1 2 New pad Wear limit 28 0 mm 25 4 mm Brake Disc Thickness New pad Wear limit 10 5 mm 2 mm 4 INSPECTION 1 Front Brake System R...

Page 600: ...easure 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 1 2 Limit 0 03 mm before installation 0 07 mm after installation Disc Run Out ...

Page 601: ...oot Scratch and bending on disc plate Remove the rear tire Measure the pad thickness and replace it if it is below the wear limit 1 2 New pad Wear limit 20 0 mm 18 4 mm Replace the brake pads at both sides as a set Measure the disc thickness at over ten points If any of measured points is below the wear limit replace the brake disc with new one 1 2 New pad Wear limit 10 mm 2 mm 2 Rear Brake System...

Page 602: ... when starting engine with pedal depressed the system is normal If not the system is defective 1 2 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 3 If the above three checks are OK the system is normal If any condition is not met check the valve vacuum hose and brake ...

Page 603: ...n pushing in the plunger If the continuity doesn t exist the stop lamp switch is normal 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 1 2 Type Plunger Pushed Not pushed N C Continuity Not continuity N O Not continuity Continuity ...

Page 604: ...08 13 4850 03 1 COMPONENTS ...

Page 605: ...08 14 ...

Page 606: ...3 1 Front Brake The front brake system uses the ventilated disc and double piston caliper Caliper carrier Pad spring Brake pad Bolt caliper Brake disc Caliper Piston Brake hose Caliper assembly Brake disc Brake pad ...

Page 607: ...08 16 2 Rear Brake Brake Disc Brake disc Lock nut Caliper Brake hose Backing plate Adjusting bolt Brake shoe Lock nut Parking brake operating lever ...

Page 608: ...08 17 4850 03 Caliper Assembly Bolt caliper Caliper Piston Pad spring Caliper carrier Brake pad Caliper assembly Brake pad ...

Page 609: ...08 18 4 Parking Brake Parking Brake Controls Operating lever Return spring lower Shoe holding spring Return spring upper Adjusting bolt Pedal assembly Equalizer assembly ...

Page 610: ...08 19 4850 03 Parking brake switch Release lever Brake damper Pedal assembly Pedal Rear brake cable LH Rear brake cable RH Tension spring Equalizer bolt Equalizer assembly Release cable ...

Page 611: ...or Active type wheel speed sensor Active type wheel speed sensor On each wheel Front air gap 0 335 0 945mm Rear air gap 0 309 0 958 Steering Wheel Angle Sensor N A Maximum angular speed 1500 sec Operating voltage 9 16V Under the steering wheel Sensor Cluster N A Integrated with yaw rate sensor and lateral sensor Under the audio assembly Pressure Sensor N A Analog output Under the master cylinder D...

Page 612: ...ating voltage 9 16V Maximum output current 10mA Maximum detection angle speed 1500 s Operating temperature 30 75 Supplying voltage 9 to 16 V battery voltage Output voltage HI approx 3 50V 3 0 to 4 1V Output voltage LO approx 1 50V 1 3 to 2 0V Description Specification Description Specification Description Specification Supplying voltage approx 5V 4 75 5 25V Output voltage while in stationary appro...

Page 613: ... vehicle stability by applying the braking pressure on each wheel according to the yaw rate lateral sensing value and driver s steering wheel control HBA Hydraulic Brake Assist System Function HBA Hydraulic Brake Assist system helps in an emergency braking situation when the driver applies the brake fast but not with sufficient pressure which leads to dangerously long braking distance ECU recogniz...

Page 614: ...ESP ABS Location 1 HECU O O Under the battery 2 Pressure Sensor O X Under the master cylinder 3 Wheel Speed Sensor O O On wheels 4 Sensor Cluster O X Under the audio assembly 5 Steering Wheel Angle Sensor O X Under the steering wheel Pressure Sensor Installed Removed ...

Page 615: ...09 7 4891 01 1 ESP Indicator 2 Steering Wheel Angle Sensor 3 ESP OFF Switch 4 Sensor Cluster Front Wheel Speed Sensor 4WD 2WD Rear Wheel Speed Sensor ...

Page 616: ...09 8 3 OPERATING PROCESS 1 Block Diagram of Input and Output ...

Page 617: ...side even when the front wheels are slipped outward As the 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 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 du...

Page 618: ...pin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs towards the vehicle cornering direction during oversteer with the yaw rate sensor and lateral sensor Then the ESP system applies the braking force to the front outer wheel to com...

Page 619: ...he steering 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 ...

Page 620: ... pedal is depressed or not depressed during cornering when the ABS is operating and when braking without the ABS It also includes the vehicle conditions when the TCS a part of the ESP system is operating Condition Understeer control Oversteer control Only ESP in operation No braking by driver ESP Normal braking no ABS operation ESP ABS brake ESP ASR ...

Page 621: ... required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the brak...

Page 622: ...ster 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 623: ...vibration that driver senses when the ESP is operating 1 Hydraulic Circuit Diagram When the ESP operates during vehicle movement the ESP warning lamp on the instrument panel flickers and beep comes on every 0 1 seconds The ESP operation shows that the vehicle stability is extremely unstable and it is used to warn the driver The ESP system is just a supplementary system for the vehicle motion and i...

Page 624: ... 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 and the hydraulic circuit will be established by the shuttle valve Then the inlet and outlet valves ...

Page 625: ...e pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the wheel starts to lock the...

Page 626: ...n In this position 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 627: ...heels are locked 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 The shuttle valve and the separation valve do not operate while decompression ...

Page 628: ...e 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 629: ...e 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 630: ...09 22 2 Electric Circuit Diagram Wheel speed sensor Stop lamp switch Self diagnostic connector Warning lamp ABS ESP ...

Page 631: ...09 23 4891 01 Brake Pressure Sensor ESP Sensor Sensor Cluster ESP OFF Switch ...

Page 632: ...t and initial speed when braking starts This also applies for vehicle with ABS where ABS always tries to set an optimum brake force on each wheel As great forces are exerted between the tires and the carriageway when braking even with ABS the wheels may scream and rubber is left on the road With an ABS skid mark one may be able to clearly recognize the tire profile The skid mark of an ABS vehicle ...

Page 633: ...ufficiently 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 ...

Page 634: ... LAYOUT The basic functions of ABS system are same with previous version However the wheel speed sensing type is different from previous version For details about the components refer to Chapter ESP Front Active Wheel Speed Sensor 4WD 2WD ABS HECU Rear Active Wheel Speed Sensor ...

Page 635: ...10 6 3 ABS SYSTEM OPERATION 1 Block Diagram ...

Page 636: ... is higher due to the better use of rear axle braking capability Advantages Elimination of conventional proportioning valve EBD utilizes the existing rear axle wheel speed sensor to monitor rear wheel slip Based on many variables in algorithm a pressure hold increase and or decrease pulsetrain may be triggered at the rear wheels insuring vehicle stability Vehicle approaches the ideal brake force d...

Page 637: ... front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 638: ...s closed The speed of the wheel that hydraulic pressure is delivered reduces gradually No Hydraulic Pressure Circuit when ABS is Operating As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases At this m...

Page 639: ...ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber circulates to...

Page 640: ...10 11 4891 01 3 Circuit Diagram ...

Page 641: ...ameter mm 390 Steering gear box Type Rack and pinion type Steering angle Inner 36 4 Outer 31 5 Steering oil pump Type Vane type Maximum pressure kgf cm2 90 3 Pulley size mm Ø115 Operating temperature 40 150 Steering oil Type S PSF3 Capacity L approx 1 1 Minimum turning radius m 6 08 Tilting angle 3 ...

Page 642: ...r box cross member mounting bolt 7 0 9 0 68 6 88 2 Steering gear box and lower shaft connection bolt 2 5 3 0 24 5 29 4 Tie rod end and knuckle connection nut 3 5 4 5 34 3 44 1 Tie rod end lock nut 6 5 8 0 63 7 78 4 Steering gear box and pressure hose connection nut 3 2 3 8 31 4 37 2 Steering gear box and return line connection nut 3 2 3 8 31 4 37 2 Power steering pump Eye bolt for oil supply pipe ...

Page 643: ...drive 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 ...

Page 644: ...n 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 column...

Page 645: ...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 646: ...heck 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 steering whee...

Page 647: ...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 and noise If the oi...

Page 648: ...e 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 pressure F To prevent ...

Page 649: ...fully 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 650: ...11 12 1 SYSTEM LAYOUT ...

Page 651: ...Tire 16 inch 225 65R16 Tire inflation pressure 35psi Wheel 16 inch 6 5J 16 Balance weight Inner Clip on type Outer Clip on type Tightening torquse of wheel bolt 127 4 156 8 Nm 2 WHEEL DESIGNS 16 inch 225 65R 16 16 inch 225 65R 16 2WD 6 5J 16 P TIME 6 5J 16 ...

Page 652: ...according to the driver s driving habit improper servicing low tire inflation pressure changed tire location etc 1 Structure of Tire Tread This thick layer of rubber provides the interface between the tire and the road Wear resistant rubber is used to protect the carcass and belt against fractures and impacts and to deliver a long driving life Shoulder Located between the tread and sidewall the sh...

Page 653: ...es the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly resulting in increased life 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 is excessive so a lot of heat is generated and the tire is worn...

Page 654: ...be blown out in 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...

Page 655: ...t with the road surface but rotate floating 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 2 Hydro Planing ...

Page 656: ...lance 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 2 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 a if tw...

Page 657: ... AND COMPONENTS Type Air cindotioner controller FATC Manual air conditioner It change sun load coming through front windshield into current to input to FATC controller Air mix door actuator PTC If equipped Duct temperature sensor Mode door actuator Air conditioner wiring Thermo AMP Air source door actuator Air conditioner filter Bloewr motor Blower high speed relay Power transistor ...

Page 658: ...ature and high pressure liquid refrigerant Condenses high temperature and high pressure vapor refrigerant into low temperature high pressure liquid refrigerant Detects A C AUTO switch position coolant temperature engine condition and driving condition to control the air conditioner A sensor that detects coolant temperature and transmits to engine ECU Blower motor Power transistor Air conditoner hi...

Page 659: ...01 4 1 Ventilation System 1 Location of Vents Front Ventilation Rear Ventilation A C vents Heater vents ...

Page 660: ...01 5 6810 30 2 Ventilation Modes Vent mode Bi level mode Floor mode Defrost and floor mode Defrost mode Rear air conditioning mode ...

Page 661: ... CONDITIONER MODULE WIRING AND LAYOUT 1 Front Air Conditioner Module Air source selection door actuator Air conditioner filter Evaporator Blower motor Blower high speed relay Heater core Wiring layout Components ...

Page 662: ...10 30 2 Rear Air Conditioner Module Roof air conditioner duct Blower motor Evaporator Mixer door Heater core Air mixer door actuator Rear floor heater duct Heater air conditioner pipes Wiring layout Components ...

Page 663: ...conds Engine speed below 650 rpm Maximum output due to abrupt acceleration Excessive acceleration Increased load during engine idling to prevent the engine from shutting off Refrigerant pressure over 32 bar or below 2 bar Defects in A C related system refrigerant pressure sensor coolant temperature sensor cooling fan 1 2 3 4 5 6 7 8 ...

Page 664: ...01 9 6810 30 3 CIRCUIT DIAGRAM 1 FATC Full Auto Temperature Control D20DTR PWM Motor Coolant Fan SUB relay ...

Page 665: ...01 10 GSL 3 2 Condenssor Fan Relay ...

Page 666: ...01 11 6810 30 Front Blower Motor Mode Circulation In car Sensor Ambient AQS Sensor ...

Page 667: ...01 12 Rear Air Conditioner Blower Mode Actuator ...

Page 668: ...01 13 6810 30 2 Manual Air Conditioner D20DTR Motor Mode Intake Air Mix PWM ...

Page 669: ...01 14 GSL 3 2 Condenssor Fan Motor ...

Page 670: ...01 15 6810 30 Blower Motor Front Rear Rear Mode Actuator ...

Page 671: ...G Impact record Diagnostic Trouble Code Description Specification 3 point seat belt Limited load type by stopper length of webbing 3 200 mm Height adjuster Side button type stroke 25 mm x 3 steps 75 mm Pre tensioner optional Retract distance over 120 mm Retracting time 8 to 12 ms Slide button type Retracting tension 2 to 3 2 kN Spool out limit below 50 mm Seat belt warning lamp driver s Buckle Swi...

Page 672: ... seat belt Retracting distance over 120 mm Retracting time 8 to 12 ms Retracting tension 2 to 3 2 kN Spool out limit below 50 mm Buckle for ELR Buckle for fixed type belt ELR type Webbing type Fixed type Webbing and floor type Description Specification Remark 11 seaters 3 point seat belt LH RH ELR Fixed type seat belt Center seat belt Fool proof type Length of webbing 3 200 mm 3 point Buckle for E...

Page 673: ... or rear impact If the severity of impact to the vehicle is not significant and the seat belts are enough to protect occupants Air bag seldom inflates when Oblique impact rollover Weak impact in which the sensor is unable to detect under the inflation requirements Impact against narrow objects such as a utility pole or a tree The vehicle falls into a drainage or a puddle The front of the vehicle c...

Page 674: ... cause injuries The air bag system must be disposed only by Ssangyong Dealer or Ssangyong Authorized Service Operation Replace the steering wheel with only Ssangyong genuine part When the engine starts the air bag warning lamp comes on for a system check It goes out after 3 to 7 seconds when the system is normal If this warning lamp stays ON then the system may be defective Have the air bag system...

Page 675: ...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 gas When the air bag is deployed non toxic gas will come out This gas may cause skin eye...

Page 676: ...02 8 Height Adjuster Front Seat Belt Passenger s Air Bag Air Bag Unit Belt Type Buckle Foxed Type Buckle Driver s Air Bag 1 LAYOUT Front Seat 1 Components Driver s Passenger s ...

Page 677: ...nsioner Driver s Passenger s Seat Belt 2 point for rear 1st row seat swivelled Center Seat in Rear 1st Row Seat Center Seat in Rear 2nd Row Seat Center Seat in Rear 3rd Row Seat Rear 1st Row Seat Rear 2nd Row Seat Rear 3rd Row Seat ...

Page 678: ...02 10 Front Seat 3 point Rear 1st Row Seat 3 point 2 point Rear 2nd Row Seat 3 point 2 point Rear 3rd Row Seat 3 point 2 point 2 Seat Belt Arrangement ...

Page 679: ...02 11 8810 03 2 CIRCUIT DIAGRAM ...

Page 680: ... Seat warmer switch Back flat adjust lever 1 LAYOUT AND COMPONENTS 1 Components of Seat Seat Control Switch Driver s Seat Seat position control Seat height control Reclining control Back supporter Driver s seat Sliding control ...

Page 681: ...03 3 7410 01 Seat sliding adjust lever Seat swivel control lever Rear 3rd Row Seatback Folding Lever Headrest Back folding adjust lever ...

Page 682: ...03 4 Rear 1st row 3 point 2 point Rear 2nd row 3 point 2 point Rear 3rd row 3 point 2 point Front Seat Belt 3 point 2 COMPOSITIONS OF SEAT BELT 1 11 Passengers ...

Page 683: ...03 5 7410 01 2 9 Passengers Front Seat Belt 3 point Rear 1st row 3 point Rear 2nd row 3 point Rear 3rd row 3 point 2 point ...

Page 684: ...03 6 3 7 Passengers Front Seat Belt 3 point Rear 2nd row 3 point 2 point Rear 1st row 3 point ...

Page 685: ...03 7 7410 01 3 SEAT LAYOUT 1 Layout 11 Passengers Front seat Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed ...

Page 686: ...03 8 2 Layout 9 Passengers Front seat Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed ...

Page 687: ...03 9 7410 01 3 Layout 7 Passengers ...

Page 688: ...to the far front Back semi full flat Rear 1st seat Move to the far end Rear 2nd seat Move to the far end Rear 3rd seat Fixed Front seat Move 36 mm from the far end to the front Rear 1st seat Move to the far front Remove head rest Back full flat Rear 2nd seat Move to the far end Back semi full flat Rear 3rd seat Fixed ...

Page 689: ...at back folding while driving Rear 1st seat Move to the far end Center seat jumping Swiveled Rear 2nd seat Move to the far end Rear 3rd seat Fixed Rear 1st seat Move to the far end Center seat jumping Swiveled Rear 2nd seat Move to the far end Back folding Rear 3rd seat Fixed ...

Page 690: ...sengers with loading Front seat Move to the far front Rear 1st seat Middle Center seat jumping Swiveled Rear 2nd seat Middle Back folding Rear 3rd seat Fixed Front seat Move 36 mm from the far end to the front Rear 1st seat Middle Rear 2nd seat Middle Rear 3rd seat Double folding ...

Page 691: ...eat Move 36 mm from the far end to the front Rear 1st seat Move to the far end Rear 2nd seat Middle Rear 3rd seat Double folding Front seat Move to the far end Back folding Rear 1st seat Middle Back folding Rear 2nd seat Middle Back folding Rear 3rd seat Middle Back folding ...

Page 692: ...03 14 5 Entry Way Rear 1st seat Folding center seat Rear 2nd seat Folding center seat Rear 3rd seat Fixed ...

Page 693: ...03 15 7410 01 6 Sliding of Rear 1st and 2nd Seat 4 rail 1 610mm for rear 1st and 2nd seat sliding Rail mounting Floor bolt type ...

Page 694: ... in this chapter are based on the driver s seat and rear 1st seat 1 Components Seat warmer connector Seat position up down motor Seat position up down rail Seat position rear up down motor Seat position front up down rail Sliding rail Sliding motor Reclining motor ...

Page 695: ...eat moves up down controlled by seat position control switch 2 Operation of seat Sliding Seat moves from front to rear controllde by sliding control switch Seat cushion angle adjustment front end Rear side of seat moves up down controlled by seat position control switch ...

Page 696: ...03 18 Seat cushion height adjustment Seat moves up down controlled by seat height control switch Seatback reclining Seat back reclining controlled by seat reclining control switch ...

Page 697: ...03 19 7410 01 When seating When jumping 3 Operation of center seat Pull up the center seat when to jump Push down the center seat when to seat ...

Page 698: ...03 20 4 OPERATION OF REAR SEAT Rear 1st seat swivel seat Jumping mechanism Seat back folding cable Seat back flat cable Sliding cable Swivel lever Sliding lever ...

Page 699: ...03 21 7410 01 5 Operation of rear seat Rear 1st and 2nd seat Seat sliding Front Rear ...

Page 700: ...03 22 Rear 1st 2nd seat Rear 2nd Rear 1st 6 Seat back flat When to recline or to flat fully 7 Seat back folding Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table ...

Page 701: ...0 01 8 Seat swing Rear 1st seat Turn around seat as the swing lever is pulled As the seat is folded disconnect hook and spread out the board 9 Rear 3rd seat Pull the lever behind back seat to fold the back seat ...

Page 702: ...04 3 7340 01 1 SUNROOF LAYOUT ...

Page 703: ...04 4 2 COMPONENTS OF SUNROOF ...

Page 704: ...04 5 7340 01 Drain hose Control switch Sun shade glass Control unit Sun roof motor 3 COMPONENTS AND LOCATIONS ...

Page 705: ... front side of the button when the glass is closed then mtor actuate the operating cable to lift up the glass Push the rear side of the button to put down the glass Motor actuates the operating cable Mechanical equipment lifts up down the glass ...

Page 706: ...04 7 7340 01 2 Sliding push the rear side of the button to slide the door back Motor actuates the operating cable Mechanical equipment slides the glass back and forth ...

Page 707: ...04 8 5 CIRCUIT DIAGRAM ...

Page 708: ...05 3 7630 01 1 BODY INTERIOR 1 Storage Boxes Overhead console Front door map pocket Center console Glove box CD carrier Coin box Seatback pocket ...

Page 709: ...05 4 2 Convenient Devices Ticket holder Seatback table Power outlet Rear cup holders Tea table Power outlets Front cigarette lighter Front cup holder ...

Page 710: ...05 5 7630 01 3 Assist Grips 1 On passenger side ceiling 2 On B pillar 3 On ceiling above rear seats Above rear 1st seat Above rear 2nd seat ...

Page 711: ...05 6 The OVM tool box is located under the floor in luggage compartment OVM Tools 4 OVM Tools ...

Page 712: ...06 3 7870 01 Outside Rearview Mirror Front Bumper Assembly 1 LAYOUT AND COMPONENTS Hood Assembly Roof Rack Front Door Rear Door ...

Page 713: ...06 4 Tailgate Rear Bumper Assembly Rear Spoiler Sunroof Assembly ...

Page 714: ...07 3 5110 01 Top View Side View Front View Rear View 1 MAJOR EXTERNAL DIMENSIONS ...

Page 715: ...07 4 2 JACK POINTS Rear jack point Front jack point Be sure to lift the vehicle only on the designated jack point otherwise the vehicle could be body damaged ...

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