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SSANGYONG Rodius 2013, Manual

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Summary of Contents for Rodius 2013

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

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

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

Page 121: ... Visual VIN Label Engine Number Gasoline Engine The engine number is stamped on the lower area of cylinder block in exhaust manifold side VIN Number The VIN number is stamped on the floor under the passenger s mat 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...

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Page 139: ...03 3 0000 00 1 GLOSSARY ...

Page 140: ...03 4 ...

Page 141: ...03 5 0000 00 ...

Page 142: ...03 6 ...

Page 143: ...03 7 0000 00 ...

Page 144: ...03 8 ...

Page 145: ...03 9 0000 00 ...

Page 146: ...03 10 ...

Page 147: ...01 3 0000 00 Left view Right view Rear view Front view 1 ENGINE LAYOUT ...

Page 148: ...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 149: ...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 150: ...oil 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 ...

Page 151: ...ortened under severe conditions Coolant Inspection Change every 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 Fuel filter EU Change every 40 000 km Draining water from fuel filter whenever replacing ...

Page 152: ...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 153: ... 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 154: ...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 155: ...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 156: ... 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 157: ...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 158: ...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 159: ...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 160: ...er 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 NOT EQUIPPED Select ABS or ESP ABS TCS ESP SSPS 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 TPMS NO Select NO YES ...

Page 161: ...edan RV Select Sedan RV Limousine Vehicle code Platform Rodius Select Rodius Rexton Korando C Kyron Korando Sport Vehicle code Engine D32DT Select D20DTR D27DT D27DTP D20DTR ECU coding status ECU not coded Select ECU coded ECU coded Signal not valid Not defind ...

Page 162: ...aust 1 09 mm Valve recess Intake 0 6 to 1 0 mm Exhaust 0 6 to 1 0 mm 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 Inta...

Page 163: ...02 4 2 MAJOR CHANGES Rear Engine Mounting Insulator for 4WD Design changed for reducing abnormal noise during driving ...

Page 164: ...r bolt 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...

Page 165: ... 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 25 2 ...

Page 166: ...pressure 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 ...

Page 167: ...ket 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 tool...

Page 168: ... type 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...

Page 169: ...02 10 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 170: ...urize 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 o...

Page 171: ...e 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 the ...

Page 172: ...m Do 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 ...

Page 173: ...essories 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 174: ...iability 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 175: ...rease 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 176: ...ust 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 177: ... 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 boo...

Page 178: ...02 19 0000 00 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 179: ...T 4WD A T 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 180: ...ing 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 181: ... 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 182: ...D COVER 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 183: ... 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 184: ...ontains 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 185: ... 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 186: ...st gears 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 187: ...earance 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 188: ...rofile 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 189: ...t 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 oil ...

Page 190: ...hydraulic 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...

Page 191: ... 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 Check ...

Page 192: ...he guide 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 g...

Page 193: ...02 34 Screw plug Oil seal Timing gear case cover Timing gear case cover TGCC 5 Timing gear case cover ...

Page 194: ...al and 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 195: ...02 36 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 196: ...ing 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 197: ...ansaxle 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 by re...

Page 198: ...ch range 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 mo...

Page 199: ...02 40 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 200: ...and 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 201: ...inder 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 the ri...

Page 202: ...Selecting 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 203: ...he 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 204: ... 815 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 c...

Page 205: ... 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 206: ...Selection 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 207: ...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 208: ...02 49 0000 00 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 209: ... 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 cros...

Page 210: ...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 F...

Page 211: ...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 212: ...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 213: ...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 214: ... 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 215: ...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 216: ...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 217: ...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 218: ...03 11 2210 01 4 Fuel System Check Procedure ...

Page 219: ...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 220: ...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 221: ... 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 222: ...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 223: ...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 224: ... 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 225: ...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 226: ...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 227: ... 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 228: ...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 229: ...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 230: ... to injectors 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 High pressure pump Generating high pressurized fuel and supplying it according to engine rpm required volume required pressure ...

Page 231: ...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 232: ...03 25 2210 01 3 Input Output devices Refer to Chapter Engine Control ...

Page 233: ...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 234: ...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 235: ...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 236: ...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 237: ...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 238: ... 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 239: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM For more information refer to Chapter Engine Control ...

Page 240: ...04 9 1719 00 4 OPERATING PROCESS Work Flow ...

Page 241: ...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 242: ...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 243: ...sembly 1 MAJOR CHANGES Muffler assembly parts A B changed due to change of rear subframe A Connecting pipe between muffler and tail silencer moved by 20 mm B Gap between tail silencer pipe and body changed from 16 mm to 25 mm ...

Page 244: ...05 4 2 TROUBLESHOOTING 1 Work Flow ...

Page 245: ... the 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 v...

Page 246: ...y 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 247: ...05 7 1729 01 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 248: ...ocharger 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 E VGT turbocharger Plate Impeller Turbine Unison ring Turbine housing Compressor housing E VGT actuator ...

Page 249: ...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 250: ...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 251: ...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 252: ...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 253: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 254: ...06 9 1914 01 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 255: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 256: ...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 257: ...06 12 2 Work Flow for Troubleshooting ...

Page 258: ...06 13 1914 01 ...

Page 259: ...06 14 ...

Page 260: ...06 15 1914 01 ...

Page 261: ...06 16 ...

Page 262: ...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 263: ... 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 264: ...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 T MAP sensor Improves the engine power HFM sensor Booster pressure and temperature ...

Page 265: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 266: ...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 267: ...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 268: ...vice 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 Service interval EU Change every 20 000 km or 12 month...

Page 269: ...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 270: ...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 271: ...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 272: ... type Cross flow Antifreeze Type SYC1025 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 273: ...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 274: ... 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 275: ...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 276: ...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 277: ...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 278: ... 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 MT 400W AT 600W ...

Page 279: ...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 280: ...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 281: ...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 282: ...09 6 3 Checking Battery ...

Page 283: ...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 284: ...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 285: ...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 286: ...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 287: ...09 11 1451 01 2 OPERATING PROCESS 1 Charging Flow ...

Page 288: ...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 289: ...09 13 1451 01 3 CIRCUIT DIAGRAM ...

Page 290: ...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 291: ...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 292: ...10 5 1413 00 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 293: ...10 6 3 Circuit Diagram ...

Page 294: ...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 295: ...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 296: ...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 297: ...10 10 5 Pre glow and Post glow This shows the pre glow and post glow step as a chart ...

Page 298: ... 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 299: ... 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 300: ...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 301: ...11 6 2 Circuit Diagram ...

Page 302: ... vehicle speed must be greater than 36 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 303: ...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 roads 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 The described speed value may vary slightly depending on the road conditions ...

Page 304: ...ne switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an accelerator pedal intervention during the cruise control running 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 result in collision...

Page 305: ...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 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 306: ...ruise control lever and hold it 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 Push down the DECEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control syst...

Page 307: ...oward the cruise control lever when the current vehicle 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 The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 308: ...e cruise control When the brake pedal is depressed When the cruising speed is downed less than 38 km h When the OFF switch is operated by pulling the cruise control lever Type A or by pushing the ON OFF switch of the cruise control lever Type B When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be op...

Page 309: ...yong Dealer for diagnosis of the cruise control system Abnormal changes of the gear selector lever can damage the engine Do not move the gear shift lever to Neutral while driving at the set speed Automatic transmission damage may result The speed that has been set may not be maintained on uphill or downhill slopes The speed may drop to less than the set speed on a steep uphill grade The accelerato...

Page 310: ... 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 311: ...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 312: ...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 313: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 314: ...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 315: ...ot 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 traffi...

Page 316: ... 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 accumulated ash...

Page 317: ...of DPF 4 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 318: ...ss 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 the CDPF is...

Page 319: ...ody using a oxidation reaction the DPF collects the PF Particulate Material for regeneration of it However each of these devices can only reduce a part of the exhaust gas This evoked the necessity of the CDPF with both features The DOC capacity is more on the manual transmission than the automatic transmission DOC Diesel Oxidation Catalyst It is called as a oxidation catalyst which purifies CO and...

Page 320: ...14 8 ...

Page 321: ...sure 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 322: ...erature 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 valve...

Page 323: ...as is 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...

Page 324: ...d 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 mass...

Page 325: ...s temperature 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 thro...

Page 326: ... 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 327: ...nters 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...

Page 328: ...st 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 temperature...

Page 329: ... 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 are not pe...

Page 330: ...14 18 6 CIRCUIT DIAGRAM ...

Page 331: ... 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 Knocking ...

Page 332: ...15 4 Oxygen Sensor Glow Plug 1 MAJOR COMPONENTS HFM Air mass Temperature Injector C3I IMV E VGT Actuator ...

Page 333: ...15 5 0000 00 GCU Glow Plug Control Unit EGR Bypass Valve EGR Valve Electric Throttle Body Water Sensor Variable Swirl Valve Actuator ...

Page 334: ...15 6 Fuel Rail Pressure Sensor Front EGT Sensor Differential Pressure Sensor Camshaft Position Sensor Rear EGT Sensor ...

Page 335: ...15 7 0000 00 Fuel Temperature Sensor Coolant Temperature Sensor Knock Sensor 2 T MAP Sensor D20DTR ECU ...

Page 336: ...15 8 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 337: ...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 338: ...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 339: ...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 340: ...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 341: ...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 342: ...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 343: ...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 344: ... 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 345: ...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 346: ... 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 347: ...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 348: ...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 349: ...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 350: ...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 351: ...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 352: ...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 353: ...15 25 0000 00 B Input Output for variable swirl valve ...

Page 354: ...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 355: ... 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 356: ... 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 357: ...15 29 0000 00 C Input Output of E EGR system ...

Page 358: ...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 359: ...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 360: ...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 361: ...15 33 0000 00 C Input Output for E VGT system ...

Page 362: ...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 363: ... 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 364: ...15 36 C Input Output for oxygen sensor ...

Page 365: ...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 366: ...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 367: ...15 39 0000 00 C Input Output for cooling fan and A C compressor ...

Page 368: ...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 369: ...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 370: ...M sensor This device 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 ...

Page 371: ...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 372: ...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 373: ...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 374: ...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 375: ...15 47 0000 00 C Input Output for CDPF control ...

Page 376: ...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 377: ...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 378: ...15 50 3 Input Output for CAN communication ...

Page 379: ...01 4 1 COMPONENT LOCATOR 1 Front View ...

Page 380: ... 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 381: ...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 382: ...installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equ...

Page 383: ...02 3 1113 01 1 SPECIFICATIONS 1 Engine Specifications ...

Page 384: ...02 4 2 Performance Curve ...

Page 385: ...02 5 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 386: ...02 6 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 387: ...02 7 1113 01 1 Fastener Tightening Specifications Cont d ...

Page 388: ...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 389: ...03 4 Temperature vs resistance ...

Page 390: ......

Page 391: ...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 392: ...05 4 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 393: ...06 3 9210 01 1 OIL CIRCULATION ...

Page 394: ...y 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 o...

Page 395: ...07 3 2110 01 1 GENERAL SPECIFICATIONS ...

Page 396: ...07 4 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 397: ...07 5 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 398: ...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 399: ...07 7 2110 01 2 COMPONENT LOCATOR ...

Page 400: ...eces 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 reservoir tank Clamp Clamp Make up hose holder Reservoir 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 401: ...08 3 1452 01 1 GENERAL SPECIFICATIONS ...

Page 402: ...08 4 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 403: ...rms 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 one half charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted by t...

Page 404: ...es 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 s...

Page 405: ...08 7 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 406: ...09 3 1522 16 1 ENGINE DATA DISPLAY TABLE ...

Page 407: ...09 4 2 FASTENER TIGHTENING SPECIFICATIONS 1 Temperature vs Resistance ...

Page 408: ... vehicle speed must be greater than 36 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 409: ...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 roads 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 The described speed value may vary slightly depending on the road conditions ...

Page 410: ...ne switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed And you can set to other vehicle speeds again with above steps after an accelerator pedal intervention during the cruise control running 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 result in collision...

Page 411: ...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 4 3 Tap up while the cruise control system is running Push up the ACCEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control system is running This is a tap up switching When you operate a tap up s...

Page 412: ...ruise control lever and hold it 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 Push down the DECEL switch of the cruise control lever less than 0 5 second per one switching while the cruise control syst...

Page 413: ...oward the cruise control lever when the current vehicle 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 The resume position should only be used if the driver is fully aware of this speed and wishes to resume this particular speed ...

Page 414: ...e cruise control When the brake pedal is depressed When the cruising speed is downed less than 38 km h When the OFF switch is operated by pulling the cruise control lever Type A or by pushing the ON OFF switch of the cruise control lever Type B When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be op...

Page 415: ...yong Dealer for diagnosis of the cruise control system Abnormal changes of the gear selector lever can damage the engine Do not move the gear shift lever to Neutral while driving at the set speed Automatic transmission damage may result The speed that has been set may not be maintained on uphill or downhill slopes The speed may drop to less than the set speed on a steep uphill grade The accelerato...

Page 416: ...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 417: ...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 418: ...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 419: ...01 6 3 MAJOR CHANGES Interior fuse and relay box Heated steering wheel added Voltage stabilizer module added ...

Page 420: ...EW The 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 8 3 CIRCUIT DIAGRAM SB1 SB4 C FAN HI LO REALY F HEATER RELAY 1 Engine Room Fuse and Relay Box ...

Page 422: ...01 9 8410 02 SB5 SB8 Ef5 Ef6 2ND A PUMP RELAY ENG MAIN RELAY START RELAY ...

Page 423: ...01 10 SB9 SB11 Ef10 Ef23 RR BLOWER RELAY DEFOGGER RELAY ...

Page 424: ...01 11 8410 02 Ef2 Ef4 Ef19 Ef20 B HORN RELAY H LAMP LO HI RELAY COMP RELAY ...

Page 425: ...01 12 Ef7 Ef9 Ef21 FRT FOG LAMP RELAY TAIL LAMP RELAY ...

Page 426: ...01 13 8410 02 Ef11 Ef16 POWER WINDOW RELAY ...

Page 427: ...01 14 Ef17 Ef18 Ef22 Ef24 Ef26 FUEL PUMP RELAY ...

Page 428: ...01 15 8410 02 2 Interior Fuse and Relay Box F1 F5 ...

Page 429: ...01 16 F6 F12 ...

Page 430: ...01 17 8410 02 F13 F16 ...

Page 431: ...01 18 F17 F24 ...

Page 432: ...01 19 8410 02 F25 F30 ...

Page 433: ...01 20 F31 F36 ...

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

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: ...r 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 Door SW lamp door courtesy g handle door open warning lamp defogger ...

Page 475: ...02 44 Central door lock ...

Page 476: ...02 45 8710 01 Wiper rain sensing wiper ...

Page 477: ...amage the system starting will be impossible so never attempt to remove damage or modify it The remote engine starter cannot be installed to the vehicle equipped with the immobilizer system Do not drop or shock to the transponder in the ignition key as it may be damaged With a damaged transponder the engine cannot be started For the vehicle with the immobilizer there can be a problem in starting t...

Page 478: ...03 4 1 SYSTEM LAYOUT 1 Location Immobilizer Warning Lamp Immobilizer Unit ECU REKES Key Diagnostic Connector ...

Page 479: ...5 7010 06 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 480: ...er 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 481: ......

Page 482: ...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 483: ...ponder 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 ca...

Page 484: ...03 10 2 Circuit Diagram ...

Page 485: ...5V Operating temperature Standard 30 C 75 C while driving Black face 30 C 80 C Storage temperature 40 C 85 C Performance guarantee voltage DC 10V 15V Dark current Standard below 3mA 12V 25 C Stabilized conditions standby mode around 180 seconds after IGN OFF Black face below 1mA 12V 25 C Stabilized conditions standby mode around 180 seconds after IGN OFF ...

Page 486: ...uty 1 3 Bias 1 Standard 2 Black face Description Specification LCD display type Speedometer segment LCD display Specification Selective display TRIP A TRIP B Driving time Average speed Average fuel economy Distance to empty Illumination control Constant display Odometer Instant fuel economy Gear selector lever position ...

Page 487: ...04 5 8010 01 Warning box Warning box introduced Instrument cluster Black face cluster introduced 2 MAJOR CHANGES Warning indicator lamp LCD screen ...

Page 488: ... 6 Warning Box Standard Black face Cluster Standard Black face TRIP switch 2 LAYOUT 1 OVERVIEW The instrument cluster for this vehicle consists of the Meter cluster and the Warning lamp Indicator cluster ...

Page 489: ...Turn signal lamp 2 21W Position lamp 2 5W Front fog lamp 2 H16 Side repeater 2 5W Rear combination lamp Tail stop lamp 4 5W 21W Turn signal lamp 2 21W Back up lamp 2 16W Rear fog lamp 2 21W License plate lamp 2 5W High mounted stop lamp 5 5W Interior lamp Front room lamp 2 5W Glove box lamp 1 5W Door courtesy lamp 4 5W Side room lamp 4 5W Rear room lamp 1 5W ...

Page 490: ...nction changed 2 MAJOR CHANGES 1 Exterior Lamp Front view Headlamp Tail lamp 12V 5W Turn signal lamp 12V 28W Low beam 12V 55W High beam 12V 55W Low beam H7 55W Tail lamp W5W Turn signal lamp P21W High beam DRL EU 55W 15W GEN 55W Front fog lamp Headlamp Front fog lamp ...

Page 491: ...lamp Reflex reflector lamp Turn signal lamp 12V 27W Stop lamp 12V 8W Tail lamp 12V 8W Turn signal lamp PY21W Stop lamp and tail lamp P21 5W High mounted stop lamp Rear combination lamp Reflex reflector lamp Rear fog lamp High mounted stop lamp High mounted stop lamp design changed due to spoiler modification ...

Page 492: ...ate Combination Lamp Design changed Side view Backup lamp Stop lamp and tail lamp P21 5W Backup lamp W16W Reflex reflector lamp Rear fog lamp Design change due to changed rear bumper Side repeater lamp design changed ...

Page 493: ... H16 WY5W DRL Day Time Running Light The day time running lamp DRL comes on when starting the engine without intervention of light switch It goes out when turning on the headlamp low beam DRL is optional only for EU market Low beam H7 55W Tail lamp W5W Turn signal lamp P21W High beam DRL EU 55W 15W GEN 55W ...

Page 494: ...ear tailgate combination lamp Rear side High mounted stop lamp License plate lamp Reflex reflector lamp Rear fog lamp Stop tail lamp P21 5W Turn signal indicator PY21W Stop tail lamp P21 5W Backup lamp W16 12V 5W 5EA 12V 5W 1 on each side ...

Page 495: ...07 9 8310 01 2 CONFIGURATION FOR INTERIOR LAMP Front room lamp Glove box lamp Side rear 1st row and 2nd row room lamp Door courtesy lamp Rear room lamp Center console rear lamp ...

Page 496: ...07 10 3 CIRCUIT DIAGRAM 1 Interior Lamp ...

Page 497: ...07 11 8310 01 2 External Lamp 1 Head lamp DRL day time running light unit ...

Page 498: ...07 12 2 Head lamp leveling device ...

Page 499: ...07 13 8310 01 3 Tail lamp ...

Page 500: ...07 15 8310 01 5 Fog lamp ...

Page 501: ...07 14 4 Turn signal hazard lamp ...

Page 502: ...07 16 6 Stop back up lamp ...

Page 503: ...Driver front passenger seat warmer switch Fog lamp switch 2 4WD Switch HLLD Switch Rear Wiper Operation Switch Item Specifications 4WD switch HLLD switch rear wiper operation switch assembly Washer switch DC 12 V 3 8 A lamp load Wiper switch DC 12 V 3 0 A max 10 A 4WD switch DC 12 V 300 mA HLLD switch DC 12 V 1 A inductive load 3 Steering Wheel Switch Item Specifications Steering wheel switch Rate...

Page 504: ...Light switch ON 1A Relay load Dimmer and passing switch High beam low beam passing 0 3 A Relay load Turn signal switch 6 6 0 5 A Lamp load Wiper switch Low 5 A Motor load High 7 A Motor load Auto 0 22 0 05 A Relay load Fixed max 28 A Motor load Washer switch 4 A Motor load Intermittent wiper switch max 25 mA Mist switch 5 A Motor load ...

Page 505: ...ng wheel switch assembly Power button deleted steering wheel heating option switch added Design changed Multifunction switch assembly Connector pin layout changed due to newly added steering wheel heating option circuit Contact coil and steering wheel angle sensor changed ...

Page 506: ...06 6 Overhead console switch Multimeter function deleted maintain digital clock Digital clock ...

Page 507: ......

Page 508: ...ing Wheel Angle Sensor 4WD Switch Headlamp Leveling Switch Rear Wiper Switch 1 LAYOUT Seek button Volume button Manual gear shift down switch Manual gear shift up switch Mode button Bluetooth handsfree Steering wheel heating switch With audio OFF press the MUTE button briefly to switch on With audio ON press and hold the MUTE button to switch off MUTE button ...

Page 509: ...console switch Auto light sensor Cigarette lighter Power outlet socket Driver s seat warmer switch Rear fog lamp switch ESP OFF switch Defogger switch Passenger s seat warmer switch Front fog lamp switch Front room lamp switch Sunroof switch Door coupled room lamp switch Hazard warning flasher switch ...

Page 510: ...07 3 7810 01 1 SPECIFICATIONS OF WIPER ...

Page 511: ... 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 512: ...ate Front wiper blade Before Conventional type driver 600 mm front passenger 450 mm After Aero blade type driver 600 mm front passenger 450 mm 3 MAJOR CHANGES IN WIPER RAIN SENSOR SYSTEM Front view Rear view Rear wiper blade Wiper arm design changed no change in wiper blade dimension ...

Page 513: ...07 6 1 SYSTEM LAYOUT Components ...

Page 514: ...07 7 7810 01 2 CIRCUIT DIAGRAM ...

Page 515: ...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 516: ...T Low Relay6 Wiper High STICS The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS and STICS drives the wiper directly At this moment STICS determines the wiper operation mode washer MIST AUTO then sends the information to the rain sensor ...

Page 517: ...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 518: ...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 519: ...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 520: ...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 521: ... 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 522: ...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 523: ...osition 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 receiving the ground fixed or IGN fixed signal from the rain sensor 3 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal 2 from the rain sensor while the ign...

Page 524: ...08 12 3 OPERATION MODE OF RAIN SENSING WIPER SYSTEM ...

Page 525: ... 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 526: ...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 527: ...08 15 8610 11 5 DIAGNOSIS PROCEDURES ...

Page 528: ...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 STICS drives 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 529: ...08 17 8610 11 7 RAIN SENSING WIPER ...

Page 530: ...emperature 30 80 Maximum humidity 95 High internal pressure 24 V Insulation resistance No heat fire due to current leak Max permissible current Unit 100 mA or less Sensor 35 mA or less PAS sensor Operating frequency 58 KHz Detection range 30 cm 120 cm based on lineal distance between sensor and obstacle Tolerance 10 cm Operating voltage range DC 8 V ...

Page 531: ...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 532: ...0 01 PAS sensor Operating frequency changed 40 KHz 58 KHz and sensor appearance and connector changed insert type 3 Major changes for PAS unit PAS unit Detection range changed from 25 cm 120 cm to 30 cm 120 cm ...

Page 533: ...he driver with alarm sounds when the vehicle is moving backward The system emits the ultrasonic wave signals from the sensors on the rear bumper with a specific interval and detects the reflected signals from obstacles The alarm interval becomes shorter as the obstacle approaches to assure the safety distance and to facilitate parking of the vehicle 2 Layout ICM box Buzzer integrated into ICM box ...

Page 534: ...tion of PAS sensor Rear obstacle detection sensor 3 off Activated for reverse driving only PAS sensor PAS unit Control PAS sensor and send its status to ICM box buzzer LH RH sensor CTR sensor LH sensor CTR sensor RH sensor ...

Page 535: ...sensors are activated when the transmission gear is in the R reverse position 2 Sensing distance and range 3 Alarm section and interval from PAS buzzer in ICM box 0 30 cm third sound produced within area to be ignored LH sensor Central sensor RH sensor ...

Page 536: ...ure from temperature sensor The ultrasonic wave sensor directs the distance value by receiving the sensor operating temperature from the sensor and compensating for the detecting deviation since it varies depending on the ambient temperature Temperature Thermistor output value Temperature Thermistor output value 80 6 93 V 20 2 16 V 70 6 24 V 10 1 45 V 60 6 04 V 0 1 15 V 50 5 34 V 10 0 98 V 40 4 62...

Page 537: ...gear shifted R position after initial ignition ON The self diagnosis fails and the buzzer sounds under any of the following conditions Open circuit in sensor TX Open circuit in power wires and In the event of sensor failure itself a b c If normal warning buzzer sounds for 0 065 seconds Alarm interval during self diagnosis ...

Page 538: ...09 11 8790 01 5 Wiring diagram ...

Page 539: ...09 12 6 FLOW CHART ...

Page 540: ... 290KHZ Preset FM1 6ch FM2 6ch AM 6ch MW 6ch LW 6ch Usable sensitivity AM 25dBu FM 10dBu S N raito limit value AM 54dB FM 60dB LCD Type FSTN Operating voltage 9 0V VDD 3 0 3 3V Operating temperature 30 80 Operating temperature 40 85 Size W x H 132X36 Bluetooth Component MD 5XR Bluetooth multimedia module Application technology Bluetooth 2 0 EDR Enhanced Data Rate Specification Supports HFP A2DP AV...

Page 541: ... 6X9 inch Max input 40 W Impedance 300 Hz of 4Ω 15 Item Specification Operating current Max 150 mA Operating voltage DC 10 5 V 16 V Operating temperature 30 60 Storage temperature 40 80 I O impedance 75Ω FM 4 Handsfree microphone Item Specification Storage temperature 30 80 Operating temperature 40 85 Sensitivity 35 2 dB Impedance Up to 2 2 S N ratio 60dB or higher S N ratio signal to noise ratio ...

Page 542: ...h setting mode and design changed Steering wheel switch Power button deleted steering wheel heating option switch added Design changed 2 MAJOR CHANGES USB AUX jack assembly Ø3 5 3 pole stereo AUX input and USB port used USB AUX jack assembly added ...

Page 543: ...11 6 Radio antenna specification changed Changed to micro pole antenna from glass antenna with radio antenna amplifier ...

Page 544: ...g so may lead to an accident or electric shock Please contact a Ssangyong service dealer immediately The system should be used only when the engine is started Using the system for an extended period of the with the engine off may discharge the battery Do not leave beverages or foreign materials around the system If they enter the system they may cause a fire The system may break down if a disc not...

Page 545: ...EW The audio head unit is fitted with the Bluetooth handsfree for convenience And it has a micro pole antenna and its own integrated amplifier to improve the radio frequency reception rate and to provide the high quality sound Audio head unit Front tweeter speaker USB AUX jack assembly ...

Page 546: ...11 9 8910 05 Micro pole antenna Quarter speaker Handsfree microphone Tweeter speaker Audio head unit Steering wheel switch USB AUX jack assembly ...

Page 547: ...andsfree seek up down mute switch is operated 3 OPERATION PROCESS Audio head unit The audio system plays a various types of music such as radio MP3 CD and USB It has a built in high output amplifier allowing to provide the high quality sound Micro pole antenna Micro pole radio antenna is fitted to ensure the high sensitivity Glass antenna removed Bluetooth handsfree Once the pairing is complete af...

Page 548: ...11 11 8910 05 Front door speaker LH Front door speaker RH Quarter speaker LH Quarter speaker RH Front tweeter speaker LH Front tweeter speaker RH ...

Page 549: ...hold 3 SCAN INF button Scan in each station automatically enter the file search mode press switch the display items press and hold 4 CALL button Receive the incoming a call press connect the Bluetooth device press and hold 5 END button End a call press release the Bluetooth connection press and hold 6 SEEK button Find a station manually or skip a track press seek a station automatically or up down...

Page 550: ... Number 1 to 6 D buttons Store each station press and hold receive each stored stations or select the CD USB playback as below press 2 RPT Repeat playback 3 INT Intro playback 4 RDM Random playback 5 D Folder down 6 D Folder up 13 POWER MUTE button with VOLUME VOL dial Turn the power on turn the radio mute or CD USB pause playback on off press tune the power off press and hold adjusts the volume r...

Page 551: ...Current folder directory number Current file track number USB indicator Folder select mode indicator Playback mode indicators RPT Repeat INT Intro RDM Random 8 9 10 11 12 Bluetooth function indicator Playing time EQ Equalizer indicator POP ROCK COUNTRY VOICE JAZZ CLASSIC 13 14 15 TP lights up when a TP Traffic Program station is tuned in TA lights up when TA Traffic Announcement standby function i...

Page 552: ...s is saved and the Setting mode is quit By rotating the TUNE dial you can select one of the following EQ Styles EQ OFF POP ROCK COUNTRY VOICE JAZZ CLASSIC By rotating the TUNE dial you can select one of the following Tone Control items BASS MIDDLE TREBLE BALANCE FADER PREVIOUS Press SET button to enter the Setting mode EQ TONE and BT appear on the display Rotate TUNE dial to select the TONE menu t...

Page 553: ...ate TUNE dial to select device list or adjust value then press ENTER button 4 PAIR enter the pairing Key Code 00xx SELECT selects one of 5 Bluetooth devices for connection PRIORITY selects the priority of connection DELETE deletes a Bluetooth device PREVIOUS return to the BT menu Incase of the delete selecting Rotate TUNE dial to select the YES or NO then press ENTER button YES Deletes the selecte...

Page 554: ...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 5 kΩ Resistance P N 20 kΩ TCU EGS 52 Shift solenoid valve 25 Resistance 3 8 0 2 Ω Operating distance 0 2 mm Operating current 1 5 2 A Item Specification Input...

Page 555: ...rent 1 5 2 0 A Operating range 3rd to 5th gears Speed sensor Resistance HALL type Operating voltage 6 V 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 Ite...

Page 556: ...01 5 3650 01 Part Name Part Number Description 126589 020900 Piston collar nut Install and remove the output shaft collar nut 2 SPECIAL SERVICE TOOLS ...

Page 557: ... 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 558: ...650 01 TGS A T rod O ring and mass damper used for reducing noise and vibration Mass damper TGS A T rod changed O ring TGS A T knob changed TGS A T knob Changed to metal wood grain pattern type 4 MJOR CHANGES ...

Page 559: ... 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 560: ...01 9 3650 01 Characteristics ...

Page 561: ...01 10 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 562: ...t 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 reduced speed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with reduced speed Output shaft Clockwise ro...

Page 563: ...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 564: ...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 565: ...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 566: ...tary 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 increased speed Center sun gear Clockwise rotation with increased speed by C3 activation Cen...

Page 567: ... 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 568: ... 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 569: ...01 18 3 CIRCUIT DIAGRAM Start Motor Selector Lever CAN Communication ...

Page 570: ...01 19 3650 01 Solenoid Oil temperature sensor Speed sensor N2 N3 ...

Page 571: ... 75W 85 SK Capacity 2 2 ℓ Service 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 occasionally Taxi patrol service or delivery service extended idling and excessive driving with low speed F...

Page 572: ... 2 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 pin...

Page 573: ...nce 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 574: ...41 1 1 EA Loctite 4 Reverse shift fork retainer bolt 53 9 67 6 2 EA Loctite 5 Backup lamp switch 29 4 34 3 1 EA Loctite 6 Oil drain plug 58 8 78 4 1 EA Loctite 7 Interlock bolt 14 7 21 5 1 EA 8 Neutral switch 29 4 34 3 1 EA Loctite 9 Oil filler plug 58 8 78 4 1 EA Loctite 10 Extension housing 42 1 53 9 12 EA 11 Concentric slave cylinder bolt 9 8 15 6 3 EA 12 Front bearing retainer bolt 19 6 24 5 8...

Page 575: ...Bolt 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 Plug 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 576: ...02 8 3162 00 Main shaft ...

Page 577: ...b Synchronizer Sleeve 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 Sleeve Synchronizer Stopper Synchronizer key Bearing ...

Page 578: ... 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 Sleeve 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 579: ...Adapter 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 580: ...iner 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 Lug 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 581: ...TGS 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 ...

Page 582: ... 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 583: ...smission 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 584: ...02 16 1st speed 2 POWER FLOW 2nd speed ...

Page 585: ...02 17 3170 01 4th speed 3rd speed ...

Page 586: ...02 18 6th speed 5th speed ...

Page 587: ...02 19 3170 01 Reverse gear ...

Page 588: ...02 20 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 589: ...e Dry 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 0 mm Inner diameter Ø 15 87 Concentric slave cylinder Maximum operating travel Max 20 mm Operating pressure Max 2 200 N Clutch fluid Type DOT 4 Capacity...

Page 590: ...03 4 2 TROUBLESHOOTING ...

Page 591: ...ay and measure the pedal stroke A 1 2 3 Stroke A 150 3 mm 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 3 mm 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 592: ...htly depress the clutch pedal until you feel the resistance from 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 593: ...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 594: ...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 595: ... 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 596: ...03 10 Clutch cover assembly 3 Layout Clutch disc Dual mass flywheel DMF Concentric slave cylinder T M Input shaft ...

Page 597: ...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 598: ...Hypoid Gear Final gear reduction ratio Engine M T 4 55 Engine A T 3 54 Oil Capacity 1 2 L Specification SAE 80W 90 API GL 5 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 4 55 Engine A T 3 54 Oil Capacity 1 5 L Specification TOTAL ISU EP B 85W 90 ...

Page 599: ...t pan angle for rear axle changed due to change of rear sub frame 2 CHANGES Changes in rear axle assembly Changes in rear axle shaft assembly Rear Axle Shaft Assembly Increased rear axle shaft length 15 0 mm due to change of rear sub frame Mounting section ...

Page 600: ...sion Propeller shaft Rear propeller shaft Final reduction gear Rear axle Rear axle shaft Rear wheels In 4WD mode the drive power to the rear wheels is distributed to the front wheels in order of Front propeller shaft Front axle Front axle shaft Front wheel via the T C assembly And 4WD solenoid valve releases the vacuum and engage the locking hub actuator to the LH RH front hub end gear to transfer...

Page 601: ...ing in 2WD mode but if the driver operates the drive power is distributed to the front wheels rather than rear wheels via the transfer case only in 4WD mode in following order Front propeller shaft Front axle Front axle shaft Front wheel Refer to CHASSIS T C section for detailed information for 4WD drive ...

Page 602: ...including oil Oil capacity 1 4 L 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 343 mm 1 SPECIFICATIONS ...

Page 603: ...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 604: ...drive 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...

Page 605: ...05 6 2 4WD SYSTEM COMPONENTS Front axle Exterior components 4WD solenoid valve Hub locking hub Actuator T C assembly T C control motor assembly Front propeller shaft Rear axle Rear propeller shaft ...

Page 606: ...05 7 3240 01 Interior Components 4WD Switch assembly Warning Indicator Lamp for 4WD TCCU ...

Page 607: ...05 8 3 SYSTEM LAYOUT ...

Page 608: ... and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Booster Vacuum pump Vacuum generation process in front hub actuator ...

Page 609: ...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 610: ...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 611: ...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 612: ...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 613: ...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 614: ...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 615: ...bly Increased part B of rear propeller shaft assembly due to change of rear sub frame 6 0 mm Specifications Item M T 2WD A T 2WD A T 4WD Old New Old New Old New A mm 1886 1 1892 1 1969 1 1975 1 1587 1 1593 1 B mm 769 5 775 5 769 5 775 5 769 5 775 5 ...

Page 616: ...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 617: ...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 618: ...Spring 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 0 0 10 Camber 0 12 0 50 Caster 4 80 0 50 Rear Wheel Alignment Toe in 0 48 0 15 Camber 1 20 0 50 Caster ...

Page 619: ...its link length changed Stabilizer bar Stabilizer link Stabilizer bar Stabilizer link 4320 01 Rear sub frame module Rear sub frame module changed Front stopper added 4331 01 Camber link Apperance changed 4331 06 Tension link Apperance changed 3 MAJOR CHANGES ...

Page 620: ...e changed 4221 01 Wheel carrier assembly Appearance changed 4331 11 Thrust link Apperance changed 4511 01 Rear shock absorber assembly Its operation length changed Max operation length 487 mm to 500 mm Min operation length 326 mm to 339 6 mm ...

Page 621: ...t patches of the tires The suspension also protects the vehicle itself and any cargo or luggage from damage and wear 2 Rear Suspension Multi Link Type 1 OVERVIEW Double wishbone suspension is an independent suspension design using two occasionally parallel wishbone shaped arms to locate the wheel Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle The shock abs...

Page 622: ......

Page 623: ... shapes and to ensure the drivability Lower Arm Knuckle There are two types of knuckle 4WD 2WD Cam bolt 1 Front Suspension Double Wishbone The lower arm is mounted to the knuckle the shock absorber and the lower arm assembly It relieves the load delivered from the tire to the knuckle This enables to absorb the various impacts according to the load shapes and to ensure the drivability 2 COMPONENTS ...

Page 624: ...re closer to the body After the fast turn then the downward pressure is reduced and the paired wheels can return to their normal height against the vehicle kept at similar levels by the connecting stabilizer bar Stabilizer bar Stabilizer bar Bracket Stabilizer bar link Coil spring The shock absorber assembly reduces the effect of traveling over rough ground leading to improved ride quality and inc...

Page 625: ...nk 2 Rear Suspension Rear coil spring Wheel carrier assembly Rear sub frame bush Nut Upper washer Upper bush Bumper stopper Lower bush Dust cover Shock absorber Bolt Nut Collar Front Rear Rear shock absorber assembly ...

Page 626: ...07 11 4411 01 Thrust link Camber link Tension link Track rod Rear stabilizer bar assembly Stabilizer bar Stabilizer bar mounting bracket Stabilizer bush Stabilizer link ...

Page 627: ...outwards by the camber while driving Prevention of uneven outward tire wear Prevention of toe out from wearing of steering linkage 1 Toe in The difference of measured distances between the front ends of the tires A and the rear ends of the tires B along the same axle when viewed the wheels from the top Toe in Front 0 0 10 Rear 0 48 0 15 Necessity for Wheel Alignment Wheel alignment consists of adj...

Page 628: ...vehicle Better corner driving when the vehicle makes turn as the cornering force Negative camber Disadvantages Cornering force decreases as the positive camber increases when the vehicle makes turn The hub bearing is worn unevenly if camber is excessive Advantages The axle is not bent when it is loaded The force required to operate the steering wheel is reduced due to smaller contact area or load ...

Page 629: ...traight following control Restoring force of the wheel restored to the straight ahead direction Prevention of wheel shimmy wheels wobble left and right Negative caster Top of the king pin is tilted forward from the vertical line of the wheel center when viewed the tires from the side Positive caster With considering the height difference between the wheel centers of the front and rear wheels Under...

Page 630: ...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 631: ...08 4 2 CHANGES IN BRAKE SYSTEM Rear brake hose assembly With ABS With ESP Rear brake hose routing changed due to change of rear sub frame assembly ...

Page 632: ...08 5 4850 03 3 SPECIAL SERVICE TOOL Piston Puller Caliper Piston Compressor Hydraulic pressure shut off clamp for brake hose For preventing hydraulic pressure from brake hose ...

Page 633: ... 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 Repl...

Page 634: ...ce Incorrectly adjusted free play of brake pedal Adjust Faulty master cylinder Replace Lack of lubrication in sliding parts Lubricate Faulty brake booster vacuum leak Repair Poor parking brake Wear hardening or poor contact of brake pad Replace Oil or water on lining Repair or replace Fixed or broken parking brake cable Replace Excessive stroke of brake lever Adjust notch Faulty auto clearance adj...

Page 635: ...ot 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 636: ...linder 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 5 INSPECTION 1 Front Brake Syst...

Page 637: ...re 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 638: ...on boot 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 Sy...

Page 639: ...hen starting engine with pedal depressed the system is normal If not the system is defective 2 If the above three checks are OK the system is normal If any condition is not met check the valve vacuum hose and brake booster 3 Brake Booster OK NG Engine stopped Engine running Depress the brake pedal when the engine is running If the pedal height is not changed for 30 seconds after stopping the engin...

Page 640: ...ushed N C Continuity Not continuity N O Not continuity Continuity 5 Pedal Free Play Check the pedal free play with below procedures Stop the engine Depress the brake pedal several times to discharge the vacuum pressure of the brake booster Depress the brake pedal until you feel the resistance and measure the movement A 1 2 3 Specified value A 3 10 mm If the free play is below the specified value c...

Page 641: ... 0 2 mm 1 Turn in direction of A to decrease the clearance Turn in direction of B to increase the clearance 1 Adjust the parking brake shoe depress the parking brake pedal 5 times and release it 2 Adjust the equalizer assembly bolt under the vehicle so that the equalizer assembly stops at the first notch when the parking brake pedal is depressed with a force of 19 to 22 kgf 3 Turn in the direction...

Page 642: ...08 15 4850 03 1 COMPONENTS ...

Page 643: ...08 16 ...

Page 644: ...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 645: ...08 18 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 646: ...08 19 4850 03 Caliper Assembly Bolt caliper Caliper Piston Pad spring Caliper carrier Brake pad Caliper assembly Brake pad ...

Page 647: ...08 20 4 Parking Brake Parking Brake Controls Operating lever Return spring lower Shoe holding spring Return spring upper Adjusting bolt Pedal assembly Equalizer assembly ...

Page 648: ...08 21 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 649: ...nsor Active type wheel speed sensor Active type wheel speed sensor On each wheel Front air gap 0 3 1 3mm Rear air gap 0 3 1 3 mm Steering Wheel Angle Sensor N A Maximum angular speed 1500 sec Operating voltage 9 16 V 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 Des...

Page 650: ...Wheel Speed Sensor Operating voltage 9 16 V Maximum output current 10 mA Max current consumption 100 ma Maximum detection angle speed 1500 s Operating temperature 30 75 Supplying voltage 9 to 16 V battery voltage Description Specification Description Specification Description Specification Supplying voltage approx 5 V 4 75 5 25 V Output voltage while in stationary approx 2 5 V Ignition ON Output r...

Page 651: ...emergency driving conditions and to control the brake for each wheels and the engine power when the brake system or acceleration will not work any more in dangerous circumstances TCS Traction Control System When the wheel is slipping due to an excessive engine torque while starting off or driving this controls the driving force braking force engine torque in order to prevent the wheel from slippin...

Page 652: ...art Vehicle with ABS Vehicle with ESP HECU Yes Yes Front wheel speed sensor Rear wheel speed sensor ABS warning lamp EBD indicator lamp G sensor integrated in HECU 4WD Yes 2WD No No Sensor cluster Yaw rate sensor lateral sensor G sensor No Yes ESP operation indicator lamp and warning lamp ESP OFF switch and indicator Steering wheel angle sensor ...

Page 653: ...plied and when the brakes are not applied on a curve If the ESP system operates when the brake is applied the brake pressure will be increased on the corresponding wheel which already has braking pressure for the ESP controls Noise and vibration that driver feels when ESP system is operating The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the mot...

Page 654: ...ultifunction switch 4 CHANGES IN ESP Steering wheel angle sensor changed Wheel speed sensor changed Wheel speed sensor Front Rear Front Rear Connector s appearance and length changed Sensor cluster changed Sensor cluster Appearance and its connector 6 pin 4 pin changed ...

Page 655: ... applied during cornering at the speed of 100 km h the ABS will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 degree seconds the ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function This may cause...

Page 656: ...09 10 Pressure Sensor Installed Removed 2 LAYOUT HECU Hydraulic Electronic Control Unit ESP ABS Front Wheel Speed Sensor 4WD 2WD Rear Wheel Speed Sensor 1 Exterior Components ...

Page 657: ...heel Angle Sensor Warning buzzer ESP PAS buzzer Located in ICM box ESP warning and indicator lamp ESP OFF indicator lamp ABS warning lamp Parking brake operating indicator EBD warning lamp both parking brake operating indicator and ABS warning lamp come on at the same time 1 2 3 4 ESP buzzer ...

Page 658: ...09 12 3 OPERATING PROCESS 1 Block Diagram of Input and Output ...

Page 659: ...nside 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 d...

Page 660: ...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 661: ...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 662: ...ake 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 Item Understeer control Oversteer control Only ESP in operation No braking by driver ESP Normal braking no ABS operation ESP ABS brake ESP TCS ...

Page 663: ... 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 664: ...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 665: ...t note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns The ve...

Page 666: ...s in effect Consequently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is still available even when turning off the ESP system by ESP OFF switch However if the ESP system is shut off due to a system failure the ARP system is also not available ...

Page 667: ... 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 second 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 668: ... 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 669: ...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 670: ...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 671: ...heels are locked The inlet valve closes and the outlet valve opens as in the ESP 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 672: ...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 673: ...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 674: ...09 28 2 Electric Circuit Diagram Wheel speed sensor Stop lamp switch Self diagnostic connector Warning lamp ABS ESP ...

Page 675: ...09 29 4891 01 Brake Pressure Sensor ESP Sensor Sensor Cluster ESP OFF Switch ...

Page 676: ...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 677: ...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 678: ... 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 679: ...10 6 3 ABS SYSTEM OPERATION 1 Block Diagram ...

Page 680: ... 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 681: ... 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 682: ...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 683: ...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 684: ...10 11 4891 01 3 Circuit Diagram ...

Page 685: ...e mm Ø115 Operating temperature 40 150 Steering oil Type S PSF3 Capacity L approx 1 1 Lower shaft Type Universal joint Angle 38 Configuration Universal joint top bottom rubber coupling Minimum turning radius m 6 09 Steering column shaft Tilting angle 2 Steering wheel heating indicator Power consumption Below 95 W Rated voltage 13 5 0 1 V Usable voltage 9 16 V Low voltage 7 5 0 5 V High voltage 18 ...

Page 686: ...e to change of multifunction switch Steering wheel body and heating system Heating controller added due to newly adopted steering wheel heating system 2 CHANGES IN STEERING SYSTEM Steering wheel heating switch Heated wire used in steering wheel switch option Heating controller Mounting bracket ...

Page 687: ... gear 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 p...

Page 688: ...ve belt Adjust or replace Clogging of fluid line Repair or replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace Steering wheel pulls to one side Damaged steering linkage Replace Damaged wheel or tire Repair or replace Defective brake system Repair or replace Defective suspension Repair or replace Excessive free play of steering wheel Worn steering gear Replace the...

Page 689: ...olumn 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 co...

Page 690: ...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 on a ...

Page 691: ...n Check the oil level in the power steering oil reservoir Adjust the oil level between MAX and MIN A B C D Oil Change If the difference between two measurements is below 5 mm and the level is between MAX and MIN level it s normal If it is over 5 mm bleed air from the system Open the power fluid reservoir cap and drain the fluid completely with oil suction device To make it easy turn the steering w...

Page 692: ...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 oil le...

Page 693: ...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 694: ...open G Pressure at no load 3 5 bar If the pump pressure is in specified range the pump is normal If not replace the power steering pump H Turn the steering wheel right or left until it stops with the engine idling and valve fully open I Oil pressure 78 83 bar ...

Page 695: ...e relief valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydraulic ...

Page 696: ...11 14 2 SYSTEM LAYOUT ...

Page 697: ...the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Return hose tube Lower shaft Column shaft Steering wheel Power steering gear box High pressure hose Power steering pump tank Return line High pressure line Steering pump Steering return pipe Steering cylinder ...

Page 698: ...cation Tire 16 inch 225 65R16 17 inch 235 60R17 Tire inflation pressure 35 psi Wheel 16 inch 6 5JX16 17 inch 7 0JX17 Balance weight Inner Clip on type Outer Tape type Tightening torques of wheel bolt 127 4 to 156 8 Nm Wheel offset 2WD 38 mm 4WD 50 mm ...

Page 699: ... wheel and tire Wheel assembly 16 inch 6 5JX16 17 inch 7 0JX17 2WD 4WD 2WD 4WD 225 65R16 235 60R17 16 inch wheel design changed same as before for tire size 17 inch wheel specification added 235 60R17 tire 2 CHANGES Wheel tire design changed and specification added With spare tire Spare tire Winch assembly ...

Page 700: ...nly 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 th...

Page 701: ...he 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 out...

Page 702: ...an 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...

Page 703: ...th 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 Hydroplaning ...

Page 704: ...the balance weight of a weight corresponding to unbalanced weight from B to A to maintain the static balance If the static balance is not maintained tramping up and down vibration of the wheels occurs 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...

Page 705: ...is farther out than the top it is called negative camber Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground thus maximizing tire life and ensures straight and true tracking along a straight and level road Camber angle alters the handling qualities of a particular suspension design in particular negative camber impr...

Page 706: ... enhance straight line stability The mechanism that causes this tendency is clearly illustrated by the castering front wheels of a vehicle The steering axis of a vehicle wheel is set forward of where the wheel contacts the ground As the vehicle is driving forward the steering axis pulls the wheel along and since the wheel drags along the ground it falls directly in line behind the steering axis Th...

Page 707: ...ction coefficient road Uneven friction coefficient road Driving Force Braking Force Supporting the Vehicle Weight Transferring the Driving Force Braking Force to Road 5 FUNCTIONS OF TIRE Supporting the Vehicle Weight ...

Page 708: ...2 V Current consumption 2 2 A Refrigerant fluid PAG RL 897 150cc Condenser Size 655 8wX485 6hX16 0t Receiver drier Moisture absorbent XH 9 Pressure switch Refrigerant pressure sensor Front heater A C module Heating capacity 7000 Kcal hr Cooling capacity 6200 Kcal hr Expansion valve Block type Rear heater A C module Heating capacity 4300 Kcal hr Cooling capacity 3200 Kcal hr Refrigerant type R134a ...

Page 709: ...01 4 Rear cooler duct Appearance changed 2 MAJOR CHANGES ...

Page 710: ......

Page 711: ...ontrols the temperature and air quality inside the vehicle by providing the heating cooling and preventing the hazardous gas from entering to keep indoor air fresh 2 LAYOUT 1 External Climate System Front expansion valve Condenser AQS sensor Ambient temperature sensor ...

Page 712: ...01 7 6810 30 PWM electronic fan A C compressor Receiver drier PTC box PWM Refrigerant pressure sensor ...

Page 713: ...01 8 2 Internal Climate System Front climate system Front mode actuator Interior temperature humidity sensor Sun sensor Air mix door actuator Duct temperature sensor PTC heater ...

Page 714: ...01 9 6810 30 A C controller Rear blower switch front Air source mode actuator A C filter Thermo AMP Front power transistor Front blower motor Manual FATC ...

Page 715: ...01 10 Rear mode actuator Rear expansion valve Rear climate system Rear blower resistance Rear blower motor Rear blower switch rear Heater valve ...

Page 716: ...01 11 6810 30 Rear Ventilation Front Ventilation Heater vents A C vents 3 Ventilation System 1 Location of Vents ...

Page 717: ...01 12 2 Ventilation Modes Vent mode Bi level mode Floor mode Defrost and floor mode Defrost mode Rear air conditioning mode ...

Page 718: ...filter Evaporator Blower motor Blower high speed relay Heater core Wiring layout Components Sun sensor Interior temperature sensor Front mode actuator Air mix actuator Duct temperature sensor PTC heater A B C D E F Thermo amplifier Front power transistor Front blower motor A C filter Air source mode actuator Rear blower switch G H I J K M ...

Page 719: ...ioner duct Blower motor Evaporator Mixer door Heater core Air mixer door actuator Rear floor heater duct Heater air conditioner pipes Wiring layout Components Rear mode actuator Rear expansion valve Rear blower motor Heater valve Rear blower resistance ...

Page 720: ... 2 seconds 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 721: ...ation Condenser Condition Gas Liquid Function Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure Condition Gas Liquid Function Keeps the refrigerant free from moisture by separating collecting the moisture from it Receiver drier Expansion valve Condition Liquid Liquefied gas Function Performs adiabatic expansion and flow control for easier evaporation 1 Basi...

Page 722: ...g the pressure to the level at which evaporation easily takes place before the liquid refrigerant is sent to the evaporator is called Adiabatic Expansion During adiabatic expansion the expansion valve lowers the pressure of the refrigerant and determines the correct amount of refrigerant going into the air conditioning evaporator That is the amount of heat which is needed to stop the evaporation i...

Page 723: ...01 18 5 CIRCUIT DIAGRAM 1 FATC Full Auto Temperature Control D20DTR PWM Motor Compressor relay ...

Page 724: ...01 19 6810 30 GSL 3 2 Condenser Fan Relay ...

Page 725: ...01 20 Actuator mode intake AQS sensor ...

Page 726: ...01 21 6810 30 Rear Air Conditioner Blower Mode Actuator ...

Page 727: ...01 22 2 Manual Air Conditioner D20DTR Motor Mode Intake Air Mix PWM ...

Page 728: ...01 23 6810 30 GSL 3 2 Condenser Fan Motor ...

Page 729: ...01 24 Blower Motor Front Rear ...

Page 730: ......

Page 731: ...rotection 24 V Ground resistance 100 mΩ or less Driver passenger air bag module Operating voltage 8 0 V to 16 5 V Seat air bag module Operating voltage 10 0 V to 16 5 V Side impact sensor voltage 8 0 V to 16 5 V Seat belt pretensioner Operating voltage 10 0 V to 16 5 V If you measure the air bag module using a multitester the air bag module may be deployed causing a personal injury Never use the m...

Page 732: ... 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 cras...

Page 733: ... and 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 sy...

Page 734: ...ne 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 eyes or...

Page 735: ...le Seat air bag module Seat air bag module used for driver and front passenger seats 2 Side Impact Sensor Side impact sensor Side impact sensor fitted to lower side of B pillars for driver and passenger sides due to newly adopted seat air bag system ...

Page 736: ...longitudinal G sensor The side air bag sensor is installed in both B pillars The front air bag module side air bag module and seat belt pretensioner are installed for each seat The pretensioner operates with the front seat The side air bag operates according to the signal from the lateral G sensor longitudinal G sensor and side air bag sensor The front air bags operate independently 2 COMPONENTS ...

Page 737: ...nsioner Driver s Passenger s Seat Belt 2 point for rear 1st row seat swiveled 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 738: ...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 739: ...02 11 8810 03 3 CIRCUIT DIAGRAM ...

Page 740: ...SS 1 Air Bag System Block Diagram The overall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyong Motors ...

Page 741: ...02 13 8810 03 ...

Page 742: ...uld damage the seat on the seat The front and rear seats are equipped with the heated wire seat warmer system Using the seat warmer system excessively may cause minor burns The following occupants should exercise special care when using the heated wire seat 1 2 3 4 5 6 Infant child old or handicapped person Person with sensitive skin Exhausted person Persons who is drunk or took medicine which cau...

Page 743: ...d can result in battery becoming discharged Operating more than one seat adjustment switch at the same time can cause damage to the seat motor Therefore operate the seat switch only one at a time Do not use organic solvents such as benzene thinner alcohol or gasoline to prevent the seat cover from being damaged while cleaning Do not operate the seat position adjustment switch forcefully when the s...

Page 744: ... 2 point seat belts for LH RH seat removed as the rear 1st row seat swing function has been removed Rear 1st row and 2nd row seat cushions changed 11p Only Moving distance for rear 1st row and 2nd row seats changed whole moving distance changed from 680 mm to 720 mm ...

Page 745: ...liding adjust lever 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 746: ...03 7 7410 01 Seat sliding adjust lever Rear 3rd Row Seatback Folding Lever Headrest Back folding adjust lever ...

Page 747: ...03 8 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 748: ...03 9 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 749: ...03 10 3 7 Passengers Front Seat Belt 3 point Rear 2nd row 3 point Rear 1st row 3 point ...

Page 750: ...seat Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed Passenger s seat Second row seat right Third row seat right Driver s seat Second row seat left Third row seat left Center jump seat Fourth row seats ...

Page 751: ...t Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed Passenger s seat Second row seat right Third row seat right Driver s seat Second row seat left Third row seat left Fourth row seats ...

Page 752: ...0 01 3 Layout 7 Passengers Passenger s seat Second row seat right Third row seat Driver s seat Second row seat left Front seat Move 36mm from the far end to the front Rear 1st seat Movable Rear 2nd seat movable ...

Page 753: ...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 754: ... from the far end to the front Rear 1st seat Middle Rear 2nd seat Middle Rear 3rd seat Double folding 5 passengers with loading Front seat 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 ...

Page 755: ...03 16 2 passengers with loading Front seat Move to the far end Rear 1st seat Middle Back folding Rear 2nd seat Middle Back folding Rear 3rd seat Fix Back folding ...

Page 756: ...03 17 7410 01 5 Sliding Moving Amount Item Sliding distance Front seats A 228 mm Rear 1st row seats B 380 mm Rear 2nd row seats C 340 mm Total length of rear seat rail 1 610 mm ...

Page 757: ...pport sleeve However raise the headrest while pressing the headrest support sleeve A in order to remove it 4 FRONT SEAT 1 To Adjust Front Seat While the driver seat is provided as two models a power seat and a manual seat the manual seat is only used for front passenger seat To adjust headrest To adjust headrest tilting Move the headrest to the arrow direction to adjust the angle ...

Page 758: ... the recline switch forward backward the seatback angle is adjusted as the recline motor rotates the rail Manual Seat To adjust seat slide To move the seat forward or backward pull and hold the seat slide lever up and move the seat To adjust seat back angle To fold the seatback pull the seatback lock release lever to release the lock Then lean back to the desired angle and release the lever To adj...

Page 759: ...up down motor rotates the rail to move the whole seat cushion up down Manual Seat To adjust seat cushion angle and height Turn the adjusting knob on the side of the seat clockwise or anticlockwise to adjust the height or angle of the front side or rear side of the cushion To adjust driver seat lumbar support When you raise and lower the adjusting lever on the power and manual seats the lumbar supp...

Page 760: ...al Configuration of Seatback Lumbar support Recline motor Seat cushion rear up down motor Seat cushion rear up down rail Slide motor The descriptions in this chapter are based on the driver s seat and rear 1st seat 1 Components Slide rail Seat cushion front up down rail Seat cushion front up down motor ...

Page 761: ...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 762: ...03 23 7410 01 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 763: ...03 24 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 764: ...5 7410 01 Seat back flat cable 4 Rear 1st 2nd row seat mechanisms Seat back folding cable Flat lever Seat back folding cable Seat back flat cable Folding lever Jumping mechanism Sliding lever Sliding cable ...

Page 765: ...03 26 5 Operation of rear seat Rear 1st and 2nd seat Seat sliding Front Rear ...

Page 766: ... 27 7410 01 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 767: ...03 28 8 Rear 3rd seat Pull the lever behind back seat to fold the back seat As the seat is folded disconnect hook and spread out the board ...

Page 768: ...ssing the seat warmer switch for the driver and or front passenger seat with IGN ON the seat warmer operates Press the switch again to stop the seat warmer Operation procedures When pressing the seat warmer switch for the driver and or front passenger seat the seat warmer relay in the ICM box is activated to supply power to the seat warmer ICM Box Driver Front Passenger Seat Warmer Activated The d...

Page 769: ...he force required to hold even an infant on your lap can become so great that you could not hold the child no matter how strong you are Do not allow a child in the cargo areas while the vehicle is moving If the shoulder belt contacts the face or neck move the child closer to the center of the vehicle Never allow a child to put the shoulder belt under an arm or behind their back Please note that th...

Page 770: ...tems Do not carry your child on your lap while driving You cannot resist against the impact pressure in an accident The child could be crushed between you and the parts of vehicle Remember that a child restraint seat left in a concealed vehicle can cause it to be very hot Check the seating surface before putting your child in the child restraint When your child restraint is not in use remove it fr...

Page 771: ... facing I 9 to 18 kg 9 month 4 year Forward facing child seat X X U 3 point belt II 15 to 25 kg 4 year 6 years Booster seat X X U 3 point belt III 22 to 36 kg 6 year 12 years Booster seat X X U 3 point belt U Suitable for universal category restraints approved for use in the mass group UF Suitable for forward facing universal category restraints approved for use in the mass group L Suitable for pa...

Page 772: ...at Secure the child restraint with a seat belt as shown in the figure A child in a rear facing child restraint installed in the front seat can be seriously injured if the front passenger air bag inflates Secure a rear facing child restraint in the rear seat When installing a child restraint system follow the instructions provided by the manufacturer ...

Page 773: ...cation with the added benefit of easier and quicker installation When using the ISOFIX lower latch system all unused vehicle rear seat belt metal latch plates or tabs must be latched securely in their seat belt buckles and the seat belt webbing must be retracted behind the child restraint to prevent the child from reaching and taking hold of unretracted seat belts Unlatched metal latch plates or t...

Page 774: ...d restraint is not properly secured to the vehicle and a child is not properly restrained in the child restraint the child could be seriously injured or killed in a collision Always follow the instructions provided by the manufacturer for installation Make sure the latches of the child restraint system are latched to the lower latches In this case you can hear the click sound Incorrectly installed...

Page 775: ...UF C ISO R3 X X X GROUP I 9 TO 18KG D ISO R2 X X IUF C ISO R3 X X X B ISO F2 X X IUF B1 ISO F2X X X IUF A ISO F3 X X IUF Suitable for ISOFIX forward child restraints systems of universal category approved for use in this mass group Suitable for particular ISOFIX child restraint systems CRS given in attached list These ISOFIX CRS are those of the specific vehicle restricted or semi universal catego...

Page 776: ... the child restraint at proper location Child restraint has 5 categories based on the weight as below GROUP 0 0 10KG GROUP 0 0 13KG GROUP I 9 18KG GROUP II 15 25KG GROUP III 22 36KG Group 0 0 Rear facing child restraint fitted on the rear seat Group I Forward facing child restraint fitted on the rear seat Group II III Booster seat fitted on the rear seat with seat belt fastened Always follow the i...

Page 777: ...03 38 Driver power seat 7 CIRCUIT DIAGRAM ...

Page 778: ...03 39 7410 01 FRT seat warmer ...

Page 779: ...rrent 6 A Normal operation 25 A Max load current Operating temperature 30 85 Storage temperature 40 90 Operating time Open close max 9 sec Open close max 15 sec 20 Tilt max 1 5 sec Tilt max 4 sec 20 Glass open level 1st step sliding open 326 5 mm 2nd step sliding open 376 5 mm Tilt up open 43 5 3 mm Glass thickness 4 0 2 mm Displacement 2L min ...

Page 780: ...ecially in winter never operate the sunroof if operation areas are iced Wait until melted To prevent a theft make sure that the sunroof is completely closed when leaving the vehicle In addition rain or snow can get into the vehicle through the open sunroof When the sunroof is fully open wind buffeting symptom can be worse In this case try to adjust the sunroof position manually or open the sunroof...

Page 781: ... control unit sunroof motor sunroof glass and drain hose The sunroof motor is operated by the sunroof control unit according to the operating signal from the sunroof switch which results in opening and closing of the sunroof glass 2 LAYOUT Sunroof motor Sunroof control unit Sunroof switch Sunroof assembly ...

Page 782: ...roof Welt sunroof Screw BRKT sunroof SUPT Hose sunroof drain FRT Grommet sunroof drain hose FRT 1 2 3 4 5 6 7 8 9 Hose sunroof drain RR Grommet sunroof drain hose RR Cover sunroof tooling hole PNL ASSY sunroof sunshade Cover side INR Cover side OTR Wind deflector ASSY sunroof 10 11 12 14 15 16 17 ...

Page 783: ...04 7 7340 00 Drain hose Control switch Sun shade glass Control unit Sun roof motor 4 COMPONENTS AND LOCATIONS ...

Page 784: ... front side of the button when the glass is closed then motor 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 785: ...04 9 7340 00 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 786: ...04 10 6 CIRCUIT DIAGRAM ...

Page 787: ...05 3 7630 01 Multi tray Delete multi tray 1 MAJOR CHANGES Cluster fascia panel Cluster fascia panel design changed ...

Page 788: ...lower trims design changed Quarter upper and lower trims Quarter upper and lower trims design changed Quarter upper trim Quarter lower trim Quarter upper trim Quarter lower trim Tailgate lower trim Tailgate upper trim Tailgate lower trim Tailgate upper trim ...

Page 789: ...0 00 Quarter rear panel assembly Rear combination lamp and quarter front rear glass installation design changed 1 MAJOR CHANGES Front Fender Panel Assembly Headlamp and side repeater installation design changed ...

Page 790: ... 4 Hood panel assembly Hood panel design changed and hood lifter used Hood insulation Hood panel change results in design change due to interference Rear door panel assembly Rear door panel design changed ...

Page 791: ...06 5 0000 00 Front bumper assembly Front bumper design changed Tailgate Panel Assembly Tailgate panel design changed Door outside handle assembly Front and rear parts design changed ...

Page 792: ...06 6 Radiator grille assembly Radiator grille design changed Rear bumper assembly Rear bumper design changed Fashion rail assembly Fashion rail design changed ...

Page 793: ...06 7 0000 00 Spoiler assembly Spoiler design changed Front Front bumper fascia change results in installation design change Rear Changed from split type to integral type Wheel house cover ...

Page 794: ...06 8 Rear Rear mudguard design changed Front Front mudguard design changed Mudguard ...

Page 795: ...07 3 5110 01 Top View Side View Front View Rear View 1 MAJOR EXTERNAL DIMENSIONS Unit mm Optional ...

Page 796: ...07 4 2 JACK POINTS Be sure to lift the vehicle only on the designated jack point otherwise the vehicle could be body damaged Front jack point Rear jack point ...

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