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SSANGYONG Rexton W 2012.06, Руководство пользователя

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SSANGYONG Rexton W 2012.06 Скачать руководство пользователя страница 301

15-7

0000-00

Fuel rail pressure 

sensor

(2) Components for ECU Input

CAN

- ABS & ESP
- GCU
- Instrument 
  cluster
- TCU
- STICS

Swirl valve 

position sensor

Differential 

pressure sensor

E-EGR valve 

position sensor

Camshaft position 

sensor

Coolant 

temperature 

sensor

Exhaust gas 

temperature 

sensor

HFM sensor

Oxygen sensor

T-MAP sensor

Crankshaft 

position sensor

Accelerator pedal 

sensor

Throttle position 

sensor

Knock sensor

-Auto cruise switch
- Rear right wheel 
  speed (without ABS)
- Refrigerant pressure 
  sensor
- Clutch pedal signal
- Blower switch signal
- Brake pedal signal

Water sensor

Содержание Rexton W 2012.06

Страница 1: ...CIFICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK POINTS 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 TIGHTENING TORQUE OF STANDARD BOLTS 3 4 6 7 19 20 21 22 24 ...

Страница 2: ......

Страница 3: ...01 3 0000 00 Top view Side view Front view Rear view Unit mm 1 DIMENSIONS ...

Страница 4: ...01 4 2 SPECIFICATIONS Optional 2WD DPF D20DTR Diesel 2 0 EU5 D20DT Diesel 2 0 D27DTP Diesel 2 7 Power Up D27DT Diesel 2 7 G32D Gasoline ...

Страница 5: ...01 5 0000 00 Specifications Cont d ...

Страница 6: ... manifold side Vin Label Chassis Number The chassis number is stamped on the frame behind the front right tire D20DTR D27DT D27DTP Diesel Engine D20DTR D27DT D27DTP The engine number is stamped on the lower area of cylinder block behind the Intake manifold Certification Label The certification label is located on the driver s door sill ...

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

Страница 8: ...01 8 ...

Страница 9: ...01 9 0000 00 ...

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

Страница 11: ...01 11 0000 00 ...

Страница 12: ...01 12 ...

Страница 13: ...01 13 0000 00 3 Scheduled Maintenance Services GEN Diesel Engine D27DT D27DTP ...

Страница 14: ...01 14 ...

Страница 15: ...01 15 0000 00 ...

Страница 16: ...01 16 4 Scheduled Maintenance Services Gasoline Engine ...

Страница 17: ...01 17 0000 00 ...

Страница 18: ...01 18 ...

Страница 19: ...commended 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 D20DTR Diesel 2 0 EU5 D20DT Diesel 2 0 D27DTP Diesel 2 7 Power Up D27DT Diesel 2 7 G32D Gasoline ...

Страница 20: ...01 20 Front Double wishbone Rear 5 link 6 JACK POINTS ...

Страница 21: ...ey should be coded by the scan tool Connector Pin Diagnostic connector Pin No Function 1 CAN HI S203 18 2 CAN LO S203 8 3 4 Ground 5 Ground 6 CAN HI S202 14 7 8 ABS ESP unit 2 9 Air bag unit 9 10 11 TCU A18 5 A T 12 SSPS unit 8 13 TCCU 21 14 CAN LO S202 4 15 STICS B21 16 B 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR ...

Страница 22: ...01 22 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Страница 23: ...01 23 0000 00 2 Components Locator ...

Страница 24: ...ard 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 Pla...

Страница 25: ...h front fog lamp 1 EXTERIOR 7871 01 Front Bumper and Front PAS Sensor Changed the front bumper design according to the design changes of front combination lamp and radiator grille Changed the location of front PAS sensor Head lamp Low beam Turn signal Position lamp Head lamp High beam Head lamp High beam Head lamp Low beam Position lamp LED Front fog lamp Front PAS sensor Turn signal Front fog lam...

Страница 26: ...ion lamp assembyl 7850 11 Outside Rearview Mirror Introduced the turn signal lamp on outside rearview mirror 7810 04 Windshield Wiper Blade Changed the aero blade material from steel to rubber Outside turn signal lamp 6110 01 Hood Panel Changed the hood panel design Front fog lamp Front fog lamp Turn signal lamp ...

Страница 27: ...e side repeater lamp to the outside rearview mirror 7930 11 Door Garnish Deleted the front and rear door garnishes 7931 20 Side Lower Step Changed the side lower step design Side repeater lamp Side 7110 10 Door Outside Handle Changed the door outside handle design 7931 06 Front Wheel Arch Garnish Changed the front wheel arch garnish design ...

Страница 28: ...pe diamond cut type Standard wheel Alloy wheel Unify the wheel tire specification 255 60R18 7931 01 Side Sill Garnish Changed the garnish design from independent type to integrated type Diamond cut type Sputtering type 5210 18 Side Outer Rear Panel Changed the side outer rear panel design according to the changes of rear combination lamp ...

Страница 29: ...e rear bumper design Added additional rear PAS sensor 3 4 Rear PAS sensor Rear PAS sensor Rear Side 7950 39 Quarter Badge Installed the brand logo on LH rear quarter panel Rexton W 8912 26 Audio Antenna Changed the antenna type from shark type to pole type ...

Страница 30: ...ges of rear bumper 7940 34 Tailgate Lower Garnish Changed the tailgate lower garnish design Tail Stop lamp Stop lamp Turn signal lamp Back up lamp Tail lamp Tail lamp Turn signal lamp Back up lamp Stop lamp 8320 01 Rear Combination Lamp Changed the rear combination lamp design and functions Changed the stop lamp and tail lamp to LED type ...

Страница 31: ...ing wheel wood grain Multi station switch Hazard switch Windshield heated wire switch Rear glass outside rearview mirror heated wire switch PAS OFF switch PAS OFF switch Hazard switch HDC switch ESP OFF switch Windshield heated wire switch Rear glass heated wire switch 8511 50 Center Fascia Switch and Bezel Changed the center fascia design switches and location Changed to independent type switch f...

Страница 32: ...mrest wood grain Digital Clock Deleted the multi station and added the digital clock 8912 01 Audio Changed the audio type added Bluetooth hands free function 8510 30 Power Outlet Socket For audio type the power outlet is added on the top of center fascia panel AV type Audio type Console upper fascia Console armrest ...

Страница 33: ...k and seat cushion design 7115 01 Door Panel Changed the front headrest design Changed the color of front rear door panel wood grain 7410 12 Front Headrest Changed the front headrest design Changed the tilting type from swing type to sliding type ...

Страница 34: ...at Back board Changed the seat back board and seatback pocket design 7510 05 Rear Center Armrest Changed the rear armrest design 7410 05 Front Seat Cover Shield Changed the front seat cover shield from integrated type to split type ...

Страница 35: ...the hazard lamp relay and added some relays rear side seat warmer blower rear washer wiper 8010 01 Instrument Cluster Added TPMS related warning lamp and indicator 3 ELECTRIC SYSTEM 7010 03 Blanking Key Changed mechanical key design ...

Страница 36: ...02 13 0000 00 8790 03 PAS Sensor Changed the locking type from spring type to holder type 8790 01 PAS Unit Changed the PAS sensor operating voltage 12V 8V and added one PAS sensor rear center ...

Страница 37: ...Module Added the wheel module in each wheel according to introduction of TPMS 1491 01 Engine Control Unit Changed the logic according to introduction of TPMS 4190 13 TPMS Unit Installed TPMS unit with antenna according to introduction of TPMS ...

Страница 38: ...02 15 0000 00 1990 00 Engine Mounting Insulator Old New Adopted the optimized engine mounting insulators based on system analysis and on board test LH RH Rear LH RH Rear ...

Страница 39: ......

Страница 40: ...r Fuel rail sensor common rail 1 LOCATION OF MAJOR SENSORS ON ENGINE Major sensors and devices Injector Glow plug Common rail Camshaft position sensor Boost pressure sensor Crankshaft position sensor HP pump Common rail Injector Turbocharger vacuum modulator ...

Страница 41: ...01 4 2 ENGINE ACCESSORIES RELATED TO ECU HFM sensor HFM 6 0 To control the engine more precisely new functions such as digital signal for intake air mass have been introduced Engine ECU Location ...

Страница 42: ...01 5 0000 00 Accelerator pedal module Fuse Relay Engine main relay 4 PPS integrated two pedal position sensors Pre glow and immobilizer Engine main relay 4 IMV Priming pump Fuel filter ...

Страница 43: ... plug Pre glow control unit 3 LAYOUT OF PRE GLOW SYSTEM Pre glow indicator on instrument cluster Fuse Pre glow Pre glow control signal Ground D20DT N A Power B Pre glow complete signal K Line Glow plug terminals ...

Страница 44: ...urbocharger Turbocharger Plug in sensor Air cleaner Turbocharger Protension graph Temperature sensor Air cleaner Intake manifold Coolant port To respective cylinder From intercooler VGT control actuator Exhaust gas Throttle body Engine operating Flap open Engine stopped Flap closed Intake duct Intake duct Boost pressure sensor Power Voltage output Ground ...

Страница 45: ...inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Blow by gas air duct hose Oil oil gauge pipe Cylinder head cover oil gas Inlet port 5 LAYOUT OF EXHAUST SYSTEM VGT Turbocharger Vacuum modulator To...

Страница 46: ... CDPF Throttle body Turbocharger vacuum modulator EGR cooler EGR pipe Exhaust gas passage for recirculating the exhaust gas Intercooler Intake manifold DOC DPF Coolant port Intake manifold Exhaust gas To water pump ...

Страница 47: ...OUT OF COOLING SYSTEM From heater Thermostat internal Reservoir coolant inlet hose Radiator Radiator Return hose Coolant reservoir tank From heater Radiator Reservoir coolant inlet hose EEGR cooler EGR cooler Coolant port Water pump ...

Страница 48: ...Oil filter cap Oil cooler Oil cooler Oil filter PWM electric fan unit Fan shroud Electric fan Flap door Cylinder head Cylinder head EGR cooler Radiator upper hose EGR cooler Radiator Oil pressure switch PWM electric fan Coolant outlet port ...

Страница 49: ...gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Intake air duct hose blow by gas Baffle pl...

Страница 50: ...01 13 0000 00 Cylinder head cover Low oil pressure warning lamp on instrument cluster Oil filter and oil cooler Oil cooler Oil filter ...

Страница 51: ...pressure fuel pipe Fuel pipe Common rail IMV connector HP pump Priming pump Fuel filter Connector Returned fuel from HP pump Fuel filter Fuel tank HP pump Fuel tank Fuel return port Low pressure fuel supply port Venturi Fuel return port Fuel temperature sensor IMV valve IMV connector High pressure fuel supply port with orifice ...

Страница 52: ...01 15 0000 00 Schematic Diagram ...

Страница 53: ......

Страница 54: ...02 3 0000 00 1 SPECIFICATIONS ...

Страница 55: ...02 4 2 Engine Performance Curve Output and Torque ...

Страница 56: ...02 5 0000 00 Oil Temperature Pressure and Boost Pressure ...

Страница 57: ...her puller 2 SPECIAL SERVICE TOOLS 1 Using the Special Service Tools on Engine Injector puller Glow plug socket HP remover installer High pressure pipe remover installer Cylinder head bolt wrench Sealing caps fuel line ...

Страница 58: ...02 7 0000 00 3 TIGHTENING TORQUE ...

Страница 59: ...02 8 ...

Страница 60: ...02 9 0000 00 ...

Страница 61: ...re 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 vehicle from rolling down put the chocks under the tires when using a 4 post lift Make sure to support the c...

Страница 62: ...h is not available 3 Fuel and Oil System 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 If fine dust or foreign material enters into DI engine s fuel system there can be serious damages between H...

Страница 63: ...02 12 D20DT Engine EU IV D27DTP Engine 5 MAJOR CHANGES IN D20DT EU IV ENGINE COMPARED TO D20DT Front view 1 Engine Assembly Left side view Right side view ...

Страница 64: ...system 2 Throttle body system 3 C3I injector system Injector C3I label Layout of E EGR system Throttle body E EGR valve EGR cooler Injection nozzle hole 7 Injector label and coding D27DTP D20DT 20 digits C3I coding To meet the emission regulation especially for reducing NOx same E EGR valve and EGR cooler in power up engine Rexton II have been introduced ...

Страница 65: ...transmitting the electric signal of EGR valve operating position Vacuum modulator Vacuum modulator for turbocharger control The vacuum modulator for controlling EGR valve has been deleted Throttle body is used to prevent the engine from turning off with fluttering noise at the moment the air to intake manifold is blocked by closed flap when the engine is switched off Throttle body ...

Страница 66: ...r EGR Gas Coolant The throttle body and boost pressure sensor have been installed on the intake manifold Intake manifold Throttle body Boost pressure sensor Cylinder head Coolant port To enhance the cooling performance the coolant port has been introduced To enhance the cooling performance the coolant passage has been made in the cylinder block Cylinder head gasket Coolant passage ...

Страница 67: ...to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D20DT engine the injector MDP minimum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running However for the D20DT EURO 4 engine it is learned when the vehicle is in motion and the engine is a...

Страница 68: ...es injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor HFM Hot Film Air Mass sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emiss...

Страница 69: ...le holes 7 Injector Fuel pipe High pressure fuel pip Fuel rail pressure sensor Fuel filter Connector Priming pump Fuel from HP pump Fuel filter HP pump Fuel tank Fuel tank Common rail Fuel return port Low pressure fuel supply port Venturi High pressure fuel supply port orifice included Fuel temperature sensor IMV valve Fuel return port IMV connector ...

Страница 70: ...03 6 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE ...

Страница 71: ...let hose to intercooler 1 TIGHTENINF TORQUE The hose clamps and fasteners should be tightened to the specified tightening torque when installing removing the engine and or components for intake system 1 Hose between air cleaner and turbocharger 2 Hose between turbocharger and intercooler ...

Страница 72: ...The intake system is equipped with an electric throttle body which includes a flap This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off And the improved HFM sensor has been adopted to control the intake air volume more precisely Exhaust manifold Air coeaner Intercooler Exhaust gas VGT control actuator ...

Страница 73: ...ensor Intake Manifold Ground Supply power Output voltage To corresponding cylinders Coolant port Compressed air EGR gas Engine stopped flap closed Normal flap open Intake duct Intake duct Intake manifold Throttle body Turbo charger Throttle body ...

Страница 74: ...ally with the turbine housing downward the engine oil may be provided to variable mechanism assembled towards the turbine housing which may lead to a malfunction of the variable mechanism 2 Never re adjust the adjusting screw marked with yellow paint or the axial end of actuator Renew them if you found looseness of the screw or actuator axle because they are shipped after precisely adjusting from ...

Страница 75: ... the engine The engine oil may be provided to the compressor housing if you rapidly operate the turbocharger with excessive revolutions immediately after installing to the engine 5 6 7 Do not raise the engine rpm rapidly after starting the engine Do not raise the engine rpm rapidly after renewing the engine oil and filter element Do not stop the turbocharger rapidly after operating at high engine ...

Страница 76: ...oler VGT turbocharger Intake manifold Turbocharger intercooler intake air EGR gas from EGR cooler E EGR valve Exhaust manifold E EGR valve Coolant To intake manifold EGR cooler EGR pipe E EGR valve Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake manifold The components of the exhaust system consist of Throttle body Exhaust manifold ...

Страница 77: ...g its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors are same 3 System Met with EURO IV Regulations The Ssangyong vehicles installed with the D27DT en...

Страница 78: ...it is installed in front of the VGT turbocharger it also monitors the exhaust gas tempera ture coming to the turbocharger If the temperature of the exhaust gas flowing to the turbocharger is higher than the specification the engine lowers the exhaust gas temperature Rear Exhaust Gas Tempera ture Sensor Measures the increased ex haust gas temperature after the oxidation process of DOC If the temper...

Страница 79: ...lock the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Turbocharger may become weaker if high tem perature exhaust gas passes through the tur bocharger for DPF regeneration process The front exhaust gas temperature sensor moni tors the tem...

Страница 80: ...st gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is anintegrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in the exhaust emission and t...

Страница 81: ...PF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Front exhaust gas temperature sensor Measuring temperature of exhaust gas in exhaust manifold Rear exhaust gas temperature sensor Measuring temperature of exhaust gas escaping DOC Normally whe...

Страница 82: ... pilot injection pre injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temperature of exhaust gas The...

Страница 83: ...e The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Страница 84: ... temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filtered and bur...

Страница 85: ...ure snesor When the soot is accumulated the pressure difference be tween the front and the rear side occurs Then the engineECU performs the post injec tion to raise the exhaust gas temperature and burn the collected soot at approx 600 C The exhaust gas enters intoCDPF assembly after passing through the exhaust manifold Normal temperature of ex haust gas approx 250 C When the exhaust gas enters int...

Страница 86: ...engine ECU performs the CDPF regeneration operation However the driver is not in formed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection dur ing the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increase the tem perature ...

Страница 87: ...e step 2 1 2 3 If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumu lated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp comes on and the en...

Страница 88: ...F SYSTEM 1 Mounting Condition and Location Differential Pressure Sensor Rear exhaust gas temperature sensor Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Rear pressure port CDPF assembly Front pressure port Differential pressure sensor ...

Страница 89: ...Quality class Ssangyong genuine engine oil Approved by MB Sheet 229 1 or 229 3 or 229 31 for DSL GSL ENG without CDPF Approved by MB Sheet 229 31 for DSL ENG with CDPF Viscosity MB sheet No 224 1 Capacity Standard 9 3ℓ max 8 3 ℓ min 6 8 ℓ Service interval EU Initial check 5 000 km and replenish if necessary change every 20 000 km or 12 months But shorten the service interval under severe condition...

Страница 90: ...cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Oil gauge pipe Oil gauge pipe Inlet port Oil dipstick gauge 1 LAYOUT OF...

Страница 91: ...07 5 0000 00 Low Oil Pressure Warning Lamp Instrument Cluster Oil Pressure Switch Cylinder Head Cover Oil cooler Oil filter Oil Filter Oil Cooler ...

Страница 92: ...07 6 2 SCHEMATIC DIAGRAM ...

Страница 93: ...08 3 0000 00 PWM Fan Assembly Water Pump Port to EGR cooler Coolant Port EGR Cooler PWM fan unit Fan Flap door From coolant port To water pump Radiator 1 LAYOUT OF COOLING SYSTEM Coolant reservoir ...

Страница 94: ...N COOLING SYSTEM FOR EACH ENGINE For the D20DT EURO4 engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block ...

Страница 95: ...0 Coolant Flow in Engine 2 SCHEMATIC DIAGRAM Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Страница 96: ... diameter mm 55 Armature run out mm 0 1 Segment groove depth mm 21 7 Alternator Type CSI128D Output voltage current V A PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A Regulator type Regulating voltage V 14 6 Brush Length mm 12 5 Quantity 2 Wear limit mm 7 Battery Type M F Capacity AH 12V 90AH Glow plug Reserved capacity RC 160 Type Seized type Rated voltage 11 5 Circuit connection Par...

Страница 97: ...09 4 2 SPECIAL SERVICE TOOL Name Description Glow plug remover Tool for removing the glow plug from cylinder head ...

Страница 98: ... not used since the remote start function has been deleted Tightening torque 15 3 Nm Engine ECU Pre glow Indicator Instrument cluster Ground terminal Pre glow control signal ECU 113 IG1 power terminal Not available for the vehicle without remote start function Glow plug terminals 1 4 K Line ECU 34 G5 terminal deleted Battery main cable Glow Plug Control Relay ...

Страница 99: ...cation Rated voltage DC 12V Operating voltage DC 8 15V Operating temperature 40 100 C Relay operating voltage Over 6 5V Relay OFF voltage OVER 1 5v Relay coil resistance 11 3Ω Voltage drop Below 150Mv in each glow plug Current 16A Parasitic current Max 1mA ...

Страница 100: ...d by the ECU starts from engine start This improves the idling conditions and reduces the emission and noise 2 System Check Glow Plug Forced Shut off of Relay Check for short in each glow plug Check for open due to over voltage in each glow plug Check for open to ground in glow plug When the glow plug circuit is open to ground 1 Operation Pre heating Coolant temperature 35 C 25 C 20 C 10 C 0 C 10 ...

Страница 101: ...ecksum error Insufficient byte 3 DTC DTC Description Error P1678 GCU circuit is open GCU circuit is open P1679 GCU circuit is short GCU circuit is short P1680 GCU circuit is short to ground GCU circuit is short to ground P1676 Communication error Communication error between ECU and GCU P1677 Defective GCU Communication error between ECU and GCU P0671 GCU channel 3 opened circuit GCU channel 3 circ...

Страница 102: ...pedal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Страница 103: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Страница 104: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Страница 105: ...12 6 2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Страница 106: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could...

Страница 107: ... ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Страница 108: ...ntil the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runnin...

Страница 109: ...hicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Страница 110: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Страница 111: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Страница 112: ...NO DATA ...

Страница 113: ...01 3 0000 00 Front view Left view Right view Rear view 1 ENGINE LAYOUT ...

Страница 114: ... steering pump pulley Oil pressure switch Idler pulley No 2 Water pump pulley 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 IMV valve Crankshaft position sensor Isolation damper ...

Страница 115: ...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 E EGR valve E EGR solenoid valve EGR cooler Electronic throttle body Oil cooler assembly ...

Страница 116: ...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 Fuse relay 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 le...

Страница 117: ...0 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 Clean every 7 500 km change every 15 000 km The service interval should be shortened under severe conditions Gasoline Clean every 15 000 km replace every 60 000 km The service interval should be shortened under severe conditions Fuel filter EU Cha...

Страница 118: ...gyong genuine coolant Anti Freeze SYC 1025 Capacity approx 8 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 i...

Страница 119: ... Otherwise some electric or electronic components could be damaged 2 Servicing 1 Lifting up the vehicle Always keep the safety precautions To prevent the vehicle from rolling down put the chocks under the tires when using a 4 post lift Make sure to support the correct lifting points when using a 2 post lift 2 Exhaust system Wear the safety glove when removing the exhaust pipe Make sure that the ex...

Страница 120: ...parts 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 ...

Страница 121: ...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...

Страница 122: ... 20Nm 180 20 660 720 Nm 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 scr...

Страница 123: ...ocharger 2 10 1Nm EGR valve M8 22 3 25 2 5Nm EGR pipe bolt to exhaust manifold M8 16 2 10 1Nm EGR pipe bolt to EGR cooler M8 16 2 25 2 5Nm Name Size Numbers of fastener Tightening torque 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 m...

Страница 124: ...10 1Nm Oil dipstick 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 Powe...

Страница 125: ...em Select 5 speed A T DC 5 AT Select 6 speed A T DSI 6 AT Select Pressure sensor for A C refrigerant NO Select the appropriate system Type Pressure sensor for A C refrigerant Immobilizer NO Select YES if the vehicle has immobilizer YES YES Vehicle speed input type CAN Select CAN if the vehicle has ABS or ESP CAN WIRE Fan 2 relays Select PWM PWM fan PWM fan Auto cruise NO Select YES if the vehicle ...

Страница 126: ... Intake 0 1 to 0 35 mm Exhaust 0 1 to 0 35 mm Camshaft position sensor Distance between Camshaft position sensor and sprocket 0 20 to 1 80 mm Valve Clearance between valve and piston Intake 0 6 to 1 0mm Exhaust 0 6 to 1 0mm Valve recess Intake 0 6 to 1 0mm Exhaust 0 6 to 1 0mm Cylinder block Piston protrusion 0 475 to 0 745mm Piston ring TOP ring end gap 0 20 to 0 35 mm 2nd ring end gap 0 35 to 0 ...

Страница 127: ...200 20 Nm 180 20 660 to 720 Nm Not re usable Oil pan M6 20 18 10 1 Nm M6 35 2 10 1 Nm M6 85 2 10 1 Nm M6 120 2 10 1 Nm M8 40 2 25 2 5 Nm HP pump main nut M14 1 5 8 1 1 65 5 Nm HP pump bolt M8 55 3 25 2 5 Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1 Nm M8 60 4 25 2 5 Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket bolt M11 40 1 30 3 Nm Chain tensioner screw bolt M38 1 5 1 25...

Страница 128: ...sensor M8 28 2 20 5Nm Cam position sensor M8 14 1 10 14Nm Booster pressure sensor M6 20 2 10 1Nm Exhaust manifold M8 10 40 4Nm Turbocharger M8 3 25 2 5Nm Support bolt 1 25 2 5Nm 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 2 25 2 5Nm EGR pipe bolt Intake side M...

Страница 129: ...6 16 1 10 1Nm Oil filter cap 1 25 2 5Nm Fuel rail M8 35SOC 2 25 2 5Nm Injector clamp bolt M6 60 2 10 1Nm 120 10 High pressure pipe between HP pump and fuel rail M17 1 30 3Nm High 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 M8x25 4 25 2 5Nm Power steering pump M8 100 3 25 2 5Nm Cylinder head front cover M6 10...

Страница 130: ... gasket This test provides current engine operating status Before cranking the engine make sure that the test wiring tools and persons are keeping away from moving components of engine e g belt and cooling fan Park the vehicle on the level ground and apply the parking brake Do not allow anybody to be in front of the vehicle Measurement Warm the engine up to normal operating temperature 80 C Discon...

Страница 131: ...e test procedure do not inject the engine oil into the combustion chamber Test condition normal engine operating temperature 80 C Specified value Whole engine below 25 at valve and cylinder head gasket below 10 at piston ring below 20 Crank the engine for approx 10 seconds by using the start motor 2 Record the test result and measure the compression pressure of other cylinders with same manner 3 I...

Страница 132: ...02 9 0000 00 Position the piston at TDC and measure the piston protrusion from crank case mating surface 3 Piston protrusion check Specified value 0 475 to 0 745 mm Measure it at both ends of crankshaft ...

Страница 133: ...6 to 1 0 mm Exhaust valve 0 6 to 1 0 mm Measure the cylinder head height A 1 If the height is less than the limit the cylinder head must be replaced Insert the valves into the valve guides and measure the recesses 2 If the measured value is out of the specified range machine the valve seat as much as necessary until the specified value is achieved Valve recess a 0 6 to 1 0 mm 2 Cylinder head press...

Страница 134: ...n the vehicle while servicing in engine compartment Before work on engine and each electrical equipment be sure to disconnect battery negative terminal Before service works be sure to prepare the works by cleaning and aligning work areas Do not allow the foreign material get into the fuel injection system When removing the engine use only the safety hook on engine and engine hanger Do not support ...

Страница 135: ... not allow the fluid and engine oil to make contact with the body paintwork and hoses If work on the fluid system such as fuel and oil working area should be well ventilated and smoking should be prohibited Gasket or seal on the fuel lubrication system should be replaced with new ones and bolts and nuts should be tightened as specified After removal installation works be sure to check whether ther...

Страница 136: ...ont mounting insulator LH RH Old New RH LH RH LH The optimized engine mountings have been introduced after performing the system analysis and on vehicle test The optimized engine mountings have been introduced after performing the system analysis and on vehicle test ...

Страница 137: ...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 ...

Страница 138: ...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 ...

Страница 139: ...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 ...

Страница 140: ...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 ...

Страница 141: ...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 EGR cooler bypass valve This valve is controlled by ECU When the engine is cooled the exhaust gas goes to combustion chamber without passing through EGR cooler because the valve is c...

Страница 142: ...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 ...

Страница 143: ...cation Insulator 3 ENGINE MOUNTING D20DTR engine uses 3 point mounting type that supports the engine and transmission simultaneously Components Rear mounting insulator 2WD 4WD A T M T A T M T Front mounting insulator Left side Location Insulator ...

Страница 144: ...mounting insulator Right side Type Rubber mounting Function Supports the torque reaction Front mounting insulator Left side Type Rubber mounting Function Supports the torque reaction Rear mounting insulato Type Rubber mounting Function Supports the powertrain rod ...

Страница 145: ...d to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas 2 Exhaust Manifold Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts EGR port is integrated in cylinder head Components Components For detailes refer to Chapter Intake System Exhaust manifold For detailes refer to Chapter Exhaust System ...

Страница 146: ... HEAD 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 Front view Cylinder head cover ...

Страница 147: ... 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 ...

Страница 148: ...mshaft position sensor Components Cylinder head Cylinder head contains 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 ...

Страница 149: ... 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 Rear Coolant expansion plug M21 Oil gallery expansion plug M10 Intake side ...

Страница 150: ...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 Octagon cam for tooling Thrust journal Connected to vacuum pump Intake Camshaft Closed flow type water jacket improving cooling performance ...

Страница 151: ...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 ...

Страница 152: ...ture cylinder head block profile 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 ...

Страница 153: ...t sprocket Exhaust camshaft sprocket Teeth 42 EA 1 Chain Drive 1 Overview The drive chain is single chain drive system with simple design and variable performance and it utilizes the hydraulic tensioner to reduce the wave impact generated by the chain This chain is light weight and has high durability through single bush chain Shoulder bolts are used for better NHV 7 CHAIN AND GEAR DRIVE SYSTEM D2...

Страница 154: ...gle 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 valve Hydraulic tensioner assembl...

Страница 155: ... impact absorbing Static and dynamic force Spring 4 Guide rail The 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 cha...

Страница 156: ...02 33 0000 00 Screw plug Oil seal Timing gear case cover 5 Timing gear case cover Timing gear case cover TGCC ...

Страница 157: ...nd screw plug on the timing gear case cover Do not touch the inner lip of crankshaft front seal Be careful not to damage the screw thread when removing the lock pin to release the chain tensioner Be careful not to damage the O ring when installing the screw plug A671 997 01 46 Crankshaft front seal Location of chain tensioner screw plug ...

Страница 158: ...02 35 0000 00 Oil pan sassembly 8 OIL PAN The oil pan in D20DTR engine improves the NVH Especially the oil draining is much easier than before Components ...

Страница 159: ...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 ...

Страница 160: ...o transaxle by absorbing the impact 3 Operation Compensating the irregular operation of engine The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more less pulsation absorbing effect Transaxle protection function Reduces the torsional vibration to powertrain transaxle b...

Страница 161: ...ange Stable revolution of the primary and secondary wheel by using planetary gear Works as auxiliary damper against spring changes Less heat generation due to no direct friction against spring surface Plastic material is covered on the spring outer surface Increased durability by using plastic bushing extends the lifetime of grease 6 Drive Plate Drive plate receives the power from the start motor ...

Страница 162: ...02 39 0000 00 10 PISTON CRANKSHAFT CYLINDER BLOCK The crankshaft and the cylinder block convert the compression pressure to the rotating energy Components Cylinder block Piston Connecting rod Crankshaft ...

Страница 163: ...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 ...

Страница 164: ... cylinder bore and prevents the leaked combustion gas from 1 ring from leaking into the crank chamber Oil ring Scrapes the engine oil on the cylinder bore Piston pin Connects the piston the connecting rod and transfers the linear movement of piston to connecting rod to convert it to rotating energy Snap pin Locks the piston pin 4 Assembling the piston Install the piston rings with the Y mark on th...

Страница 165: ...ne 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 Selecting piston oversize Top of piston Top of cylinder block ...

Страница 166: ...to the rotating movement of crankshaft The big end is connected to connecting rod bearing and the crank pin journal and the small end is connected to the piston pin 2 Components Piston pin bush Connecting rod Connecting lower bearing Connecting rod cap Connecting rod cap bolt Connecting rod upper bearing ...

Страница 167: ... 0 063 2 Y 1 808 Y 1 809 0 016 54 614 1 812 1 812 50 960 0 062 3 B 1 812 R 1 806 0 015 1 816 1 809 0 061 Min 0 015 Max 0 063 3 Selection of crankshaft pin journal bearing The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections Three sets in the table below have nearly same oil clearance 0 015 0 063 mm of bearing Identification Coloe mark on bearing side surface Oil clear...

Страница 168: ...haft is installed on the cylinder block 2 Arrangement Crankshaft main bearing upper Crankshaft main bearing upper Upper thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower Lower thrust bearing Crank pin journal Main journal ...

Страница 169: ... 513 66 519 3 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 Bottom of cylinder block Selection of upper main bearing Mating surface of crankshaft sprocket Selection of lower main bearing ...

Страница 170: ... Block 1 Overview The major dimensions in D20DTR are similar to D20DT engine It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation 2 Layout Right side Right side Expansion plug Screw plug ...

Страница 171: ...02 48 Left side Expansion plug 3 Features For simple manufacturing the crankcase blow by gas passage and the oil return hole are made by casting on the cylinder block ...

Страница 172: ...sage from cylinder head to inlet port of water pump is integrated in cylinder head The engine oil from oil pump is supplied to the main oil gallery through oil channel oil filter module and cross bore in cylinder block without using external pipes This oil is supplied to main bearing cylinder head and MBU And it is sprayed to the chain through the chain tensioner connected to cross bore Crankcase ...

Страница 173: ...ure 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 Fuel tank Capacity 75 L Material Steel Fuel sender Single sender type Change interval EU every 40 000 km GEN every 45 00...

Страница 174: ...ystem 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 clean the related area in engine compartment 4 Clean the engine com...

Страница 175: ...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 Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed 6 To s...

Страница 176: ...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 ...

Страница 177: ...of injector Excessive injector backleak 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 ...

Страница 178: ...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 ...

Страница 179: ...re Device for low pressure 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 ...

Страница 180: ...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 ...

Страница 181: ...03 11 2210 01 4 Fuel System Check Procedure ...

Страница 182: ...connector and then IMV connector 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 ...

Страница 183: ...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 ...

Страница 184: ... 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 ...

Страница 185: ...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...

Страница 186: ...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...

Страница 187: ... 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 ...

Страница 188: ...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...

Страница 189: ...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 ...

Страница 190: ...n 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 film during high sp...

Страница 191: ...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...

Страница 192: ...c refer to Chapter Engine Control Engine ECU D20DTR Engine control by various signals Crankshaft position sensor Measuring engine rpm Injector C3I Pre injection main injection after injection by signals from ECU HFM sensor Measuring intake air mass and temperature Camshaft position sensor Determining injection order ...

Страница 193: ...ure Distributing the fuel to injectors Fuel filter assembly Supplying clean fuel fuel heating water separation by priming pump Plunger type HP pump 1 800 bar Vane type LP pump 6 bar T MAP sensor Measuring booster pressure and temperature High pressure pump Generating high pressurized fuel and supplying it according to engine rpm required volume required pressure ...

Страница 194: ...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...

Страница 195: ...03 25 2210 01 3 Input Output devices Refer to Chapter Engine Control ...

Страница 196: ...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...

Страница 197: ...ion Air 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 103 9 kg Operating temperature 30 100 C Intercooler Core material Aluminum Size 614W x 192H x 30T Core size 614W x 192H x 30T Tank material Plastic Molding Efficiency 80 ...

Страница 198: ...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 ...

Страница 199: ...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 ...

Страница 200: ...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 6 For more information refer to Chapter Engine Control 2313 01 Air cleaner assembly ...

Страница 201: ...ly in accordance with the engine load and rpm For more information refer to Chapter Engine Control 1719 01 Intake manifold Passage for variable swirl valve and for intake air 1719 16 Electric throttle body For more information refer to Chapter Engine Control ...

Страница 202: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM For more information refer to Chapter Engine Control ...

Страница 203: ...04 9 1719 00 4 OPERATING PROCESS Work Flow ...

Страница 204: ...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 ...

Страница 205: ...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...

Страница 206: ...05 3 1729 01 1 TROUBLESHOOTING 1 Work Flow ...

Страница 207: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Страница 208: ...em purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion 2 LAYOUT Exhaust front pipe assembly Muffler assembly Exhaust tail pipe assembly For more information refer to Chapter Engine Control ...

Страница 209: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Страница 210: ... 1 SPECIFICATION Unit Description Specification Turbocharger Max expansion coefficient 4 0 Max turbine speed 226 000rpm Max temperature of turbine housing 790 Weight 6 5kg E VGT actuator Operation duty cycle 250Hz ...

Страница 211: ...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...

Страница 212: ...uling the turbocharger Oil Leakage Followings are the reasons for oil leakage condition Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and the rotation speed of turbine wheel Please note this is not a turbocharger problem Oil Drain Pipe Defect In case where oil flow from the turbocharger sensor housing to the crank case is not smooth wou...

Страница 213: ...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 ...

Страница 214: ...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 ...

Страница 215: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Страница 216: ...06 9 1914 01 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Страница 217: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Страница 218: ...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...

Страница 219: ...06 12 2 Work Flow for Troubleshooting ...

Страница 220: ...06 13 1914 01 ...

Страница 221: ...06 14 ...

Страница 222: ...06 15 1914 01 ...

Страница 223: ...06 16 ...

Страница 224: ...s the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger 1 Overview Diffuser With the meaning of spreading out it is a device that transforms fluid s speed energy into the pressure energy by enlarging the fluid s passage to slow down the flow The E VGT system installed to the D20DTR engine variably controls the passages of the turbine housing to regul...

Страница 225: ...F 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 2 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 l...

Страница 226: ...uty control Accelerator pedal position sensor Transfers driver s will to accelerate to ECU Atmospheric pressure RPM signal HFM sensor Improves the engine power Coolant temperature sensor Operates the VGT according to engine warm up 세부제어로직은 엔진제어편 참조 T MAP sensor Booster pressure and temperature ...

Страница 227: ...06 20 3 INPUT OUTPUT DEVICES ...

Страница 228: ...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...

Страница 229: ...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...

Страница 230: ...ibed 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 Change every 15 000 km or 12 months But shorten the service interval under severe condition Oil injection nozzle Type Piston Operating pressure 1 5bar Closing pressure 1 0bar Oil fl...

Страница 231: ...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...

Страница 232: ...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...

Страница 233: ...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...

Страница 234: ...in cooling capacity over 72 000 kcal h Antifreeze Type Long life coolant Mixing ratio water antifreeze 50 50 Cooling fan module Type Electric Capacity Ø472 x 400W x 5B Control type PWM type Coolant reservoir Capacity over 1 5 L Circulation Closed roof type Pressure cap Screw type 1 4bar Vacuum valve Screw type 1 4bar Thermostat Type Wax pallet type Opening temperature 90 C Fully open temperature 1...

Страница 235: ... Improper 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 Clo...

Страница 236: ... 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 ...

Страница 237: ...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...

Страница 238: ...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...

Страница 239: ...the engine Coolant reservoir Long life coolant is used Thermostat When the engine coolant reaches 90 the thermostat starts to open fully open at 100 and lets the coolant flow to the radiator to maintain the engine temperature 1 SYSTEM DESCRIPTION 1 Overview Water pump Impeller vane Sealing Oil filter module ...

Страница 240: ...xchange 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 Coolant temperature sensor Measures the coolant temperature and sends the result to the engine ECU ...

Страница 241: ...CATION Alternator Crankshaft pulley Alternator pulley 1 2 94 Normal output idling 2200 rpm 70 120 A Regulator voltage 14 6 V Brush Length 12 5 mm Wear limit 7 mm Battery Type MF Capacity 90 AH Unit Description Specification ...

Страница 242: ...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...

Страница 243: ...attery Replace the battery Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace the alternator 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 Repa...

Страница 244: ...09 6 3 Checking Battery ...

Страница 245: ...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...

Страница 246: ...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...

Страница 247: ...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...

Страница 248: ...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...

Страница 249: ...09 11 1451 01 2 OPERATING PROCESS 1 Charging Flow ...

Страница 250: ...tery charger to the 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 Sinc...

Страница 251: ...09 13 1451 01 3 CIRCUIT DIAGRAM ...

Страница 252: ...tage 12 V Operating voltage 6 16 V Maximum temperature 1000 1115 C Operating temperature 18 seconds after ignition ON 980 1100 C 60 seconds after ignition ON 980 1100 C Glow plug control unit EMS operating voltage 6 16 V Operating temperature 40 C 110 C Dark current Max 1 mA ...

Страница 253: ...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 Glow indicator Engine ECU D20DT...

Страница 254: ...10 5 1413 00 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Страница 255: ...10 6 3 Circuit Diagram ...

Страница 256: ... Battery voltage 1 2 3 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 controlle...

Страница 257: ...he engine ECU before starting The time for pre heating is controlled by the ECU Input power VB V Arrival time T1 s 6 8 27 7 5 8 8 4 1 9 3 15 10 2 4 11 1 95 11 5 1 9 If the input power VB is 11 5 V or less the GCU supplies the battery power for arrival time T1 If the input power VB is greater than 11 5 V the GCU supplies the voltage of 11 5 V for arrival time T1 The time for pre heating by coolant ...

Страница 258: ...is received after the step 1 At cranking The step 3 is started after the step 2 Post glow Step 4 The post heating is for reducing HC CO after the engine is started If the time for post heating exceeds 180 sec the GCU unit cuts off the power to each glow plug even if there is pre heating request from the engine ECU Emergency glow If no CAN signal is received for 4 seconds from the engine ECU after ...

Страница 259: ...10 10 Normal operation mode This shows the pre glow and post glow step as a chart ...

Страница 260: ...10 11 1413 00 Operation when there is no engine start signal cranking after ignition ON ...

Страница 261: ...Description Specification Capacity 12 V 2 3 kW 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 ...

Страница 262: ...switch or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replace 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 ...

Страница 263: ...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 ...

Страница 264: ...11 6 2 Circuit Diagram ...

Страница 265: ...pedal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Страница 266: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Страница 267: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Страница 268: ...12 6 2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Страница 269: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could...

Страница 270: ... ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Страница 271: ...ntil the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runnin...

Страница 272: ...hicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Страница 273: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Страница 274: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Страница 275: ...alve EGR gas flow rate 120 kg h Cooling capacity 8 3 kW or more Cooling fin type Wavy fin Cooler type U shaped E EGR bypass valve Solenoid valve Drivien by Vacuum Solenoid valve E EGR cooler Position sensor Sensing type Hole sensor Supplied voltage 5V 10 Maximum signal range 5 95 Maximum power consumption 15mA ...

Страница 276: ...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...

Страница 277: ...ore warming up the engine 2 Location and Components 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 EGR pipe Transports the exhaust gas from the EGR cooler and EGR bypass valve to the intak...

Страница 278: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Страница 279: ...13 7 1793 00 2 Input Output Devices ...

Страница 280: ...he 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 Engine coolant tempe...

Страница 281: ...ission Regulation Euro V Front Area 154 06 Size DOC 158 X 124 X 78L DPF 158 X 124 X 195L CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 4 2L Material of Filter AT Aluminum Titanium Alloy ...

Страница 282: ...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 traffic d...

Страница 283: ...t gas The driver may not feel any particular difference from the vehicle Overload of CDPF warning lamp blinking 3 Warning Lamp Related to CDPF CDPF regeneration process warning lamp NOT illuminated If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process the soot is continuously accumulated in the CDPF When this condition contin...

Страница 284: ...mount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp comes on and the engine power is decreased to protect the system To solve this problem blow soot between the engine and exhaust system several times and erase the related DTC Then check if the same DTC is regenerated again If so check the D...

Страница 285: ...h the oxidation process of CO and HC And the DPF Diesel Particulate Filter collects PM Particle Matter and is regenerated to reduce the quantity of particulates HC and CO But there is a limitation in reducing the emission of exhaust gas for each system so the CDPF which combines these two system is applied ...

Страница 286: ...ce between before and after the CDPF Engine ECU DCM 3 7 Post injection Throttle valve Regulates the rate of air intake CDPF DOC DPF Front temperature sensor Protects the turbocharger Rear temperature sensor Measures the temperature of fuel combustion 2 COMPONENT For details refer to section Engine Control ...

Страница 287: ...emperature exceeds 600 the life of CDPF can be reduced So the amount of fuel post injection is decreased If the temperature drops under 600 the rate of regeneration can be decreased So the amount of fuel post injection is increased Differential pressure sensor This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF Electric throttle va...

Страница 288: ...s increased and the post injection is started for regeneration The amount of fuel post injection is controlled by the exhaust gas temperature measured by the rear temperature sensor If the temperature is less than 600 the amount of post injection is increased to increase the regeneration temperature Otherwise the fuel injection amount is decreased or the fuel is not injected When the engine is run...

Страница 289: ...temperature of DOC This sensor is located at the rear side of DOC and monitors the overheating of CDPF and post injection volume Engine ECU D20DTR Differential pressure sensor Measures the difference between inlet and outlet pressures of CDPF If the difference is higher than the specified value when collecting the PM this makes the post injection for forced recycling of PM T MAP sensor Intake air ...

Страница 290: ...mperature and burns the collected PM at approx 600 C Oxidation DOC When the exhaust gas enters into the CDPF assembly its CO HC and PM are reduced by the redox reaction of the DOC The remaining PM is filtered and collected in CDPF and the temperature of the exhaust gas is increased to between 450 and 500 C 5 OPERATING PROCESS Configuration and principle of operation The exhaust gas passed through ...

Страница 291: ... EGT sensor detects whether the DOC can burn oxidize the post injected fuel or not and sends the signal to the ECU to maintain the DOC operating temperature between 300 and 500 The DOC reduces CO and HC of the exhaust gas by redox reaction and also reduces small amount of PM 1 Oxygen adheres to the catalyst materials Less than 180 2 CO and HC are oxidized by the catalyst materials More than 180 ...

Страница 292: ...s to the inlet of a channel it is released from the outlet of the adjacent channel through the porous wall because of the closed outlet of the first channel and the PM is collected in the first channel Collecting PM of CDPF Normally when the driving distance becomes approx 600 to 1 200 km enough amount of soot to be burned is filtered and accumulated in the CDPF The ECU increases the amount of fue...

Страница 293: ...xhaust temperature intake air mass flow booster pressure etc The regeneration is started when the amount of the collected PM is 28 g or more The ECU commands post injection to increase the temperature of CDPF to 600 When the amount of the collected PM is not enough The DPF works as a filter 1 When enough amount of PM is collected The ECU commands post injection and increase the exhaust gas tempera...

Страница 294: ...tual 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 performed during driving because it decreases the fuel economy Totally 5 injections can be performed in on...

Страница 295: ...14 17 2412 02 6 ELECTRIC CIRCUIT DIAGRAM ...

Страница 296: ...ines diesel and gasoline Problems when using non designated engine oil for CDPF 3 Decreases the life span of engine oil due to accumulated ash in DPF around 30 Decreases the fuel economy due to friction resistance exhaust gas resistance and frequent recycling process of DPF The fuel containing high sulfur may cause the same problems 2 Do Not Use the Fuel Containing High Sulfur Producing white smok...

Страница 297: ...le TA 0 Full 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 mV 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 ...

Страница 298: ... 4 Glow plug Differential pressure sensor Camshaft position sensor 1 MAJOR COMPONENTS Rear EGT sensor Oxygen sensor Front EGT sensor HFM air mass temperature Injector C3I Variable swirl valve actuator IMV ...

Страница 299: ... rail pressure sensor EGR valve Electric throttle body Knock sensor 2 ea Coolant temperature sensor T MAP sensor D20DTR ECU E VGT actuator Water sensor GCU Preglow control unit E EGR bypass valve Fuel temperature sensor ...

Страница 300: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Страница 301: ...position sensor Camshaft position sensor Coolant temperature sensor Exhaust gas temperature sensor HFM sensor Oxygen sensor T MAP sensor Crankshaft position sensor Accelerator pedal sensor Throttle position sensor Knock sensor Auto cruise switch Rear right wheel speed without ABS Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal Water sensor ...

Страница 302: ...ut CAN E EGR cooler bypass valve Instrument cluster TCU Self diagnosis PTC heater Cooling fan E EGR valve Variable swirl valve E VGT actuator IMV valve A C compressor Injector Throttle position sensor Glow plug unit ABS ESP unit GCU ...

Страница 303: ...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...

Страница 304: ...ot 1 Reduces PM by injecting before main injection After PM control Pilot 2 Reduces NOx and noise by shortening main injection delay due to flammability Post 1 Reduces PM by enabling fuel activation Pre Controls NOx emission level Combustion noise and Stable idle Post 2 Activates CDPF by increasing exhaust gas temperature and supplying reduction material Pilot injection Multi injection ...

Страница 305: ...n injection The post injection is the injection process after main injection and consists of After injection Post 1 injection and Post 2 injection 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 pro...

Страница 306: ...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 pressure wi...

Страница 307: ...sure 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 enable fuel activation The PM amount in the emission and smoke can be reduced through these processes Only up to 5 ...

Страница 308: ...ressure 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 curr...

Страница 309: ... the 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 engin...

Страница 310: ...SP system the antagonistic torque engine brake transmitted to the drive wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking The system thus chooses the greater of these 2 values main flow pilot flow in order to prevent any loss of control of the vehicle during a sharp deceleration As soon as the injected fuel becomes higher than the fuel l...

Страница 311: ...el which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and chooses the smaller o...

Страница 312: ... 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...

Страница 313: ...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...

Страница 314: ...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...

Страница 315: ...to 2 500 rpm Fuel temperature 0 Fuel temperature 80 Learning 2 times for each cylinder every 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 ...

Страница 316: ...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...

Страница 317: ...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...

Страница 318: ...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 ...

Страница 319: ...15 25 0000 00 B Input Output for variable swirl valve ...

Страница 320: ...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 tangential port generates the ...

Страница 321: ...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...

Страница 322: ...duces 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 cooler Accelerator pedal module D20DTR ECU Coolant temperat...

Страница 323: ...15 29 0000 00 C Input Output of E EGR system ...

Страница 324: ...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...

Страница 325: ...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 ...

Страница 326: ...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 E VGT actuator Accelerator pedal module Crankshaft position sensor Oxygen sensor T MAP sensor Coolant temperature sensor D...

Страница 327: ...15 33 0000 00 C Input Output for E VGT system ...

Страница 328: ...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 ...

Страница 329: ... 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 ...

Страница 330: ...15 36 C Input Output for oxygen sensor ...

Страница 331: ...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 ...

Страница 332: ...culates 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...

Страница 333: ...15 39 0000 00 C Input Output for cooling fan and A C compressor ...

Страница 334: ...HI 18 bar Refrigerant pressure HI 105 Coolant temp 115 HI 115 Coolant temp OFF cut A C compressor OFF conditions Coolant temperature below 20 or over 115 Approx 4 seconds after starting the engine Engine rpm below 650 rpm or over 4500 rpm When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 30 kg then ON below 21 4 kg The output voltage from refrigerant press...

Страница 335: ...eater air outlet and increase the temperature of air to the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required PTC does not operate during engine cranking while the battery voltage is lower than 11 V or during preheating process of glow plugs B Components HFM intake air temperature Coolant temperature sensor PTC heater D20DTR ECU PTC 1 relay...

Страница 336: ...perature There are three circuits in PTC heater Only one circuit is connected when PTC1 relay is ON and two circuits are connected when PTC2 relay is ON Operation process reaches at a certain temperature high resistance low current less heat radiation temperature down high resistance high current temperature up ...

Страница 337: ...oolant temperature 15 C PTC ON after satisfying the conditions in 2nd step 2ndt 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...

Страница 338: ...d 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 For details refer to Chapter Immobilizer B Components Basic components ignition key system D20DTR ECU Immobilizer antenna Instrument cluster ...

Страница 339: ...CU 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 ...

Страница 340: ...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 ...

Страница 341: ...15 47 0000 00 C Input Output for CDPF control ...

Страница 342: ...etected 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 amount of intake air are controlled It is to raise the temperature by increasing the am...

Страница 343: ...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 ...

Страница 344: ...15 50 3 Input Output for CAN communication ...

Страница 345: ...01 3 0000 00 1 STRUCTURE AND COMPARISON D27DT EU IV Engine Front View D27DT EU IV Engine Top View ...

Страница 346: ...01 4 D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Страница 347: ...01 5 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Страница 348: ...01 6 D27DT Engine General Side View D27DT Engine General Left Side View ...

Страница 349: ...01 7 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Страница 350: ...01 8 2 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Страница 351: ...01 9 0000 00 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Страница 352: ...01 10 ...

Страница 353: ...01 11 0000 00 ...

Страница 354: ...ANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT 4 The shape and size of D27DTP POWER UP are slightly different from those of D27DT engine but the basic configuration of two systems is almost same 1 Engine Assembly ...

Страница 355: ...01 13 0000 00 2 Major Changes and Summary ...

Страница 356: ...01 14 ...

Страница 357: ...01 15 0000 00 ...

Страница 358: ...01 16 ...

Страница 359: ...01 17 0000 00 ...

Страница 360: ...01 18 ...

Страница 361: ...01 19 0000 00 ...

Страница 362: ...01 20 ...

Страница 363: ...e read this manual and follow the instructions carefully Signal words such as CAUTION and NOTE have special meanings indicates information to assist maintenance and instructions indicates a potentially hazardous situation which if not avoided could result in death or serious injury indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property d...

Страница 364: ...work To improve the efficiency of service work use only recommended and specified tools Use only Ssangyong genuine spare parts Never reuse the cotter pin gasket O ring oil seal lock washer and self locking nut Replace them with new ones If reused normal functions cannot be maintained Store the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or m...

Страница 365: ...t in the vehicle while servicing in engine compartment Before work on engine and 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 th...

Страница 366: ...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 should be replaced with new ones when removed...

Страница 367: ...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 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of abov...

Страница 368: ...01 26 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Страница 369: ...01 27 0000 00 ...

Страница 370: ...box PTC relay box Battery Vacuum modulator for VGT turbo charger 1 2 3 4 5 6 7 8 9 10 11 12 13 FFH Assembly Only for vehicle with FFH Power steering oil tank Engine oil filler cap Fan shroud E EGR Valve High capacity PCV oil separator HFM sensor 6 0 VGT turbo charger Air cleaner housing 2Coolant surge tank ABS ESP HECU Including TPMS function optional Exhaust gas FRT Temp sensor T3 14 15 16 17 18 ...

Страница 371: ...01 29 0000 00 Major Sensors and Components ...

Страница 372: ...01 30 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Страница 373: ...01 31 0000 00 ...

Страница 374: ...01 32 2 Preheat System ...

Страница 375: ...01 33 0000 00 3 Fuel System ...

Страница 376: ...01 34 Fuel Supply System ...

Страница 377: ...01 35 0000 00 4 Lubrication System ...

Страница 378: ...01 36 5 Cooling System ...

Страница 379: ...01 37 0000 00 6 Intake System ...

Страница 380: ...01 38 7 Exhaust System ...

Страница 381: ...ystem has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque 1 Coolant reservoir 2 FFH device 3 Brake fluid reservoir 4 Washer fluid reservoir 5 Common rail 6 Fuse box 7 Battery 8 Fuel filter 9 Power steering pump 10 Priming pump 11 EGR valve 12 Air cleaner assembly 13 Turbo charger 14 Oil dipstick ...

Страница 382: ...ley 4 Idle pulley 5 Coolant pump pulley 6 Alternator 7 Viscos fan clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 Drive plate MT DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR to center pipe Front View Rear View ...

Страница 383: ... 20 Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 PCV valve and oil separator 31 Oil dipstick 32 EGR LH 1 pipe ...

Страница 384: ...ock 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH 3 pipe 39 PCV valve and oil separator 40 Oil dipstick 41 High pressure pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Right Side View ...

Страница 385: ...02 7 1212 01 2 SPECIFICATIONS ...

Страница 386: ...02 8 3 ENGINE PERFORMANCE CURVE Output and Torque ...

Страница 387: ...02 9 1212 01 Oil Temperature Pressure and Boost Pressure ...

Страница 388: ...02 10 4 TIGHTENING TORQUE ...

Страница 389: ...02 11 1212 01 ...

Страница 390: ...02 12 ...

Страница 391: ...injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running How...

Страница 392: ...to the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume It is also installed on the connection of the high pressure fuel supply line of the HP pump D27DTP D27DT EU IV D27DT ...

Страница 393: ... D27DT Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail The I D and O D of the fuel rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely ...

Страница 394: ...03 6 2 COMPONENTS OF FUEL SYSTEM ...

Страница 395: ...03 7 1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Страница 396: ...e body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Страница 397: ...been deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more details refer to the next description The exhaus...

Страница 398: ...y of CDPF System by Vehicle Model Rexton II Same CDPF system for D27DTP and D27DT engines including its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors...

Страница 399: ...s burnt at 600 C CDPF Exhaust Gas Temperature Sensor The two temperature sensors inside the CDPF are installed in exhaust manifold front exhaust gas temperature sensor and in DOC rear exhaust gas temperature sensor and perform the following functions Front Exhaust Gas Temperature Sensor Rear Exhaust Gas Temperature Sensor Measures the exhaust gas temperature of the exhaust manifold As it is instal...

Страница 400: ...block the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Turbocharger may become weaker if high temperature exhaust gas passes through the turbocharger for DPF regeneration process The front exhaust gas ...

Страница 401: ...t gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in the exhaust emission and t...

Страница 402: ...ture of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Front exhaust gas temperature sensor Measuring temperature of exhaust gas in exhaust manifold Rear exhaust gas temperature sensor Measuring temperature of exhaust gas escaping DOC Nor...

Страница 403: ...raise the temperature by increasing the amount of fuel while decreasing the amount of intake air 2 Sytem Composition for Soot Combustion When the engine is running in low load range the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased To burn the soot filtered in the CDPF the control system should be installed to check the operating range and increase the tempera...

Страница 404: ...e The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Страница 405: ...ith two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filtered ...

Страница 406: ...The engine ECU detects the amount of particulate material colected by the information from temperature sensors and differential pressure snesor When the soot is accumulated the pressure difference between the front and the rear side occurs Then the engine ECU performs the post injection to raise the exhaust gas temperature and burn the collected soot at approx 600 C When the exhaust gas enters int...

Страница 407: ... engine ECU performs the CDPF regeneration operation However the driver is not informed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection during the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increase the temperature of...

Страница 408: ...p illuminated If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumulated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple overload of the CDPF To inform this to the driver the engine warning lamp comes on and the engin...

Страница 409: ...6 14 4 COMPONENTS OF CDPF SYSTEM Mounting condition and location Engine compartment RH Differential Pressure Sensor Front Exhaust Gas Temperature Sensor Throttle Body Front exhaust gas temperature sensor ...

Страница 410: ...NO DATA ...

Страница 411: ...OWERUP engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block For the D27DT engine the cooling system uses the fan clutch Cooling System for D27DTP POWER UP Engine ...

Страница 412: ...08 4 D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Страница 413: ...NO DATA ...

Страница 414: ...NO DATA ...

Страница 415: ...pedal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Страница 416: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Страница 417: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Страница 418: ...11 6 2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Страница 419: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could...

Страница 420: ... ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Страница 421: ...ntil the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runnin...

Страница 422: ...hicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Страница 423: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Страница 424: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Страница 425: ...01 3 0000 00 1 STRUCTURE AND COMPARISON D27DTP POWER UP CDPF Engine Front View D27DTP POWER UP CDPF Engine Top View ...

Страница 426: ...01 4 D27DTP POWER UP CDPF Engine Side View D27DTP POWER UP CDPF Engine Left Side View ...

Страница 427: ...01 5 0000 00 D27DT EU IV Engine Front View D27DT EU IV Engine Top View ...

Страница 428: ...01 6 D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Страница 429: ...01 7 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Страница 430: ...01 8 D27DT Engine General Side View D27DT Engine General Left Side View ...

Страница 431: ...01 9 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Страница 432: ...01 10 2 D27DTP Power Up Engine Performance Curve 1 Output and Torque vehicle with automatic transmission Oil Temperature Pressure and Boost Pressure vehicle with automatic transmission 2 ...

Страница 433: ...01 11 0000 00 3 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Страница 434: ...01 12 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Страница 435: ...01 13 0000 00 ...

Страница 436: ...01 14 ...

Страница 437: ...R CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT 4 The shape and size of D27DTP POWER UP are slightly different from those of D27DT engine but the basic configuration of two systems is almost same 1 Engine Assembly ...

Страница 438: ...01 16 2 Major Changes and Summary ...

Страница 439: ...01 17 0000 00 ...

Страница 440: ...01 18 ...

Страница 441: ...01 19 0000 00 ...

Страница 442: ...01 20 ...

Страница 443: ...01 21 0000 00 ...

Страница 444: ...01 22 ...

Страница 445: ...01 23 0000 00 ...

Страница 446: ...ad this manual and follow the instructions carefully Signal words such as CAUTION and NOTE have special meanings indicates information to assist maintenance and instructions indicates a potentially hazardous situation which if not avoided could result in death or serious injury indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damag...

Страница 447: ...ice work To improve the efficiency of service work use only recommended and specified tools Use only Ssangyong genuine spare parts Never reuse the cotter pin gasket O ring oil seal lock washer and self locking nut Replace them with new ones If reused normal functions cannot be maintained Store the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss ...

Страница 448: ... the vehicle while servicing in engine compartment Before work on engine and 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 bo...

Страница 449: ...fer 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 should be replaced with new ones when rem...

Страница 450: ...uring 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 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of above to...

Страница 451: ......

Страница 452: ...01 30 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Страница 453: ...01 31 0000 00 ...

Страница 454: ...box PTC relay box Battery Vacuum modulator for VGT turbo charger 1 2 3 4 5 6 7 8 9 10 11 12 13 FFH Assembly Only for vehicle with FFH Power steering oil tank Engine oil filler cap Fan shroud E EGR Valve High capacity PCV oil separator HFM sensor 6 0 VGT turbo charger Air cleaner housing 2Coolant surge tank ABS ESP HECU Including TPMS function optional Exhaust gas FRT Temp sensor T3 14 15 16 17 18 ...

Страница 455: ...01 33 0000 00 Major Sensors and Components ...

Страница 456: ...01 34 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Страница 457: ...01 35 0000 00 ...

Страница 458: ...01 36 2 Preheat System ...

Страница 459: ...01 37 0000 00 3 Fuel System ...

Страница 460: ...01 38 Fuel Supply System ...

Страница 461: ...01 39 0000 00 4 Lubrication System ...

Страница 462: ...01 40 5 Cooling System ...

Страница 463: ...01 41 0000 00 6 Intake System ...

Страница 464: ...01 42 7 Exhaust System ...

Страница 465: ...ystem has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque 1 Coolant reservoir 2 FFH device 3 Brake fluid reservoir 4 Washer fluid reservoir 5 Common rail 6 Fuse box 7 Battery 8 Fuel filter 9 Power steering pump 10 Priming pump 11 EGR valve 12 Air cleaner assembly 13 Turbo charger 14 Oil dipstick ...

Страница 466: ...ley 4 Idle pulley 5 Coolant pump pulley 6 Alternator 7 Viscos fan clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 Drive plate MT DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR to center pipe Front View Rear View ...

Страница 467: ... 20 Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 PCV valve and oil separator 31 Oil dipstick 32 EGR LH 1 pipe ...

Страница 468: ...ock 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH 3 pipe 39 PCV valve and oil separator 40 Oil dipstick 41 High pressure pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Right Side View ...

Страница 469: ...02 7 1212 01 2 SPECIFICATIONS ...

Страница 470: ...02 8 3 ENGINE PERFORMANCE CURVE Output and Torque ...

Страница 471: ...02 9 1212 01 Oil Temperature Pressure and Boost Pressure ...

Страница 472: ...02 10 4 TIGHTENING TORQUE ...

Страница 473: ...02 11 1212 01 ...

Страница 474: ...02 12 ...

Страница 475: ...injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running How...

Страница 476: ...to the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume It is also installed on the connection of the high pressure fuel supply line of the HP pump D27DTP D27DT EU IV D27DT ...

Страница 477: ... D27DT Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail The I D and O D of the fuel rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely ...

Страница 478: ...03 6 2 COMPONENTS OF FUEL SYSTEM ...

Страница 479: ...03 7 1881 09 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Страница 480: ...e body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Страница 481: ...been deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more details refer to the next description The exhaus...

Страница 482: ...y of CDPF System by Vehicle Model Rexton II Same CDPF system for D27DTP and D27DT engines including its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors...

Страница 483: ...s burnt at 600 C CDPF Exhaust Gas Temperature Sensor The two temperature sensors inside the CDPF are installed in exhaust manifold front exhaust gas temperature sensor and in DOC rear exhaust gas temperature sensor and perform the following functions Front Exhaust Gas Temperature Sensor Rear Exhaust Gas Temperature Sensor Measures the exhaust gas temperature of the exhaust manifold As it is instal...

Страница 484: ...block the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Turbocharger may become weaker if high temperature exhaust gas passes through the turbocharger for DPF regeneration process The front exhaust gas ...

Страница 485: ...t gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in the exhaust emission and t...

Страница 486: ...ture of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Front exhaust gas temperature sensor Measuring temperature of exhaust gas in exhaust manifold Rear exhaust gas temperature sensor Measuring temperature of exhaust gas escaping DOC Nor...

Страница 487: ...raise the temperature by increasing the amount of fuel while decreasing the amount of intake air 2 Sytem composition for Soot Combustion When the engine is running in low load range the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased To burn the soot filtered in the CDPF the control system should be installed to check the operating range and increase the tempera...

Страница 488: ...e The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Страница 489: ...ith two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filtered ...

Страница 490: ...The engine ECU detects the amount of particulate material colected by the information from temperature sensors and differential pressure snesor When the soot is accumulated the pressure difference between the front and the rear side occurs Then the engine ECU performs the post injection to raise the exhaust gas temperature and burn the collected soot at approx 600 C When the exhaust gas enters int...

Страница 491: ... engine ECU performs the CDPF regeneration operation However the driver is not informed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection during the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increase the temperature of...

Страница 492: ...p illuminated If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumulated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple overload of the CDPF To inform this to the driver the engine warning lamp comes on and the engin...

Страница 493: ...6 14 4 COMPONENTS OF CDPF SYSTEM Mounting condition and location Engine compartment RH Differential Pressure Sensor Front Exhaust Gas Temperature Sensor Throttle Body Front exhaust gas temperature sensor ...

Страница 494: ...NO DATA ...

Страница 495: ...OWERUP engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block For the D27DT engine the cooling system uses the fan clutch Cooling System for D27DTP POWER UP Engine ...

Страница 496: ...08 4 D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Страница 497: ...NO DATA ...

Страница 498: ...NO DATA ...

Страница 499: ...pedal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Страница 500: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Страница 501: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Страница 502: ...11 6 2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Страница 503: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could...

Страница 504: ... ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Страница 505: ...ntil the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runnin...

Страница 506: ...hicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Страница 507: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Страница 508: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Страница 509: ...01 4 1 COMPONENT LOCATOR 1 Front View ...

Страница 510: ... 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 ...

Страница 511: ...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 ...

Страница 512: ...nstalled in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equi...

Страница 513: ...02 3 1113 01 1 SPECIFICATIONS 1 Engine Specifications ...

Страница 514: ...02 4 2 Performance Curve ...

Страница 515: ...02 5 1113 01 2 SPECIAL TOOLS AND EQUIPMENT ...

Страница 516: ...02 6 ...

Страница 517: ...02 7 1113 01 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Страница 518: ...02 8 3 FASTENER TIGHTENING SPECIFICATIONS ...

Страница 519: ...02 9 1113 01 1 Fastener Tightening Specifications Cont d ...

Страница 520: ...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...

Страница 521: ...03 4 Temperature vs resistance ...

Страница 522: ...NO DATA ...

Страница 523: ...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 ...

Страница 524: ...05 4 4 FASTENER TIGHTENING SPECIFICATIONS ...

Страница 525: ...06 3 9210 01 1 OIL CIRCULATION ...

Страница 526: ...ry at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chain a Oil gallery from ...

Страница 527: ...07 3 2110 01 1 GENERAL SPECIFICATIONS ...

Страница 528: ...07 4 2 SPECIAL TOOLS AND EQUIPMENT ...

Страница 529: ...07 5 2110 01 3 FASTENER TIGHTENING SPECIFICATIONS ...

Страница 530: ...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...

Страница 531: ...07 7 2110 01 2 COMPONENT LOCATOR ...

Страница 532: ...ieces Bolt M6 4 pieces Upper radiator insulator Lower radiator insulator Plate Clip 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Inlet hose Outlet hose 3 way hose Deaeration hose reserver tank Clamp Clamp Make up hose holder Reserver tank Bolt M6 2 piece Cooling fan Viscous clutch Bolt M6 1 piece Bolt M6 3 piece 15 16 17 18 19 20 21 22 23 24 25 26 27 ...

Страница 533: ...08 3 1452 01 1 GENERAL SPECIFICATIONS ...

Страница 534: ...08 4 2 FASTENER TIGHTENING SPECIFICATIONS ...

Страница 535: ...arms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted by t...

Страница 536: ...s very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These systems use the EST signal from the ECM to control the EST The ECM uses the following information Engine load mass air flow sensor manifold air pressure sensor Engine coolant temperature Intake air temperature Crankshaft position Engine sp...

Страница 537: ...08 7 1452 01 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Страница 538: ...09 3 1522 16 1 ENGINE DATA DISPLAY TABLE ...

Страница 539: ...09 4 2 FASTENER TIGHTENING SPECIFICATIONS 1 Temperature vs Resistance ...

Страница 540: ...pedal The vehicle speed must be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement ...

Страница 541: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Страница 542: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Страница 543: ...10 6 2 Configuration Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ...

Страница 544: ...trol lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control system until you get used to it Improper use or not fully aware of this function could...

Страница 545: ... ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per o...

Страница 546: ...ntil the desired speed is reached while the vehicle speed is over 36 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 34 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runnin...

Страница 547: ...hicle speed is over 36 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Страница 548: ...owing conditions are applied When the brake pedal is depressed or When ESP is activated When the cruising speed is downed less than 34 km h When applying the parking brake during driving When using the clutch in order to shift M T only 1 2 3 4 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Страница 549: ...t brake properly to protect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking When the rapid acceleration is applied without acceleration pedal intervention When the cruise control lever is faulty When the brake switch an...

Страница 550: ...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 ...

Страница 551: ...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...

Страница 552: ... of the terminals do not contact with vehicle body or other metal parts Check that the grounding part has continuity with mounting bolts and vehicle body Check that wires are properly routed Make sure that wires are securely fixed to avoid contact with sharp body parts and high temperature parts such as the exhaust manifold and exhaust pipes The rotating parts such as fan pulley and fan belt pertu...

Страница 553: ...within this range Reserved temperature 40 C 85 C Max operating humidity 95 Resistible voltage 24V Insulating resistance No heat and fire due to the current leaks Confined with PCB waterproof and coating that requires the insulation Dark current below 7 0 mA When initiating the sleep mode after removing ignition key and locking the doors Voltage drop below 1 0V A Connector Pin No 31 and A Connector...

Страница 554: ...tive load 9 Door unlock relay DC 12V 200mA Inductive load 10 Siren DC 12V 260W Inductive load 11 Tail lamp relay DC 12V 200mA Inductive load 12 Hazard relay DC 12V 200mA Inductive load 13 Power window relay DC 12V 200W Inductive load 14 Rear defogger relay DC 12V 200W Inductive load 15 Wiper LOW relay DC 12V 250W Inductive load 16 Wiper HIGH relay DC 12V 250W Inductive load 17 Front washer motor D...

Страница 555: ...unlock switch LOCK OPEN UNLOCK GND 12 Rear door lock unlock switch OPEN one of rear seat GND CLOSE all rear seats OPEN 13 Tailgate lock unlock switch LOCK OPEN UNLOCK GND 14 Rear defogger switch ON GND OFF OPEN 15 Seat belt switch Unfastened GND Fastened OPEN 16 Theft deterrent alarm select switch ON GND OFF OPEN 17 Parking brake switch ON GND OFF OPEN 18 Air bag collision sensor ON 200 ms Low sig...

Страница 556: ...ndicated in each function does not include chattering processing time from switch input changing point 1 2 NO Input Signal Name Logic Status 26 Front defogger switch ON GND OFF OPEN 27 Central door lock switch ON GND OFF OPEN 28 SPWM easy access switch ON GND OFF OPEN 29 Multifunction auto light switch ON GND OFF OPEN 30 Turn signal light switch ON BAT GND OFF OPEN 5 1V 9 2V 31 SPWM Seat Position ...

Страница 557: ...02 7 8710 08 REKES Key Old New Changed the appearance of mechanical key and the company symbol 2 MAJOR CHANGES Front Back Front Back ...

Страница 558: ...ote controller and other electronic units to transmit and receive the signals and data The STICS includes the following functions Wiper control Ignition key reminder Door locking unlocking Lamp control Defogger control Time lagging control for power window Theft deterrent system control REKES key ...

Страница 559: ...02 9 8710 08 ICM Relay Box STICS Chime 2 LOCATION ...

Страница 560: ...ch is in AUTO position Fast Fast interval Slow Slow interval Front wiper operation When moving the wiper switch to MIST position and release it the windshield wipers operate one wiping cycle The wipers will operate continuously if the switch is held in this position Wipers are not in operation Operates automatically according to the vehicle speed or the amount of rain Continuous wipe slow operatio...

Страница 561: ...er will keep operating Rear wiper operation Rear wiper is not in operation Rear washer and wiper When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer Windshield washer operation In the OFF position pull the lever toward you to spray was...

Страница 562: ...o 0 59 seconds T2 with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Страница 563: ...e washer switch is turned on for more than 0 6 seconds during the wiper operation by AUTO switch the wiper operates three times When it is turned on for a certain period of time 0 1 to 0 59 seconds the wiper operates once 3 ...

Страница 564: ...02 14 System Diagram Operating MIST switch for 0 1 to 0 59 second Operating MIST switch for more than 0 59 second ...

Страница 565: ...nition switch ON and the AUTO switch OFF the washer motor output gets ON for 2 second If the system recognizes the output signal the wiper low relay output gets ON during 4 cycles and the washer motor output gets ON for 2 second Then the wiper relay output gets OFF after 3 cycles 1 System Diagram ...

Страница 566: ...dden during the auto washer coupled wiper operation The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive AUTO wiper operation When the AUTO switch input is received during the auto washer operation the auto washer operation stops and the auto INT operation is activated 2 3 4 5 ...

Страница 567: ...02 17 8710 08 System Diagram ...

Страница 568: ...02 18 Wiper Operation with Rain Sensor Auto Light Sensor except for EU market RKSTICS with rain sensing function has the system layout as shown in the figure below System layout ...

Страница 569: ... rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the auto switch from OFF to ON position regardless of communication with rain sensor while the ignition key is in the ON position When the auto switch is turned to the ON position again from the OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects t...

Страница 570: ...02 20 System Diagram AUTO Mode Switch ON Ignition Switch ON ...

Страница 571: ... input with the ignition switch ON and the AUTO switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Страница 572: ...02 22 System Diagram IGN ON AUTO Mode Switch ON ...

Страница 573: ...s increased while the ignition key is in the ON position the AUTO switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle ...

Страница 574: ...02 24 IGN ON AUTO Mode Switch ON IGN ON AUTO Mode Switch ON Wiper Motor Parked ...

Страница 575: ...g terminal is grounded while the ignition key is in ON position and the AUTO switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 The wiper motor runs only when the rain sensor requires the wiper operation System Diagram IGN ON AUTO Mode Switch ON Wiper Motor Parking Terminal Stuck in Ground ...

Страница 576: ...with the ignition key and the AUTO switch in ON position the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal 2 The wiper motor runs only when the rain sensor requires the wiper operation ...

Страница 577: ...ceived Defective Rain Sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 1 ...

Страница 578: ...gnal Received The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 2 ...

Страница 579: ... of wiper switch Check the power supply pin number 3 Ground pin number 4 IGN to sensor Check the wiper relay 1 2 3 Symptom 3 Abrupt wiper operation 3 4 times at high speed If the wiping speed control knob is positioned at FAST position this may happen because the sensitivity in FAST mode is extremely high In that case move the knob to another position Symptom 4 Continuous operation on dry windshie...

Страница 580: ...in detected headlamp If it rains heavy which requires the highest AUTO speed the headlamps are turned on automatically while the light switch is in AUTO position and the wiper switch is in AUTO position Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch...

Страница 581: ... 8710 08 Emitter lense The emitter lens located at bottom of rain sensing unit guides the infrared rays from the LED to the target point Auto light sensor Vertical Auto light sensor Horizon Auto light sensor ...

Страница 582: ...started to operate from parking position The pause time is calculated by the vehicle speed and the VOLUME If the pause time is below 1 0 second the wipers operate without pause If the pause time is over 1 5 seconds the wipers operate intermittently Controls the wiper intermittent operation by the values from the vehicle speed and the volume 1 Calculates and converts the Intermittent interval autom...

Страница 583: ...sly set speed when turning ON the INT switch from OFF position with the IGN ON The wiper operates in previously set speed when turning ON the Ignition switch with the switch ON Control during Faulty Wiper Motor Parking Function The wiper system continuously outputs wiper Low relay ON when the wiper parking terminal is stuck in ground or IGN with INT switch ON or washer switch ON The relays is turn...

Страница 584: ...ystem outputs UNLOCK signal for 5 seconds after the driver s door is opened and the door lock switch is changed to LOCK while the ignition key is in ignition switch The system outputs UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are...

Страница 585: ...ignition key is inserted during the UNLOCK output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does not work if the vehicle speed is over 10 km h 1 2 3 4 5 1 Driver s or passenger s door lock switch...

Страница 586: ... is removed The buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 Tail Lamp Left On Warning ...

Страница 587: ...02 37 8710 08 System Diagram Tail Lamp Relay ON Tail Lamp Relay ON Driver s Door Open ...

Страница 588: ... off when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Страница 589: ...02 39 8710 08 System Diagram ...

Страница 590: ...r the chime bell does not sound The seat belt warning light goes off and the chime bell stops when turning the ignition switch to the OFF position The chime bell stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime bell sounds for 6 seconds again when unfastening ...

Страница 591: ...ning the Ignition Switch to ON after Fastening Seat Belt Seat Belt Warning Light Chime The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to ON from OFF After fastening the seat belt the chime bell stops ...

Страница 592: ...he vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 The warning light blinks and the chime bell sounds for 0 6 seconds and stops for 0 3 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on The warning light goes off and the chime buzzer stops when turning off the parking b...

Страница 593: ...02 43 8710 08 System Diagram ...

Страница 594: ...ring the dimming period The front room lamp comes on for 30 seconds when unlocking the doors with REKES key The front room lamp stays on for additional 30 seconds during lamp operation in Step 5 when receiving the UNLOCK signal from REKES again The front room lamp stays on when opening a front door and operates as in Step 3 and 4 The front room lamp dims out when closing the opened door However it...

Страница 595: ...ssenger s spot lamp comes on when pressing appropriate lamp switch 1 2 in The front room lamp comes on when pressing the Door switch 3 in Center Room Lamp The center room lamp comes on when opening a rear door with the center room lamp switch in Door position System Diagram ...

Страница 596: ...pening the driver s door or passenger s door when the ignition key is removed The ignition key hole illumination stays on for 10 seconds when closing the door after step 1 The output stops when the ignition key is turned to ON position The output stops when receiving the lock signal from the remote control key under anti theft mode 1 2 3 4 ...

Страница 597: ...relay is turned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp The tail lamp relay is turned on when inserting the ignition key into the ignition switch The tail lamp relay is not turned off automatically auto cut when opening and closing the driver s door while the ignition is removed and the tail lamp is turned on 1 2 3 4...

Страница 598: ...02 48 System Diagram Power OFF IGN ON and Tail Lamp Switch ON with Driver s Door Open ...

Страница 599: ...utes when pressing this 5 Defogging Function The defogger system defrosts or demists the window glass with the heated wire integrated in glass When operating the defogger switch STICS controls the operating time only in IGN2 position Windshield heated glass switch The windshield heated glass is turned on for 12 minutes when pressing this switch Circuit Diagram of Front Rear Defogger ...

Страница 600: ...e ignition switch is ON with engine running The output stops when turning on the front defogger heated glass switch again during its operation The output is ON only for 6 minutes when turning ON the front defogger heated glass switch within 10 minutes after completion of output for 12 minutes This can be done only once 1 2 3 System Diagram ...

Страница 601: ...N 2 switch is ON with engine running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 1 2 3 4 ...

Страница 602: ... s or passenger s door key cylinder The door lock system outputs UNLOCK signal for 0 5 seconds when switching from UNLOCK to LOCK by the driver s or passenger s door key cylinder The alarm will not be activated when switched to UNLOCK by driver s or passenger s door key cylinder switch in theft deterrent mode It does not occur abnormal operation when reconnecting the battery after disconnecting th...

Страница 603: ...or Lock Switch The door lock system outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Страница 604: ...CK UNLOCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Страница 605: ...theft deterrent mode briefly press Panic press for more than 2 seconds operative only when the ignition key is in key cylinder Indicator Briefly press Blinks once Press and hold Blinks twice Door LOCK Function Briefly press Locking the doors and Arming the theft deterrent mode ...

Страница 606: ...t occur even if the vehicle speed falls below 50 km h and accelerates again to over 50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door system outputs five L...

Страница 607: ...02 57 8710 08 System Diagram Power OFF ACC ON IGN ON ...

Страница 608: ...eceiving the air bag collision signal Even though the key is turned to OFF position during the output of UNLOCK the output continues on for remaining period The room lamps come on when receiving the collision signal from the air bag collision sensor except room lamp switch OFF The hazard warning flasher relay ON when receiving the collision signal from the air bag collision sensor This function re...

Страница 609: ...ions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or UNLOCK output is ignored if LOCK or UNLOCK output is required while performing the output of LOCK or UNLOCK If the door lock system outputs LOCK and UNLOCK simultaneously only the LOCK output can be activated ...

Страница 610: ...utput is ON for 30 seconds when turning off the ignition switch The power window relay output is OFF when opening the driver s door or the passenger s door The power window relay is turned OFF when receiving the remote control key lock signal armed mode during its extended operation period of 30 seconds 1 2 3 System Diagram IGN ON OFF ...

Страница 611: ...ition DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 DOOR LOCK Indicates that all door lock switches including tailgate are in LOCK positions DOOR UNLOCK Indicates that any of all door lock switches including tailgate is in UNLOCK position 2 The door lock unlock operation does not affect the engine hood ...

Страница 612: ...s and tailgate are locked with the above three conditions met 1 2 3 4 The sleep mode is deactivated immediately if any of them is out of the specified conditions wake up mode Also the sleep mode is deactivated when receiving the UNLOCK signal from the remote control key 2 The sleep mode in Step 1 is deactivated on following conditions Operation of room lamp key hole illumination headlamp siren tai...

Страница 613: ...e is not activated This is called Ready mode In Ready mode the theft deterrent mode is cancelled when the ignition key is inserted into key cylinder or the door lock button is placed to unlock position However when closing the opened door in Ready mode the theft deterrent mode is activated with two blinks of turn signal lamps and one buzzer signal If any door is not opened within 30 seconds after ...

Страница 614: ...02 64 System Diagram Ignition Key Removed Door Closed ...

Страница 615: ...into ignition key cylinder and turn it to position 1 2 3 Alarm Conditions When any door is open in theft deterrent mode When a door switch is moved to unlock position When a door is open after completion of siren operation for 27 seconds 1 2 3 Alarm Buzzer and Hazard warning flasher Operation The siren sounds for 27 seconds with the interval of 1 second ON and 1 second OFF 1 Alarm Stop Conditions ...

Страница 616: ...02 66 After Alarm Period The siren and hazard warning flashers will be turned off 1 System Diagram Alarm Stop Conditions are Met ...

Страница 617: ...peration It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key the system outputs LOCK signal and activates the armed mode Installed Removed Normal Armed Warning Remark Normal O Armed Ready O Armed O Warning O Warning Completion O O O RELOCK Ready O ...

Страница 618: ...g the panic signal with Power OFF ACC and IGN ON the siren and turn signal lamps operate for 27 seconds ignition key should be in ignition key cylinder When pressing any button on REKES key during the panic operation the panic alarm stops Other commands are overridden 1 2 ...

Страница 619: ...d the theft deterrent mode is activated 1 Door Unlock Panic Button Indicator Briefly press Blinks once Press and hold Blinks twice Unlock briefly press If the Unlock button is briefly presses below 0 5 sec all doors and the tailgate are unlocked and the theft deterrent mode is deactivated The front room lamp comes on for 30 seconds when unlocking doors with REKES key Panic Function press and hold ...

Страница 620: ...rs are locked when briefly pressing the door LOCK switch on remote control key less than 0 5 seconds The theft deterrent mode is activated when locking the doors with Lock button on REKES key Hazard warning flashers blink twice 1 2 ...

Страница 621: ...02 71 8710 08 System Diagram ...

Страница 622: ... unlock switch on the remote control key for less than 0 5 seconds The door unlock relay is ON for 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 System Diagram ...

Страница 623: ... Button If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 System Diagram In Theft Deterrent Mode Any Door is Not Open in 30 Seconds after Unlocking Doors ...

Страница 624: ...02 74 4 CIRCUIT DIAGRAM Power Ground Diagnostic Chime Buzzer Warning lamps Brake Seat belt Door ajar ...

Страница 625: ...02 75 8710 08 Central Door Locking ...

Страница 626: ...02 76 Tail Lamp Hazard Warning Flasher Power Window ...

Страница 627: ...02 77 8710 08 Defogger ...

Страница 628: ...02 78 Panic Auto Light Rain Sensing Room Lamp ...

Страница 629: ...02 79 8710 08 FRT Wiper Washer ...

Страница 630: ...ter Coding The ignition key should be removed from the ignition key cylinder The code can be registered only by the scan tool Up to five transmitter can be registered The received code cannot be output during registration The REKES key should be coded by the scan tool 1 2 3 ...

Страница 631: ...t consists of 16 pins The REKES key should be coded by the scan tool Connector Pin Diagnostic connector Pin No Function 1 CAN HI S203 18 2 CAN LO S203 8 3 4 Ground 5 Ground 6 CAN HI S202 14 7 8 ABS ESP unit 2 9 Air bag unit 9 10 11 TCU A18 5 A T 12 SSPS unit 8 13 TCCU 21 14 CAN LO S202 4 15 STICS B21 16 B ...

Страница 632: ...hen replacing it with new one Connect the scan tool to the diagnostic connector Select RK STICS on the screen and Remote Control Coding in Diagnosis screen 1 Remove the ignition key from the key cylinder and press NEXT Press UNLOCK PANIC button on the REKES key for more than 2 seconds 2 ...

Страница 633: ...screen below is displayed with a beep Press NEXT to perform the second key coding 3 The screen below will be displayed after completion of second key coding Press PREVIOUS to complete the key coding 4 Exit from the diagnosis program and disconnect the scan tool from the diagnostic connector Make sure that the buttons on the REKES key operate properly 5 ...

Страница 634: ...pecification Immobilizer control unit Coil inductance 420uH 20 Coil turns 95T Coil wire Rich wire TBD Modulation FSK Input Output frequency 134 2kHz 4KHz PWM Antenna cable Twisted rich wire TBD Transponder Frequency 134 2kHz 4KHz Operating temperature 40 85 ...

Страница 635: ...04 4 2 MAJOR CHANGES Blanking Key Old New Changed the material of key fob Changed the key plate design ...

Страница 636: ...ponder integrated in the key and the engine control unit has the same code When the ignition key with the integrated transponder is turned to the ON position the ECU Engine Control Unit checks the crypto code of the key and if correct allows your vehicle to start the engine REKES Key 1 OVERVIEW Immobilizer Warning Lamp meter cluster Immobilizer Control Unit Diagnostic Connector ECU ...

Страница 637: ...ponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer warning lamp Immobilizer unit Transponder for Diesel engine Transponder for gasoline engine Battery ...

Страница 638: ...M DIAGRAM New The certification for the immobilizer is performed when turning the ignition switch to the ON position after the CAN communication between the ECU and immobilizer is established D20DTR D20DT D27DT D27DTP G32D ...

Страница 639: ...bilizer control unit converts the signal to crypto signal The immobilizer control unit compares the crypto signal with the signal from the transponder If two signals are identical the immobilizer control unit determines the key is valid and it sends the positive message to the ECU The ECU allows starting the engine 1 2 3 4 5 6 7 Transponder In the following cases you may be unable to start the eng...

Страница 640: ...engine control unit during engine starting and goes out after starting the engine Lamp ON in communication Blinking twice for one second immobilizer system failure Blinking once for two seconds immobilizer unit is not coded The immobilizer indicator does not come on if the communication time between immobilizer key and ECU is too short ...

Страница 641: ...the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit The transponder sends an encrypted signal to the unit as a response Transponder for DI engine Transponder for gasoline engine In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When the key i...

Страница 642: ...s the authorized one and transmits the positive message to the ECU The ECU enable the engine to be started The immobilizer indicator does not come on if the communication time between immobilizer key and ECU is too short ENGINE CONTROL UNIT ECU Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or ...

Страница 643: ...04 12 4 CIRCUIT DIAGRAM D20DTR ...

Страница 644: ...04 13 7010 09 D27DT D27DTP ...

Страница 645: ... theft deterrent mode Panic Function press and hold 2 If you are in your vehicle and feel threatened while the ignition key is inserted into the key switch you may activate the alarm to call attention If you press this button the warning siren will sound for approx 30 seconds The panic function will stop when any of the buttons on the remote control key is pressed Briefly press blinking once Press...

Страница 646: ...r Lift FRT RR 30 3mm Total number of pulses Sliding 1 200 Pulse Lift FRT RR 46 93 Pulse Operation speed Sliding 17 9 mm Sec Reclining 3 50 Sec Lift FRT RR 7 0 mm Sec Resolution Sliding 0 188 Pulse Lift FRT RR 0 64 Pulse Variable resistance REC SPWM memory switch Type Self return type Active low Contact current Min 10mA Chattering Max 10 msec Manual switch Type Self return type Active low Contact c...

Страница 647: ...2 Actuator Actuator Specifications For sliding reclining raising front and rear DC motor Rated voltage DC 12V Operation current Sliding Max 2A No load Reclining REC Max 3 6A AT 1 5 Nm Max 8 0A AT 12 Nm Lift FRT RR Max 3A Limited current Sliding Max 16A Reclining Max 13A Lift Max 11A 3 Outside Rearview Mirror Manual Mode Normal 12V ...

Страница 648: ...attering Max 10 msec Position Sensor and Folding Switch Electric Specifications of Motors Inputs Specification Mirror position motor Rated voltage DC 12V Operating current Max 0 2A Limited current Max 1 5A Mirror operating speed 2 5 0 5 sec at 12V Folding motor Rated voltage DC 12V Operating current Max 3A Limited current Max 3 4A Turn over torque by hand Manual folding min 50 kgf cm Electric fold...

Страница 649: ...he memory position switch ON once When pressing the position switch button twice consecutively three times When detecting a sensor error while recalling position switch ON three times No buzzer output for the easy access memory recall operations No buzzer output for the outside mirror position recall by the auto down operation when reversing Buzzer Buzzer Output Specification Buzzer Rated voltage ...

Страница 650: ...05 7 7410 32 2 MAJOR CHANGES Changed the memory recall logic Changed logic Changed the number of buzzer operation 2 3 after recall of memory setting for driver s seat outside rearview mirror ...

Страница 651: ...venter position not operative Mirror folding switch operation Folding and Unfolding Operations in step 1 2 override the memory operation and memory recall operation 2 3 4 To prevent the redundant current consumption during motor running the motor starting point in each process is delayed for 100 ms in automatic control memory recall The operation sequence is as below Slide Reclining Lift Front Lif...

Страница 652: ...onditions above the memory setting for driver s seat and outside rearview mirror is available Memory Setting driver s seat and outside rearview mirror Adjust the positions of the driver s seat and the outside rearview mirrors Press the set switch for over 200ms to enter the memory setting mode Within 5 seconds press one of the position buttons 1 2 3 for over 200 ms to complete the memory setting p...

Страница 653: ...ry When driving the vehicle at speed over 1 km h When the memory setting procedure is completed the memory setting procedure is automatically cancelled and the buzzer sounds twice All the stored positions position switch 1 2 3 get erased when removing the battery Recalling the Memory Setting Press one of the position buttons for over 1 5 seconds The driver s seat and outside rear view mirrors star...

Страница 654: ...eased The seat memory stop button stop switch is pressed during the recall process If the seat position is manually adjusted during recall process the seat recall operation stops but the outside rearview mirror continues to move to the set position If the outside rearview mirror is adjusted during recall process the outside rearview mirror recall operation stop but the seat continues to move to th...

Страница 655: ...rom stopping during folding unfolding process this delayed operating time is extended for additional 13 seconds if pressing the switch within 30 seconds T2 after turning the ignition OFF If pressing the switch again during the additional operating time the delayed operating time is extended again for additional 13 seconds 1 2 3 Timing Chart The outside rearview mirror folding switch is supplied th...

Страница 656: ... to send the return signal to SPWM unit If SPWM receives the data properly it operates the return operation The prohibit conditions for the easy access seat return operation are as follows The parking brake is released or the shift lever is in any position other than P Any of seat switch is operated during the return operation Ignition switch is cycled ON and OFF with short interval approx 1 1 5 s...

Страница 657: ...lowers it as far as it goes If an error is detected from the motors sliding motor cushion front motor cushion rear motor during operation after removing the ignition key the motor with error stops its operation and other motors continue to complete their operations If cycling the key reminder switch OFF ON OFF within 1 second STICS sends the easy access stop signal to SPWM unit The SPWM overrides ...

Страница 658: ...third signal and doesn t send any date to SPWM unit If an error is detected on a sensor the affected motor doesn t operate until it receives normal sensor input The vehicle speed is over 1 km h When the seat switch is operated If the shift lever is any position other than P or the parking brake is disengaged 1 2 3 4 5 6 7 LED ON Easy access operation is activated LED OFF Easy access operation is s...

Страница 659: ...r seat warmer unit is not variable control type but ON OFF control type The rear seat warmer switches LH RH control the rear seat warmer relays LH RH in the ICM 2 LAYOUT Front seat warmer unit Front seat heated wire seat and seatback Rear 1st seat heated wire seat Rear seat warmer switch Front seat warmer switch ICM box Rear for rear seat warmer ...

Страница 660: ...07 4 Front variable seat warmer Seat outside mirror memory 3 CIRCUIT DIAGRAM ...

Страница 661: ...07 5 8611 31 Front variable seat warmer Seat outside mirror non memory ...

Страница 662: ...07 6 Rear seat warmer ...

Страница 663: ...uring driving Storage temperature 40 C 85 C Performance reserve temperature DC 10V 15V Dark current below 3 mA at stable status stand by mode after 180 seconds from IGN OFF 1 Power Voltage Current 2 Illumination Level Classification When Tail Lamp ON Illumination level Day 100 100 25 6 steps Night 40 compared to the level in daytime 40 10 6 steps 1 Black Face Model ...

Страница 664: ... 2 0V 20 mA Engine oil pressure warning lamp Red 2 0V 20 mA Front fog light indicator Green 3 3V 20 A Brake warning lamp Red 2 0V 20 mA Immobilizer indicator Yellow 2 0V 20 mA Door ajar warning lamp Red 2 0V 20 mA Hazard indicator Red 2 0V 20 mA ABS warning lamp Yellow 2 0V 20 mA Engine overheat warning lamp Red 2 0V 20 mA Glow indicator Yellow 2 0V 20 mA Water separator warning lamp Red 2 0V 20 m...

Страница 665: ...icle Speedometer 1 OVERVIEW Two types Black Face type and Clear type of meter cluster are used in this model The meter clusters uses CAN communication lines with the electric units and the LCD display window is located on the lower side of the meter cluster Coolant Temperature Gauge ...

Страница 666: ...08 6 1 Black Face Type 3 WARNING LAMPS AND INDICATORS ...

Страница 667: ...08 7 8010 01 Trip switch ...

Страница 668: ...08 8 2 Clear Type ...

Страница 669: ...08 9 8010 01 ...

Страница 670: ... indicator Front fog light indicator Light indicator Glow indicator Water separator warning lamp This warning lamp comes on when the ignition switch is turned to ON and should go off in a few seconds When the water level inside the water separator in the fuel filter exceeds a certain level this warning lamp comes on When the ignition switch is turned to ON this indicator comes on and stays for a s...

Страница 671: ...ff to confirm that the air bag is operational If it does not come on or if it does not go off or if it flashes or illuminates continuously while driving it means that there is a malfunction in the system This warning lamp blinks and the warning buzzer sounds for 6 seconds when the ignition switch is turned to the ON position unless the driver s seat belt is securely fastened This warning lamp come...

Страница 672: ...mes on while driving it means there is a malfunction in the system This warning lamp comes on when the ignition switch is turned to ON and should go off in a few seconds This indicator comes on when pressing the ESP OFF switch to deactivate the ESP function If the lamp stays on or comes on while driving some of the engine control components including sensors and devices are defective This warning ...

Страница 673: ...comes on when the ignition switch is turned to ON and should go off in a few seconds This warning lamp comes on when the ABS system is defective This indicator comes on when the ignition key is communicating with the engine control unit during engine starting for 0 5 seconds The time needed for communication between the immobilizer key and ECU may vary When the time is very short the immobilizer i...

Страница 674: ...ressed Use this mode to drive off smoothly on an icy and slippery road This indicator blinks when the left turn signal switch is turned on Both indicators blink when the hazard warning switch is turned on This indicator blinks when the right turn signal switch is turned on Both indicators blink when the hazard warning switch is turned on This indicator blinks when the hazard warning flashers are s...

Страница 675: ...amps comes on blinks for 70 seconds 0 4s ON OFF Low tire pressure warning Global warning This warning lamp comes on when the ignition switch is turned to ON and should go off in a few seconds Lamp ON over inflated over 48 psi Lamp ON under inflated 24 26 psi for more than 10 minutes Lamp ON under inflated below 24 psi This indicator illuminates in green when the ignition switch is turned to ON and...

Страница 676: ...d After completion of the mode change to 4L the indicator comes on When shifting the driving mode from 4L to 4H this indicator blinks until the shifting operation is completed After completion of the mode change to 4H the indicator comes on This warning lamp comes on when the ignition switch is turned to ON and should go out if the system is normal If the 4WD CHECK warning lamp stays on 4WD system...

Страница 677: ...08 17 8010 01 3 Display Sequence ...

Страница 678: ...l Lamp ON The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps 4 Illumination Level Adjustment The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps in day mode and night mode ...

Страница 679: ...08 19 8010 01 5 System Analysis ...

Страница 680: ...08 20 ...

Страница 681: ...nd Trip Meter TRIP The total driving distance 0 to 999 999 km or 0 to 999 999 miles and the trip distance 0 0 to 999 9 km or 0 0 to 9 999 9 miles are calculated by using the value of pulse per 1 km which is programmed in the EEPROM ...

Страница 682: ...Operating temperature 20 70 Storage temperature 30 80 Sound pressure level 70dB min 2kHz square wave 10cm Buzzer Priority Remark ON_TIME OFF_TIME 160ms 1 Available only in R M T and Non PAS outputs 610ms after entering R position Description Buzzer output R position Over speed warning ESP High temp warning Fuel filter The buzzer with lower priority outputs when the buzzer with higher priority is t...

Страница 683: ...tch HDC Indicator 8 Functions of HDC Indicator The brake system operates properly even if the HDC system is defective HDC indicator ON when Turning the ignition ON There is an error in HDC system The brake system overheats ...

Страница 684: ...ON but it does not operate because the operating requirements road steep grade or vehicle speed are not met In operation HDC is operating Blinking 0 5s OFF HDC switch ON and the operating requirements are met System overheats High temperature of brake system over 350 C Stand by OFF OFF In operation The indicator blinks in green and red 0 5s Too high temperature of brake system 450 C OFF ON No inde...

Страница 685: ...control is activated If the activation reaches a certain limitation a beep sounds to warn the driver The ESP warning lamp goes off when ESP function is deactivated Even when the ESP is operated for a very short period of time the ESP warning lamp blinks at least four times every 175 milliseconds ESP 작동등 ...

Страница 686: ...turns to normal position when the OFF switch is released The ESP system will be cancelled after approximately 150ms 1 2 3 Based on the above procedures we can see that the ESP system will be cancelled after a certain period approx 150ms from releasing the switch to the original position The ESP system does not get canceled immediately when the ESP warning lamp is turned on by pressingthe ESP OFF s...

Страница 687: ...from tire pressure indication alarm or warning condition when the tire pressure in each wheel is in the specified value Tire Pressure Indicator The tire pressure indicator appears when pressing the TRIP switch for more than one second in ODO mode The tire pressure indicator returns ODO mode when pressing the TRIP switch for more than one second or wait for more than 10 seconds without any switch i...

Страница 688: ...obal Warning Failure Warning ON Conditions Warning Lamp Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Error in TPMS system Defective wheel module Error in TPMS system Low tire pressure Flat Tire Yellow Comes on immediately Yellow Affected tire symbol Yellow Comes on immediately Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Yellow Affected tire symbol ...

Страница 689: ...ormal tire comes on in yellow In tire pressure display mode the symbol for abnormal tire comes on in yellow and the other symbols come on in green Tire Pressure Indicator Yellow Blinks 0 4 s ON OFF for 70 seconds and then stays on Specified tire pressure 32 psi 10 minutes of continuous driving over 20 km h The tire pressure should be measured at 18 C in CVW Comes on in green 10 15 s and then goes ...

Страница 690: ... remaining segments are ON The mode and illumination switch inputs are overridden The instrument cluster enables all functions by receiving the vehicle s variant codes through CAN lines when turning the ignition switch to ON position The verified system by variant code activates the pre warning and time out operation If not verified all data for the systems even exiting in CAN network are overridd...

Страница 691: ...ad Turn signal light switch 6 6 0 5A Relay load Wiper switch Low 5 A High 7 A Motor load Intermittent 0 22 0 05 A Relay load Fixed Max 28 A Motor load Washer switch 4A Motor load Intermittent wiper switch Max 25 mmA Horn connector 1A Relay load Description Specification Center switch cluster Hazard switch DC 12V 10A Lamp load Windshield heated glass switch DC 12V 0 1A Indicator load Tailgate and o...

Страница 692: ...07 4 2 MAJOR CHANGES Center Switch Cluster Old New Changed to independent switch type from integrated switch type Hazard Switch Old New Changed the design of hazard switch ...

Страница 693: ......

Страница 694: ...rols all door windows Open Close Lock Unlock and doors Lock Unlock with this switch unit Auto Washer Switch When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be automatically operate 3 times Auto light position Rear wiper and washer coupled operation Front wiper operation range move the wi...

Страница 695: ...ting Switch LH Seat warmer switch RH Seat warmer switch PAS off Switch ACCEL DECEL ON OFF Hazard Switch HDC switch ESP OFF switch Heated Tailgate Glass Outside Rearview Mirror Galss Switch Heated Windshield Glass Switch Deicer Center Switch Cluster TOD Part time ...

Страница 696: ...U Headlamp High beam 2 55W 55W 15W Low beam 2 55W 55W Tail Position lamp 4 LED LED Front combination lamp Front fog lamp 2 35W 35W Turn signal lamp 2 21W 21W Outside turn signal lamp supplemental turn signal lamp 10 LED LED Rear combination lamp Stop lamp Upper 32 LED LED Stop lamp Lower 24 LED Tail lamp 16 LED LED Turn signal lamp 2 21W 21W Back up lamp 2 16W 16W Rear fog lamp 2 21W High mounted ...

Страница 697: ...cent Diode LED is a semiconductor diode that emits incoherent narrow spectrum light when electrically biased in the forward direction of the p n junction as in the common LED circuit In short it is an element that converts electric signals into light signals Yellow blue red and white LEDs are currently available The followings are the advantages of LED It is not glaring and doesn t have short circ...

Страница 698: ... the turn signal lamp and changed the tail lamp to LED type from bulb type Front Combination Lamp Old New Integrated the fog lamp and turn signal lamp 3 MAJOR CHANGES High beam Low beam Turn signal Tail lamp High beam Low beam Tail lamp Front Side Fog lamp Turn signal lamp Fog lamp ...

Страница 699: ... of rear combination lamp Changed the stop lamp and tail lamp to LED type from bulb type Rear Side Tail Stop lamp Turn signal lamp Tail lamp Back up lamp Stop lamp Tail lamp Back up lamp Turn signal lamp Stop lamp Changed the design of reflex reflector Rear fog lamp EU ...

Страница 700: ...10 7 8310 00 Outside Turn Signal Lamp Old New Introduced new outside turn signal lamp LED type Others Side Repeater Lamp Deleted the side repeater lamp Outside turn signal lamp ...

Страница 701: ... rear lamps and side lamps 1 EXTERIOR LAMPS Front lamps Head lamp Front combination lamp Rear lamps Rear combination lamp License plate lamp High mounted stop lamp Reflex reflector Side lamps Outside turn signal lamp 2 Layout Front Side High beam Low beam Tail lamp Turn signal lamp Fog lamp Outside turn signal lamp ...

Страница 702: ...10 9 8310 00 High Mounted Stop Lamp License Plate Lamp Rear Combination Lamp Rear Side Reflex Reflector Stop lamp Turn signal lamp Back up lamp Tail lamp Rear fog lamp EU ...

Страница 703: ...ead lamp and tail lamp with LIN data from the auto light sensor when the light switch is in AUTO position Low beam High beam DRL Day Time Running Light DRL is the function to turn on the high beam and tail lamp without any intervention from the light switch DRL turns off the lamps when turning off the light switch This is an additional safety device to prevent the accident Tail lamp Available only...

Страница 704: ...rns on the tail position lamp relay when receiving the lamp on signal from the light switch Position lamp Tail lamp In vehicle for EU market the tail position lamp comes on when turning the ignition switch to ON position regardless of light switch operation ...

Страница 705: ...osing the driver s door while the ignition is removed and the tail lamp is turned on 1 2 3 4 Control by STICS Tail Lamp Left ON Warning The buzzer sounds with the interval of 0 3 second when opening the driver s door while the tail lamp is turned on and the ignition key is removed The buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal ...

Страница 706: ...s the illuminance change The STICS communicates with the auto light sensor when the ignition is turned on and turns on or off the tail lamp and headlamp automatically according to the signals from the sensor when the light switch is set to AUTO position AUTO Auto light sensor STICS controls the head lamp and tail lamp with LIN data with IGN ON and the light switch in AUTO position Not available fo...

Страница 707: ...10 14 4 License Plate Lamp The license plate lamp comes on when the light switch is turned on Tail AUTO Low High ...

Страница 708: ...10 15 8310 00 Circuit Diagram of Head Lamp ...

Страница 709: ...10 16 Circuit Diagram of Tail Lamp ...

Страница 710: ...s turned on only with the light switch ON The front fog lamp goes out when turning off the ignition or light switch Rear Fog Lamp for EU Front fog lamp Rear fog lamp Rear Fog Lamp Switch The rear fog lamp comes on when the rear fog lamp is turned on only while the front fog lamp is ON ...

Страница 711: ... a turn signal lamp The turn signal lamp goes out when the steering wheel angle opposite direction with turning direction becomes over 70 from below 70 after turning on a turn signal lamp 6 Turn Signal Lamp The left or right turn signal lamp blinks when moving the light switch to appropriate direction When pressing the hazard switch both turn signal lamps come on simultaneously Outside turn signal...

Страница 712: ...10 19 8310 00 Circuit Diagram of Turn Signal Lamp ...

Страница 713: ... lamp when depressing the brake pedal When releasing the brake pedal the stop lamp goes out 8 Back up Lamp The back up lamp comes on when moving the gear shift lever to R position with IGN ON Back up lamp Stop lamp High mounted stop lamp Rear fog lamp for EU ...

Страница 714: ...10 21 8310 00 Circuit Diagram of Stop Lamp and Back up Lamp ...

Страница 715: ... Rear Room Lamp Front Room Lamp 1 Overview The interior lamps consist of front room lamps 2 center room lamp rear room lamp glove box lamp sun visor lamps 2 courtesy lamps 4 and scuff lamps 4 2 INTERIOR LAMPS 2 Layout Glove Box Lamp ...

Страница 716: ...10 23 8310 00 Door Courtesy Lamp One lamp in each door ...

Страница 717: ...nds during lamp operation in Step 5 when receiving the UNLOCK signal from REKES again The front room lamp stays on when opening a front door and operates as in Step 3 and 4 The front room lamp dims out when closing the opened door However it goes out immediately when getting into the theft deterrent mode The front room lamp comes on when opening a front door with the ignition ON And it goes out im...

Страница 718: ...eration The rear room lamp comes on when opening the tailgatewith the Tailgate lamp switch pressed in The rear room lamp comes on when opening the tailgate The rear room lamp goes out when closing the tailgate 1 2 3 Room Lamp Auto Cut When the vehicle enters into theft deterrent mode STICS sleep mode the ground circuit of room lamp is turned off Or the ground circuit of room lamp is turned off 10 ...

Страница 719: ...ove box lamp comes on when opening the glove box with the tail lamp on 5 Door Courtesy Lamp and Scuff Lamp The door courtesy lamp comes on when opening the door 6 Sun Visor The sun visor lamp comes on when opening the vanity mirror ...

Страница 720: ...10 27 8310 00 7 Circuit Diagram of Room Lamp ...

Страница 721: ...wiper switch to the OFF position before any car wash to avoid unwanted operation of the wipers Wiper mist washer coupled wiper Auto washer coupled wiper Rain sensor coupled wiper operation LIN Speed sensitive intermittent wiper Wiper low high control Check if the sensor is off the position Check if the rain sensor cover is securely installed Check if the customer is familiar to how to control the ...

Страница 722: ... arm pressure Previous Current Wiper arm pressure Driver 850 50gn Passenger 750 50g Steel blade Rubber blade Wiper blade design changed blade size is same Driver side 20inch Passenger side 20inch 3 MAJOR CHANGES Windshield wiper blade ...

Страница 723: ...uid once after the switch is turned ON and the wiper relay is turned ON for 4 cycles After that the washer motor is operated for about 1 seconds to spray the washer fluid again and the relay is turned ON for 3 cycles and then the relay is turned OFF 2 Rear Washer Fluid Supply System The front washer fluid reservoir supplies the rear washer fluid without additional washer fluid reservoir Operating ...

Страница 724: ...ol This sensor emits infrared rays through LED and then detects the amount of rain drops by receiving the rays reflected off the sensing section rain sensor mounting section on the windshield with photodiode AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay auto speed control A position that can control the sensitivity for the amount of rains on the windshield and transmit the ...

Страница 725: ...ds the operating request signal to the STICS which drives the wiper directly At this moment the STICS also sends the information on whether the wiper is in operation mode or whether the multifunction wiper switch is in AUTO position to the rain sensor STICS Underhood Fuse Box ...

Страница 726: ...08 8 Wahser nozzle Front Rear Rain sensor unit 3 SYSTEM LAYOUT INCLUDING RAIN SENSOR Wiper Front wiper Rear wiper Wiper and washer switch ...

Страница 727: ...08 9 7810 00 STICS Wahser motor Front Rear Windshield washer reservoir tank assembly Rear wiper DPS ...

Страница 728: ...eed control switch When turning to FAST wiping speed gets faster and when turning to SLOW wiping speed gets slower Stop the operation Wiper speed controls automatically according to the vehicle speed or amount of rain rain sensing wiper Wiping speed gets faster when placing the pointer at the HI position Wiping speed gets slower when placing the pointer at the LO position MIST OFF AUTO LO HI ...

Страница 729: ...e with the IGN1 ON the wiper relay is turned on after 0 1 sec has passed When the wiper returns to the park position the wiper relay is turned off When the MIST switch signal is input the wiper is operated at high speed When the switch is release from the MIST position the wiper is operated at low speed 1 2 ...

Страница 730: ...g wiper operation The wiper relay should stay ON in low high wiper operation mode even if the parking signal for the wiper motor is not received In INT AUTO wiper operation mode the wiper relay should be turned OFF after 5 seconds if there is no parking signal for the wiper for 3 seconds and informs the driver of parking position signal abnormality While the wiper operates at low high speed the fr...

Страница 731: ...her switch is below 0 6 second the wipers operate only one cycle 1 2 Windshield Washer Control Function 1 Windshield washer coupled wiper Wiper and Washer Coupled Operation Pull the switch briefly for less than 0 6 sec One wiping cycle Pull and hold the switch for more than 0 6 sec Three wiping cycles with washer fluid spray ...

Страница 732: ...fter pulling up the washer switch to ON position with IGN ON If the washer switch is turned on for more than 0 6 seconds the wiper relay is activated three times after releasing the washer switch and then the wiper motor is set to parking position 2 ...

Страница 733: ...s in Auto position sensing the vehicle speed and rain drops the wiper operates three times when the washer switch is turned on for more than 0 6 seconds and it operates once when the washer switch is turned on for less than 0 6 seconds 3 ...

Страница 734: ...e second auto washer switch signal is overridden during first auto washer coupled wiper operation When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent automatic wiping mode will be started 1 2 3 4 2 AUTO washer coupled wiper Auto washer switch If pressing the switch when the wiper switch turns to the OFF positio...

Страница 735: ...08 17 7810 00 ...

Страница 736: ...d it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer 3 Rear Wiper Control Function ...

Страница 737: ...ch signal is received during the rear washer switch operation the washer motor stops and the front washer or automatic washer motor begins to operate 1 2 Rear washer motor control When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Страница 738: ...5 Rain Sensor Coupled Wiper Control Function AUTO Wiper operates automatically by rain sensor FAST Auto delay auto speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly ...

Страница 739: ...08 21 7810 00 System layout 1 Rain sensor coupled wiper operation LIN ...

Страница 740: ...UTO wiper switch is turned on from off with the ignition switch ON the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals After then the wiper does not operate even when the INT AUTO wiper switch is turned on from off The wiper operates at low speed only when the rain sensor detects the rain drops 1 2 2 Power up reminder wiper ...

Страница 741: ...erates in washer coupled wiper operation mode However if the signal from rain sensor is the continuous operation the washer relay is turned on and the wiper keeps on running when the washer switch is ON Even though the wiper system is in washer coupled wiper operation mode the operating data should be sent to rain sensor 1 2 3 Washer coupled wiper operation during rain sensor coupled operation ...

Страница 742: ...h ON and wiper motor STOP parking position the wiper motor operates one cycle at low speed Only when the rain sensor detects rain drops If the wiping speed control switch is changed more than 1 stages within 2 seconds the wiper motor operates only one cycle 1 4 Sensitivity control instant wiping ...

Страница 743: ...urrent signal for parking status continuously The wiper motor is operated only when there is a request from the rain sensor 2 The wiper system sends continuously the signal for current status when the wiper parking terminal is shorted to ground with IGN2 ON and intermittent wiper switch in ON position The wiper motor is operated only when there is a request from the rain sensor 1 5 For abnormal wi...

Страница 744: ... faulty sensor signal S_COMMFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal S_RSFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 1 6 For faulty rain sensor ...

Страница 745: ...osition the wipers do not operate When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position the wipers operate one cycle The wiper s operation cycle depends on the vehicle speed CAN communication with instrument cluster and wiping speed the side fascia panel Wiping cycle 3 0 5 sec FAST to 19 2 sec SLOW 1 2 3 7 Speed sensitive intermittent wiper ...

Страница 746: ...rking position Elapsed time Total operating time after the wiper motor has started its operation from parking position The graph for pause time in previous page is generated by vehicle speed and wiping speed control switch 4 INT wiper switch ON time below 1 sec Continuous wiper operation over 1 5 sec Intermittent wiper operation ...

Страница 747: ...sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto speed control A position that controls sensitivity against rains on the windshield and transmits wiping demand signal accordingly Emitter lens The LED which is located at bottom emits the i...

Страница 748: ...ior Relay Box Front wiper low relay Front wiper high relay Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the intermediate INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one ...

Страница 749: ...is turned on from off with the ignition switch ON the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals After then the wiper does not operate even when the INT AUTO wiper switch is turned on from off The wiper operates at low speed only when the rain sensor detects the rain drops 1 2 1 Power up Reminder Wiper 2 FUNCTIONS OF RAIN SENSING WIPER SYSTEM...

Страница 750: ...s in washer coupled wiper operation mode However if the signal from rain sensor is the continuous operation the washer relay is turned on and the wiper keeps on running when the washer switch is ON Even though the wiper system is in washer coupled wiper operation mode the operating data should be sent to rain sensor 1 2 2 Washer Coupled Wiper Operation During Rain Sensor Coupled Operation ...

Страница 751: ...ly when the rain sensor detects rain drops If the wiping speed control switch is changed more than 1 stages within 2 seconds the wiper motor operates only one cycle 1 3 Sensitivity Control Instant Wiping 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating with the rain sensor while the ignition key is in ON position 1 ...

Страница 752: ...er system continuously sends the signal for current status when the wiper parking terminal is stuck in ground with IGN2 ON and intermittent wiper switch in AUTO position 1 The wiper motor is operated only when there is a request from the rain sensor ...

Страница 753: ...s a faulty sensor signal S_COMMFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal S_RSFAULT from rain sensor unit with IGN ON and INT AUTO switch ON 1 6 For faulty rain sensor ...

Страница 754: ...te INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level For example the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Страница 755: ...ss When receiving other ultrasonic signals metal sounds or air braking noises from heavy commercial vehicles When there is heavy rainfall or water drops When the sensor is covered with snow Sensor Cannot Detect When the sensor is frozen operate normally when it s thawed When the sensor is covered with foreign materials such as snow or condensation if the foreign materials are removed the sensor op...

Страница 756: ...rs Old New 3 sensors 4 sensors PAS Unit Old New Operating voltage 12V 8V Connector pin 3 pins 4 pins PAS sensor holding type Old New Spring type lock Holder type lock 3 MAJOR CHANGES Left Center Right Left Right Center RH Center LH ...

Страница 757: ......

Страница 758: ... or rear bumper detect the distance to any obstacle Driver can figure out the distance from the obstacle to the vehicle by the alarming sound The alarm interval becomes faster as the vehicle approaches the object 2 LAYOUT Two sensors in front bumper Activated when the gear selector lever is D or R position Operated only when the vehicle speed is below 10 km Front PAS sensor Left Right ...

Страница 759: ...is switch turns the front PAS sensor ON and OFF When the LED on the switch is ON PAS system is not available Rear PAS Sensor TGS Lever R D Center RH Center LH Right Left Left Center LH Center RH Right PAS Unit Controls the PAS sensor and sends the sensing signals to the instrument cluster and buzzer ...

Страница 760: ...SS 1 Detection Range Rear LH sensor Rear RH sensor Rear center RH sensor Rear center LH sensor Front Rear PAS Rear PAS Rear LH sensor Rear RH sensor Rear center RH sensor Rear center LH sensor Front RH sensor Front LH sensor ...

Страница 761: ...ar sensor Detecting range and alarm interval alarm from external buzzer Level Rear sensor Center left Center right Rear Left Right Front Left Right Alarm interval 3 30 50cm 30 50cm 30 40cm Stays ON 2 50 80cm 50 80cm 40 60cm ON OFF 0 065 s 1 80 120cm ON 0 065 s OFF 0 196 s Tolerance 5cm 10 ...

Страница 762: ...Height 0 Bottom of bumper Range B From bottom of bumper Range C Detection No detectable Detection area Tolerance 5cm 5cm 3 Horizontal Detection Range Front Rear The sensors may not detect the obstacle when it is above the range A 80cm ...

Страница 763: ...sensors The front PAS sensors are turned off when the vehicle speed exceeds 15km h 1 Self Diagnosis Buzzer indication Starts the self diagnosis mode when turning the ignition on Starts the self diagnosis mode when moving the gear selector lever into R position Fail conditions of self diagnosis a Sensor circuit is open short b Power circuit is open short c Sensor is defective If the sensors are wor...

Страница 764: ...11 12 Rear PAS system ...

Страница 765: ...ATION MODE Operation of LED Operation when detecting the obstacle Operation of front PAS OFF switch Switch Sensor P R N D OFF LED ON Front OFF ON OFF ON Rear OFF ON OFF ON ON LED OFF Front OFF ON OFF ON Rear OFF ON OFF ON ...

Страница 766: ...eds 15km h the front sensors are turned off If it goes below 10km h the sensors start their operation again Gear selector lever in D position Front PAS OFF switch in OFF position When turning on the ignition the self diagnosis is performed but no buzzer output ...

Страница 767: ...11 15 8790 04 5 CIRCUIT DIAGRAM ...

Страница 768: ...11 16 6 FLOW CHART Front Rear PAS System ...

Страница 769: ...11 17 8790 04 Rear PAS System ...

Страница 770: ...4dB FM 60dB LCD Type ISTN Operating voltage 9 0V VDD 3 0 3 3V Operating temperature 30 75 Storage temperature 40 85 Size width x height 132X36 Bluetooth Composition MD 5XR Technology Bluetooth 2 0 EDR Product name HFP A2DP AVRCP Current consumption below 5A max 10A Dark current below 3mA Unit Description Specification Frequency EU FM 87 5 108MHz MW 522 1620 KHz LW 144 290 KHz Latin America FM 87 5...

Страница 771: ...4 4 Unit Description Specification Micro pole antenna Audio Operating current max 150mA Operating voltage DC 10 5V 16V Operating temperature 30 60 Storage temperature 40 80 Input Output impedance 75Ω FM ...

Страница 772: ...10 05 2 MAJOR CHANGES Audio Assembly Old New Changed the audio assembly added Bluetooth hands free function AVN type Audio type Audio Antenna Old New Changed the antenna from integrated type to micro pole type ...

Страница 773: ...14 6 Audio Assembly 1 LAYOUT Audio CD Radio USB AUX Bluetooth hands free Audio Remote Control Switches Front Door Tweeter Speaker Front Door Speaker ...

Страница 774: ...14 7 8910 05 Hands free Microphone Rear Door Speaker USB AUX Micro Pole Antenna ...

Страница 775: ...ory button 1 6 and Audio function button 3 Bluetooth hands free CALL button 4 Bluetooth hands free END button 5 Previous and Next button 6 SCAN INFO button 7 BAND AS button 8 SETTING button 9 Display window LCD 10 RDS setup 11 Disc Play button 12 Disc Eject button 13 Disc slot ...

Страница 776: ...ge 12V Maximum operating current 10A Isolated resistance 5MΩ Return time 13 5 sec after pushing it Power outlet Rated voltage 12V Maximum operating current 10A Isolated resistance 5MΩ Digital clock Rated voltage 12V Operating voltage 8V 16V Operating temperature 30 80 Time tolerance 0 25 SEC Current consumption IGN ON MAX 150 mA IGN OFF MAX 2 5 mA Display color Yellow green Display type LCD 1 SPEC...

Страница 777: ... Old New Deleted the speaker and installed new power outlet on top of center instrument panel 2 MAJOR CHANGES 1 Power Outlet Digital Clock Digital Clock Old New Deleted the multi station and installed new digital clock ...

Страница 778: ...VIEW The electric accessories are Horn Cigarette lighter Power outlet Digital clock and Siren Theft deterrent alarm 1 Interior Electric Accessories Digital Clock Cigarette Lighter Power Outlet Tray in luggage compartment ...

Страница 779: ...15 6 2 Exterior Electric Accessories LH Horn High RH Horn Low Siren Theft Deterrent Alarm ...

Страница 780: ...8510 00 2 OPERATING PROCESS 1 Horn 1 Operating Condition B always ON 2 Operation The horn sounds when pressing the horn switch on the steering wheel 3 Operating Process Horn switch air bag module integrated ...

Страница 781: ...l lamp ON 2 Operation of Cigarette Lighter Press in the cigarette lighter and wait until it pops out Heating coil The barrel of the cigarette lighter becomes very hot when it is fully charged When touched by or dropped on bare skin this may cause burns Dropping the hot cigarette lighter can cause damage to a car seat or even start a fire ...

Страница 782: ...of a certain hour the minute indicator will show if this button is pressed When the time is between 30 and 59 minutes of a certain hour the minute indicator will show and one hour will be added to the hour indicator if this button is pressed 4 Siren Theft Deterrent Alarm 1 Operating Condition This horn sounds once when the vehicle is armed into theft deterrent mode This horn sounds for 27 seconds ...

Страница 783: ...lti plate clutches All hydraulic functions are directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications Automatic transaxle DSI M78 TCU under driver s seat TCU is located under the driver s seat and controls the transmission TCU use the power from the ignition power supply to start and stop its operation TCU is connected...

Страница 784: ...utton Hole when Locked in the P Position If you cannot move the gear select lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt Mode Switch Selection of Manual Automatic Shift Function Positions of gear select lever P Parking R Reverse N Neutral D Drive...

Страница 785: ...id Fluid Fuchs ATF 3292 ATF 용량 교환주기 약 9 5L 30 000Km 주행시마다 또는 1 년마다 점검 점검 후 필요시 교환 Resistance of oil temperature sensor 20 430 7 533 9 kΩ 0 146 8 175 7 kΩ 20 56 74 65 86 kΩ 100 3 201 3 399 kΩ Gear position sensor 1 2 3 D 2 686 kΩ 8 N 5 036 kΩ 8 R 8 953 kΩ 8 P 16 786 kΩ 8 Fluid Fuchs ATF 3292 ATF Capacity Approx 9 5 L Change interval Check the fluid at every 30 000 km or 1 year and change it if nece...

Страница 786: ...01 5 3650 01 4WD Automatic Transmission 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Inhibiter switch Adapter housing 2 Appearance ...

Страница 787: ...01 6 4WD 2WD 3 Sectional Diagram ...

Страница 788: ...01 7 3650 01 4 Shift Pattern Diagram Vehicle speed Km h Output shaft speed rpm ...

Страница 789: ...shaft locking nut M24 x 15 100 110 Pump cover to oil pump M8 x 55 24 27 Pump cover to transmission housing M8 x 40 24 34 Pump cover to transmission housing M8 x 58 24 34 Upper valve body to lower valve body M6 x 30 15 17 Detent spring M8 x 16 20 25 Variable bleed solenoid and speed sensor M4 x 12 2 8 3 2 Transmission oil level plug 30 35 Front cooling lines to transmission cooler 25 35 Rear coolin...

Страница 790: ...e directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications The six forward gears and one reverse gear are obtained from a single planetary set followed by a double planetary set This type of gear set arrangement is commonly known as Lepelletier type gear set The automatic transmission is electronically controlled The con...

Страница 791: ...ted on the transmission system as there is sufficient engine strategy to protect the system However reverse gear engagement is prevented until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12 and vehicle speed is less than 10 km h Converter Clutch Lock Up In All Gears The transmission features converter clutch lock up in all gears This feature provides improved...

Страница 792: ...led by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change Coastdown downshifts occur at 0 accelerator pedal when the vehicle is coasting down to a stop To reduce the shift shock and to improve the shift feeling during downshift TCU electronically controls the t...

Страница 793: ...t lever from the P position try to move the lever while pushing down here with a sharp object such as a ballpoint pen For your safety turn off the engine and depress the brake pedal before the attempt 1 Gear Position 4 P Park R Reverse N Neutral D Drive 4 Mode Switch 3 W Winter mode Start off the vehicle in 2nd gear S Standard mode Use the standard mode in normal driving conditions 3 Selection of ...

Страница 794: ...ccelerator pedal completely to the floor Then a one or two lever gear will automatically be engaged This is called the Kickdown function 4th gear position Use on a long and gentle slope 4 3 4 2 and 4 1 automatic kickdown shift is available 6th gear position 6 5 and 6 4 automatic kickdown shift is available 5th gear position 5 4 and 5 3 automatic kickdown shift is available 1st gear position Use on...

Страница 795: ...to OBD II regulation 1 2 3 4 In case of overheated transmission The TCU enters the limp home mode when the batter voltage drops below 8 V If the transmission is overheated the shift pattern is changed to the hot mode to cool the transmission more efficiently While the transmission is overheated the selector lever symbol and engine temperature warning lamp on the instrument cluster blink until the ...

Страница 796: ...n with 26 pin connector TCU processes the signals and information analog and digital through CAN bus from the sensors Transmission input speed Transmission output speed Accelerator pedal position Gear selector position Engine torque Engine speed This information is used by the TCU to decide which shift pattern to select and for shift energy management Electro hydraulic solenoid valves and variable...

Страница 797: ...be locked up properly If it is failed TCU releases the torque converter clutch to activate the fail safe operation 4 Shift Energy Management This function involves reducing or increasing the engine output torque during shifting This reduces the energy which is dissipated in the friction elements of the transmission during up shift This is done by reducing the engine torque during the gear ratio ch...

Страница 798: ... shift operation 5 Shift Mode Selection by TCU The driver can select Standard S or Winter mode W with the mode switch TCU automatically changes the shift mode according to the transmission oil temperature uphill or downhill gradient and altitude to keep the good driving conditions Standard Mode S Uphii and Downhill Mode Altitude Mode Standard Mode is selected when setting the mode switch in Standa...

Страница 799: ...il temperature is below 20 C The torque converter cannot be locked up below 20 C to provide the warming up process of transmission Hot Mode If the transmission oil temperature is between 110 C and 145 C the system provides the cooling and reduces the load to the transmission This is called Hot Mode Above 110 C Above 130 C Above 145 C In Hot Mode any of shift mode is not available Auto Cruise Contr...

Страница 800: ...mbeded Memory Module EMM The embedded memory module EMM is matched to the transmission s valve bodies during transmission assembly to ensure refined shift quality The EMM is integrated into the input speed sensor which is mounted on the valve body in the transmission The EMM is used to store data such as valve body calibration data and valve body serial number Upon installation the TCU will downlo...

Страница 801: ...atio Engaged element clutch band C1 C2 C3 B1 B2 1 2OWC M1 3 536 ON ON 1st 3 536 ON ON 2nd 2 143 ON ON 3rd 1 478 ON ON 4th 1 156 ON ON 5th 0 866 ON ON 6th 0 677 ON ON Reverse 3 094 ON ON Gear S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A M1 ON 1 0 1 1st ON 1 0 0 1 2nd ON ON 1 0 1 0 1 3rd ON ON 1 0 1 0 1 4th 0 0 0 1 5th ON 0 1 1 0 1 6th ON ON 0 1 1 0 1 Reverse ON ON ON 1 1 1 0 1 Gear Selection and Enga...

Страница 802: ...01 21 3650 01 Hydraulic Circuit Diagram ...

Страница 803: ... ON C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON ON Power Flow Diagram Manual 1st gear is not engage...

Страница 804: ...01 23 3650 01 1st Gear M 3 53 1 ...

Страница 805: ...moved to the left end C1 clutch not engaged C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 53 ON 1 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 53 ON ON Power Flow Di...

Страница 806: ...01 25 3650 01 1st Gear D 3 53 1 ...

Страница 807: ...FF C2 clutch engaged by drive oil Drive oil for C2 clutch engagement is regulated by VBS S6 S4 ON B1 shift valve moved to the left end B1 band operated Drive oil for B1 band engagement is regulated by VBS S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC ...

Страница 808: ...01 27 3650 01 2nd Gear D 2 14 1 ...

Страница 809: ...g Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 2 14 ON ON ON 1 0 0 1 0 1 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 2 14 ON ON Power Flow Diagram ...

Страница 810: ...01 29 3650 01 2nd Gear D Lock Up ...

Страница 811: ...engaged C2 shift valve open S2 OFF C2 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 48 ON ON 1 0 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 48 ON ON Power Flow Diagram C3 clutch canno...

Страница 812: ...01 31 3650 01 3rd Gear D 1 48 1 ...

Страница 813: ...gaged by drive oil C2 shift valve open S2 OFF C2 clutch engaged by drive oil Drive oil for C1 and C2 engagement is regulated by VBS S6 and S6 Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 1 16 0 0 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 1 16 ON ON Power Flow Diagram 4th gear is use...

Страница 814: ...01 33 3650 01 4th gear D 4th gear D in Limp home mode 1 16 1 ...

Страница 815: ...C2 clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S3 and S7 ON C3 shift valve moved to the left end C3 clutch engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 87 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 87 ON ON Power Flow Diagram ...

Страница 816: ...01 35 3650 01 5th gear D 0 87 1 ...

Страница 817: ...end C2 clutch not engaged C1 shift valve open S1 OFF C1 clutch engaged by drive oil S4 ON B1 shift valve moved to the left end B1 Band engaged Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 0 68 ON ON 0 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 0 68 ON ON Power Flow Diagram ...

Страница 818: ...01 37 3650 01 6th gear D 0 68 1 ...

Страница 819: ... Band directly through manual valve S3 ON Pressure to C3 increased or regulated S1 and S2 ON C1 not engaged in any case Connecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 ON ON ON 1 1 1 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Страница 820: ...01 39 3650 01 Reverse gear R 3 09 1 ...

Страница 821: ...onnecting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A 3 09 0 0 0 0 0 0 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI 3 09 ON ON ON Power Flow Diagram ...

Страница 822: ...01 41 3650 01 Reverse R Limp Home Mode ...

Страница 823: ...necting Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Страница 824: ...01 43 3650 01 Park ...

Страница 825: ...g Components Gear ratio ON OFF solenoids Variable pressure sol valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A N A ON ON ON 0 1 Gear ratio Engaged element C1 C2 C3 B1 B2 OWC Lock up clutch AO AI R AO AI N A Power Flow Diagram ...

Страница 826: ...01 45 3650 01 Neutral ...

Страница 827: ...ical D D Electrical Parking lock system Brake switch signal TGS lever Reverse lock system CAN TGS lever Selected lever indication P R N D Lever position 1 2 3 4 5 CAN Oil temperature sensor Resistance R D 0 5 2 5kΩ Resistance P N 20kΩ TCU EGS 52 Shift solenoid valve 25 Resistance 3 8 0 2Ω Operating distance 0 2mm Operating current 1 5 2A Item W5A330 300 W5A580 400 Input torque 330Nm 1 SPECIFICATIO...

Страница 828: ...rating current 1 5 2 0A Operating range 3rd to 5th gears RPM sensor Resistance HALL type Operating voltae 6V Start lockout switch Switch contact ON D position Switch contact OFF P N position Mode switch W Winter S Standard One way clutch F1 F2 Planetary gear set Plain planetary gear 3 number of pinion 3 4 3 4 4 4 Disc clutch Disc C2 C2 C3 Single plate type Disc brake Disc B1 B2 B3 Single plate typ...

Страница 829: ...rque 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 ...

Страница 830: ...ue Converter 3 MAJOR CHANGES The torsion damped has been newly installed in the torque converter The torsion damper absorbs the shock vibration and noise when delivering the engine driving force This improves NVH performance in this vehicle ...

Страница 831: ...e 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 connected to TCU by cylindrical 13 pin connector DCAG 5 speed automatic transmission offers ...

Страница 832: ...01 8 Characteristics ...

Страница 833: ...01 9 3650 01 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 ...

Страница 834: ...anetary 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 rotati...

Страница 835: ...el Front 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 G...

Страница 836: ...anetary 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 ...

Страница 837: ... ring gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center ring gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center sun gear and ring gear direct connectio...

Страница 838: ...y gear carrier Rotation with reduced speed Rear planetary gear carrier Clockwise rotation with reduced speed Center ring gear and rear planetary gear carrier Clockwise rotation by clutch C2 activation Rear sun gear Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear increasedspeed Center sun gear Clockwise rotation with increased speed by C3 activation Center ...

Страница 839: ...t shaft Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locked by B3 Center planetary gear carrier Counter...

Страница 840: ... 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...

Страница 841: ...01 17 3650 01 3 CIRCUIT DIAGRAM Start Motor Selector Lever CAN Communication ...

Страница 842: ...01 18 Solenoid Oil temperature sensor Speed sensor N2 N3 ...

Страница 843: ...e interval Inspect and replenish every 60000 km or 3 years under severe driving conditions change every 120 000 km 1 SPECIFICATION Reversing High force type What s the severe conditions Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly Taxi patrol service or delivery service extended idling and excessive driving with low speed Frequent stop and go traffic exten...

Страница 844: ... 2 SPECIAL SERVICE TOOLS Install the main shaft reverse sleeve and bearing Install the main drive pinion assembly front ball bearing Install the main shaft double angular ball bearing Install the 3rd 4th synchronizer hub Install the main shaft 5th gear Install the main shaft 6th gear Install the main shaft 1st gear sleeve Install the drive pinion assembly front ball bearing Install the main shaft ...

Страница 845: ...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 ...

Страница 846: ... 41 1 1EA Loctite 4 Reverse shift fork retainer bolt 53 9 67 6 2EA Loctite 5 Backup lamp switch 29 4 34 3 1EA Loctite 6 Oil drain plug 58 8 78 4 1EA Loctite 7 Interlock bolt 14 7 21 5 1EA 8 Neutral switch 29 4 34 3 1EA Loctite 9 Oil filler plug 58 8 78 4 1EA Loctite 10 Extension housing bolt 42 1 53 9 12EA 11 Concentric slave cylinder bolt 9 8 15 6 3EA 12 Front bearing retainer bolt 19 6 24 5 8EA ...

Страница 847: ...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 Pulg Seal 53 9 67 6 Nm Cylinder assembly Concentric slave Plunger Rolling Boot Guide Oil Spring Guide Bolt Flange 42 1 53 9 Nm 12 13 14 15 16 17 18 19 ...

Страница 848: ...02 8 3162 00 Main shaft ...

Страница 849: ...b Synchronizer Sleeeve Synchronizer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Ring assembly Triple cone Gear assembly 1st speed Sleeve 1st gear Bearing Double angular ball Ring Snap Gear Main shaft 5th Spacer Gear Main shaft 6th Sleeve Reverse gear Bearing Needle roller Gear assembly Reverse speed Ring assembly Triple cone Hub Synchronizer Sleeeve Synchronizer Stopper Synchronizer key Bearin...

Страница 850: ... Bearing Needle roller Gear assembly 5th speed Key assembly Synchronizer Ring assembly Triple cone 1 2 3 4 5 6 7 8 9 10 Hub Synchronizer Sleeeve Synchronizer Ring Synchronizer Sleeve Speed gear Bearing Needle roller Gear assembly 6th speed Gear Counter shaft Nut Locking 156 9 186 3 Nm Bearing Needle roller 11 12 13 14 15 16 17 18 19 ...

Страница 851: ...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 ...

Страница 852: ...er ball Pin Spring Rail sub assembly Shaft 1st 2nd Bushing Rail sub assembly Shaft 3rd 4th Lug Shaft 5th 6th 1 2 3 4 5 6 7 8 Lug _ Reverse shaft Fork Reverse shaft Rail Shaft 5th 6th Fork Shaft 5th 6th Pin Spring Lever assembly Shaft 5th 6th Bolt Flange 14 7 21 5 Nm 9 10 11 12 13 14 15 ...

Страница 853: ...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 ...

Страница 854: ... 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 ...

Страница 855: ...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 ...

Страница 856: ...02 16 2nd speed 1st speed 2 POWER FLOW ...

Страница 857: ...02 17 3170 01 4th speed 3rd speed ...

Страница 858: ...02 18 6th speed 5th speed ...

Страница 859: ...02 19 3170 01 Reverse gear ...

Страница 860: ...02 20 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 Lug arrangement ...

Страница 861: ...d gear 1 536 4th gear 1 000 5th gear 0 807 Reverse gear 3 591 Transmission fluid Specification ATF DEXRON II Fapacity ℓ 4WD 3 6 2WD 3 4 Change interval Inspect at every 10 000km replace at every 60 000km add or replace if necessary Description Tightening torque Oil drain plug 4 5kgf m 39 22 49 03Nm Backup lamp switch 3 4kgf m 29 42 39 22Nm Extension housing bolt 4 2 5 7kgf m 41 18 55 89Nm Selector...

Страница 862: ... 2WD Gasoline Features All gears use the helical type and high strength materials 1 The helical type gear prevents the axial gear missing and provides less noise The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to pro...

Страница 863: ...03 5 3170 01 2 SYSTEM COMPONENTS 1 Gear Combinations 2 Shift Fork and Rail Combinations ...

Страница 864: ...03 6 3 Sectional View ...

Страница 865: ...ro sleeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Needle bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52...

Страница 866: ...03 8 IDI Engine equipped vehicle 4WD ...

Страница 867: ...leeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5th needle...

Страница 868: ...03 10 IDI Engine equipped vehicle 2WD ...

Страница 869: ...iner ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5th needle bearing 53 5...

Страница 870: ...tening torque 30 40 Nm Shift rail 3 4th Interlock bolt tightening torque 40 50 Nm 1 2 3 4 5 6 7 8 9 Shift lever 10 Interlock plate 11 Shift rail 1 2nd 12 Shift rug 1 2nd 13 Shift fork 3 4th 14 Input shaft 15 Counter shaft 16 Reverse idler assembly 17 Spring pin 6 x 25 18 Spring pin 6 x 25 Backup lamp switch Concentric slave cylinder adaptor Apply Loctite 243 Apply Loctite DRI LOC 200 19 20 8 6 ...

Страница 871: ...ock bolt Stopper plate Air vent tightening torque 30 40 Nm Lock washer TGS bushing Outer spring pin TGS pin Lock bolt tightening torque 17 26 Nm 1 2 3 4 5 6 7 8 9 10 Offset lever Offset lever bushing Rolling plunger Return spring Spring plug tightening torque 30 35 Nm Apply Long term grease MoS2 when installing the offset lever 11 12 13 14 15 A ...

Страница 872: ...03 14 6 Power Flows 1st gear Counter shaft 2nd gear ...

Страница 873: ...03 15 3170 01 7 Power Flows Cont d 3rd gear 4th gear ...

Страница 874: ...03 16 8 Power Flows Cont d 5th gear Reverse gear ...

Страница 875: ... MECHANISM 1 Interlock System Interlock system prevents the gears from meshing over two sets 2 Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward ...

Страница 876: ...e next shift easier the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected 1 Offset lever 2 Shift lever 3 Shift shaft 4 Rolling plunger rolling plunger return spring and ball ...

Страница 877: ...he selected gear from getting out of its meshed position 1 Gear pump out locking device It prevents the shift lever is beyond the correct shift position while shifting 2 Guiding a control direction and preventing an over stroke 3 4 Backup Lamp Switch It is normal open type switch Its circuit is formed when the reverse gear is selected Sealant Loctite DRI LOC 200 Tightening torque 3 kg m 4 kg m ...

Страница 878: ...nizer inner cone and middle cone Single cone type Double cone type 1 2 shift 3 4 shift 5 R shift 1 2 shift 3 4 shift 5 R shift 1 Synchronizer sleeve 2 Synchronizer hub 3 Synchronizer ring 4 Synchronizer key 5 Synchronizer key locking ring 6 Synchronizer inner cone 7 Synchronizer middle cone Be careful not to mix up the 1 2 shift synchronizer sleeve with 3 4 or 5 R shift synchronizer sleeve The 3 4...

Страница 879: ...g the transmission main shaft is turning and the clutch gear is spinning Even though the clutch is disengaged the clutch gear continues to spin until friction slows it down or stops it Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at different speeds By using synchronizers the possibility of broken or damaged teeth is reduced and shifting effort is low...

Страница 880: ...ut area Needle bearing for 5th gear 3 4 7 End Play of Taper Roller Bearing 1 Taper roller bearing for input shaft 2 Taper roller bearing for counter shaft A End play A 0 85 2 28 mm B End play B 1 17 1 97 mm Use the following spacers to adjust the end play A or B between input shaft and counter shaft Specified range of end play 0 05 0 1 mm For input shaft 0 75 1 45 mm 15 spacers with increment of 5...

Страница 881: ...ear assembly receives the axial force and this force acts as a resistance to rotating gears 9 Lubrication Transmission oil SAE 75W 90 Initial installation for taper roller bearing and needle roller bearing lubrication for shift rail MoS2 Grease Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm ...

Страница 882: ...03 24 1 Oil filler plug 2 Air vent Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm 4WD 2WD ...

Страница 883: ...03 25 3170 01 4 CIRCUIT DIAGRAM BACKUP LAMP ...

Страница 884: ... ratio DI engine M T 3 73 DI engine A T 3 54 Gasoline engine A T 4 27 Description Specification Axle shaft type Semi floating Axle housing type Build up Differential Type Conventional type Gear type Hypoid Gear Final gear reduction ratio DI engine M T 3 73 DI engine A T 3 31 Gasoline engine A T 4 27 Oil Capacity 1 4L Specification SAE 80W 90 or API GL 5 Oil Capacity 2 0L Specification SAE 80W 90 o...

Страница 885: ...10 3 4122 01 1 SPECIAL TOOLS AND EQUIPMENT ...

Страница 886: ...07 3 3260 01 1 SPECIFICATIONS ...

Страница 887: ...gears without a control unit to operate AWD function It also doesn t have the TC Transfer Case shift motor and 4WD transfer switch Since it doesn t have a control unit such as TCCU Transfer Case Control Unit it delivers the driving force to the front and rear propeller shafts according to the gear ratio based on the gear combinations The distribution ratio of driving force is 40 60 front wheels re...

Страница 888: ...07 5 3260 01 2 LOCATION Distribution of Driving Force in AWD ...

Страница 889: ...07 6 3 STRUCTURE 1 Sectional View ...

Страница 890: ... 5 Front sun gear 6 Differential carrier assembly 7 Thrust washer 8 Rear sun gear 9 Snap ring 10 Cover assembly 11 Oil seal 12 Rear output shaft assembly 13 Air breather 14 Front output shaft assembly 15 Oil seal 16 Retaining ring 17 Driven sprocket 18 Chain 19 Clip 20 Bolt 21 Plug ...

Страница 891: ...07 8 4 POWER FLOW Distribution of Front Output Torque Distribution of Rear Output Torque ...

Страница 892: ...ius while cornering the tight corner braking symptom occurs in part time transfer case However for the AWD this gap of turning radius is compensated by the differential so that the tight corner braking symptom will not occur The ESP also operates the wheel slip under control in order to keep the vehicle stable under severe conditions such as icy road ...

Страница 893: ... toward the moving direction with the torque ratio of 40 60 The front wheels should rotate faster than the rear wheels while cornering including wheel slip since the front wheels turning radius is larger than the rear wheels At this moment the step pinion 19T 13T should rotate faster than the pinion 13T in relation to the carrier s movement This function is similar to the regular differential func...

Страница 894: ...06 3 3240 01 1 SPECIFICATIONS ...

Страница 895: ...axle and rear axle the TPS signals from engine and the operating signals from ABS control unit via CAN Based on these data TOD control unit controls the electro magnetic clutch to distribute the 3 97 44 56 of driving force to front wheels and rear wheels The conventional system uses FR driving theoretically the 100 of driving force is transferred to rear wheels on normal paved road When the system...

Страница 896: ...ground grab capacity against side winds and rain Distribution ratio 15 for front wheels and 85 for rear wheels 2 When turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capacity at hi...

Страница 897: ...um torque into front and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set Releasing the 4L Mode When selecting 4H mode 4L drive mode is released and 4H mode is resumed 4H switch Self return type 4L switch Push lock type 3 4WD Operation Overview To make the mode shift easier stop the vehicle de...

Страница 898: ...06 7 3240 01 2 POWER FLOW System Layout 4WD Switch Instrument Panel Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output ...

Страница 899: ... When turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capacity at high level Distribution ratio 30 for front wheels and 70 for rear wheels When climbing or starting off on the road...

Страница 900: ...t and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set 4H switch Self return type 4L switch Push lock type 3 4WD Operation Overview To make the mode shift easier stop the vehicle depress the brake pedal select the mode switch and move the selector lever with the sequence of N P N ...

Страница 901: ...06 10 4H Mode 4WD Drive High Speed Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Страница 902: ...06 11 3240 01 4L Mode 4WD Drive Low Speed Front Axle Front Wheel Transmission Rear Axle Rear Wheel ...

Страница 903: ...06 12 3 CIRCUIT DIAGRAM ...

Страница 904: ... Total length 343mm Mating surface of front flange 40mm Weight 32 4 kg including oil Oil capacity 1 4L Oil type ATF DEXRON II or III Location Transfer case Major element Housing Part time TOD Bolt 11EA M8 x 1 25 Input shaft A T outer spline M T inner spline ...

Страница 905: ...nd 2 48 of reduction gear ratio when selecting 4WD LOW The silent chain in transfer case transfers the output power to front wheels The simple operation of switches on instrument panel allows to shift between 2H and 4H easily while driving for 4L stop vehicle first The warning lamp warns the driver when the system is defective Side View Rear View ...

Страница 906: ...rive 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 For Automatic Transmission Stop the vehicle on level ground and move the gear selector lever into the N position Turn the switch to the desired position For Manual ...

Страница 907: ...03 6 2 LAYOUT Front axle Front locking hub system IWE Front propeller shaft Part time transfer case Rear propeller shaft Rear axle ...

Страница 908: ...03 7 3240 01 3 SYSTEM LAYOUT ...

Страница 909: ...system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Booster Operating Process Vacuum pump Vacuum generation process in front hub actuator ...

Страница 910: ...lenoid valve Check valve This valve allows the vacuum pressure to flow through it in only one direction This prevent the vacuum from abruptly releasing due to faulty vacuum pump The vacuum pressure is released from the hub actuator At this time the front hub end gear is engaged 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be...

Страница 911: ... 10 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 ...

Страница 912: ... Flow Output shaft of transmission Rear propeller shaft Rear wheel Rear axle Rear wheel Input shaft of transfer case Output shaft of transfer case The driving force is directly engaged 1 1 to rear axle and is transferred only to the rear wheels ...

Страница 913: ...03 12 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 ...

Страница 914: ...e 4 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 ...

Страница 915: ...r shaft length outer diameter mm A T 607 1 Φ63 5 at compressed condition Rear propeller shaft length outer diameter mm 2WD A T Front axle 1078 2 Φ63 5 Rear axle 561 4 Φ63 5 at compressed condition 4WD A T Front axle 696 3 Φ63 5 Rear axle 561 4 Φ63 5 at compressed condition 2 TIGHTENING TORQUE Item Tightening torque Mounting bolt on front rear axle 66 6 73 5 Nm Mounting bolt on transfer case 79 4 8...

Страница 916: ...er shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration Front propeller shaft Rear propeller shaft Function of propeller shaft Transmits driving torque Compensates the angle change u...

Страница 917: ...type Torsion bar type Rear Suspension Suspension type 5 link type multi link type Spring type Coil spring Shock absorber type Reciprocating cylindrical type gas type Stabilizer bar type Torsion bar type 2 WHEEL ALIGNMENT LH RH Camber 0 12 0 25 0 0 25 Caster 4 28 0 4 4 38 0 4 Toe in 2 2mm Inspect the tire inflation pressure and underbody before checking the wheel alignment Tire inflation pressure 3...

Страница 918: ...assembly Axle shaft assembly Steering knuckle Lower arm assembly Shock absorber yoke assembly 1 2 3 4 5 6 7 Shock absorber to yoke bolt 122 5 142 1 Nm Upper arm knuckle side nut 137 2 156 8 Nm Lower arm knuckle side nut 137 2 156 8 Nm Yoke lower lower arm side nut 147 0 166 6 Nm 1 2 3 4 ...

Страница 919: ...05 5 4411 01 A 5 Link type B Multi link type changed lower arm ball joint In lower arm design the current mass production vehicle A is different from the new model B from July 2012 ...

Страница 920: ...8 8 78 4Nm Stabilizer bar link upper nut Tightening torque 29 4 49 0Nm Upper arm frame side bolt nut Tightening torque 107 8 127 4Nm Stabilizer bar clamp bolt Tightening torque 39 2 58 8Nm Lower arm shock absorber yoke side nut Tightening torque 147 0 166 6Nm Lower arm frame side bolt nut Tightening torque 205 8 225 4Nm ...

Страница 921: ......

Страница 922: ...5 8 4 SYSTEM LAYOUT AND TIGHTENING TORQUE OF REAR SUSPENSION Lower arm link Stabilizer bar link Stabilizer bar Shock absorber Coil spring seat upper side Lateral rod Axle housing Upper arm link Top View ...

Страница 923: ... 98 0Nm Upper arm bolt nut Tightening torque 147 0 176 4Nm Lower arm bolt nut Tightening torque 147 0 176 4Nm Stabilizer bar mounting bracket Tightening torque 39 2 58 8Nm Stabilizer bar link upper Tightening torque 29 4 44 1Nm Lateral rod Tightening torque 147 0 196 0Nm Stabilizer bar link lower Tightening torque 58 8 78 4Nm ...

Страница 924: ...orque Bent or broken coil spring Replace Damaged tire Replace Worn bushing Replace Vehicle pulls to one side Deformed arm assembly Replace Worn bushing Replace Bent or broken coil spring Replace Hard steering Excessive resistance of lower arm ball joint Replace Insufficient tire pressure Replace Faulty power steering Replace Unstable steering Worn or loosened lower arm bushing Retighten or replace...

Страница 925: ...comfortable and reasonably well isolated from road noise bumps and vibrations etc These goals are generally at odds so the tuning of suspensions involves finding the right compromise It is important for the suspension to keep the road wheel in contact with the road surface as much as possible because all the forces acting on the vehicle do so through the contact patches of the tires The design of ...

Страница 926: ...e advantage of a double wishbone suspension is that it is fairly easy to work out the effect of moving each joint so the kinematics of the suspension can be tuned easily and wheel motion can be optimized It is also easy to work out the loads that different parts will be subjected to which allows more optimized lightweight parts to be designed They also provide increasing negative camber gain all t...

Страница 927: ...nk type suspension is the independent suspension It provides good ride comfort and drivability by reducing the coil spring weight Also it increases the space for passenger compartment by lowering the floor This type of suspension consists of multiple links such as coil spring shock absorber upper and lower arms lateral rod and stabilizer bar ...

Страница 928: ...ations to obtain a specific handling characteristic Necessity for Wheel Alignment Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other The purpose of these adjustments is maximum tire life and a vehicle that tracks straight and true when driving along a straight and level road The symptoms of a vehicle that is out of...

Страница 929: ... top When viewed from the top the distance between the tire centers is smaller in the front than in the rear Side slip protection Parallel front wheels rotation straight ahead driving is ensured by toe in to prevent the wheels from tilting outwards by the camber while driving Prevention of uneven outward tire wear Prevention of toe out from wearing of steering linkage Toe in 2 2mm ...

Страница 930: ... contracts and the restoration force is applied to the steering wheel Cornering force decreases as the positive camber increases when the vehicle makes turn The hub bearing is worn unevenly if camber is excessive Zero camber When the tire center line is perpendicular to the ground level Negative camber Better traction force due to wide load area applicable for off road vehicle Better corner drivin...

Страница 931: ...e to go straight following control Restoring force of the wheel restored to the straight ahead direction Prevention of wheel shimmy wheels wobble left and right Caster Caster LH 4 28 0 4 RH 4 38 0 4 Positive caster Advantages Negative caster Advantages Disadvantages Top of the king pin is tilted forward from the vertical line of the wheel center when viewed the tires from the side Top of the king ...

Страница 932: ...NO DATA ...

Страница 933: ... 1 SPECIFICATION Service Interval Change the brake oil at every 2 years DOT It is the quality grade of brake fluid established by US Department of Transportation Rear brake Multi Link IRS Axle Type Ventilated disc Outer diameter of disc Ø307 mm Thickness of disc 20 mm wear limit 18 4 mm Area of brake pad 42 5cm Pad wear indicator Mechanical type Brake booster Type Vacuum assist type Master cylinde...

Страница 934: ...g 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 Replace Poor braking O...

Страница 935: ...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...

Страница 936: ...oot 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 ...

Страница 937: ...mply any problems with the brake system Symptom 2 Slip or screech after the brake pad replacement Symptom 3 Groaning sound occurs in the automatic transmission vehicle when slightly taking the foot off the brake pedal to slowly start after waiting for the signal or slightly depressing the brake pedal This usually occurs when the bed in is not made between the disc and the pad s friction material T...

Страница 938: ...terial does not get into brake line Always work with another staff 3 AIR BLEEDING Fill up the brake fluid up to MAX line on the reservoir A Fill the reservoir with brake fluid and pump the brake pedal several times Then keep it depressed B Loosen the bleed screw and collect the bleeding brake fluid from the brake line with the order in the figure C Fill the reservoir with the brake fluid as much a...

Страница 939: ...r brake D Air bleed screw at front brake E Repeat the air bleeding procedures until clear brake fluid comes out of air bleed screw F Check for oil leaks from the brake lines G Air bleeding completed Air in brake fluid Deteriorated fluid ...

Страница 940: ...e length A B C D 4 RAKE SYSTEM CHECK Maximum Stroke of Brake Pedal Over the specified value Specified value A 138 mm Below the specified value Cause Action Worn brake pad Replace Worn brake shoe Replace Improper stroke of hand brake Adjust Air in brake line Air bleeding Oil leak Repair or replace Brake booster push rod Replace or adjust Improperly adjusted stopper bolt Adjust Cause Action Brake bo...

Страница 941: ...op lamp switch assembly Loosen the lock nut on the pedal push rod Turn the pedal push rod to adjust the pedal height Tighten the lock nut Install the stop lamp switch assembly Connect the stop lamp switch connector Check if the stop lamps come on when pressing the brake pedal around 5 mm If the stop lamp dpes not come on adjust the stop lamp switch assembly again If the stop lamps come on tighten ...

Страница 942: ...p lamp switch is normal Connect the multimeter to stop lamp switch connector N C and check if the continuity exists when pushing in the plunger If the continuity doesn t exist the stop lamp switch is normal A B If the free play is below the specified value check if the clearance between the outer case of the stop lamp and the brake pedal is within the specified range If the clearance is out of the...

Страница 943: ...f any condition is not met check the valve vacuum hose and brake booster Brake Booster Depress the brake pedal when the engine is running If the pedal height is not changed for 30 seconds after stopping the engine the system is normal If not the system is defective C Depress the brake pedal several times with engine off If the brake goes down when starting engine with pedal depressed the system is...

Страница 944: ...servoir If it is below MIN mark check for oil leaks and refill the reservoir with the specified fluid The water in the brake fluid has an adverse effect to the brake system If the fluid contains around 3 of water the boiling point of the brake fluid goes down by 25 It will cause the vapor lock frequently Water content in fluid around 3 after 18 months around 7 10 after few years The water ib fluid...

Страница 945: ...r limit replace the brake disc with new one New disc Wear limit 28 mm 25 4 mm Disc Run Out C Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when brakin Limit 0 03 mm before installation 0 07 mm when installed If a ...

Страница 946: ...and visually check the followings Damage and tear on boot D Uneven wear and oil contamination E Damage crack and wear on cylinder body A and guide pin B F Wear rust and damage on the cylinder and piston Scratch and bending on disc plate G H ...

Страница 947: ...imit replace the brake disc with new one Limit 0 03 mm before installation 0 07 mm when installed Rear Brake Install the dial gauge on the side of brake disc and measure the run out while rotating the brake disc If the measured value exceeds the limit replace the brake disc with new one Otherwise it may cause the pedal vibration and shimmy when braking New pad Wear limit 10 mm 2 mm New disc Wear l...

Страница 948: ...fied value with the parking brake adjusting nut Check the parking brake force after adjustment If the parking brake force is not enough check the parking brake lever and cable Replace the components if needed A B C D Specified notches 5 Never park the vehicle only with the parking brake on the stiff hill It may cause roll down of the vehicle due to release of the parking brake Place the wheel choc...

Страница 949: ...master cylinder booster pedal and supply lines pipes and hoses Hydraulic Brake Brake Pedal This system uses the leverage effect and Pascal s principle When depressing the brake pedal the pedal pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure The hydraulic pressure generated by the master cylinder is delivered to the brake caliper through the brake...

Страница 950: ...ntil you bring your vehicle to a complete stop This is called as stopping distance What is braking distance Tire slip occurs until the vehicle stops completely when the the brake is applied This slip is what we call a braking distance What is free running distance The free running distance is the time from the driver sees the obstacles and begins to prepare for depressing the brake pedal until the...

Страница 951: ......

Страница 952: ...06 22 Brake Master Cylinder Booster 2 SYSTEM LAYOUT Wheel Speed Sensor 4WD A Front B Rear Front Brake Caliper Assembly Front Brake Pad HECU Assembly ...

Страница 953: ...06 23 4850 01 Indicator Warning Lamp A ABS indicator warning lamp B Parking brake indicator Parking Brake Lever Brake Pedal Rear Brake Caliper Assembly Rear Brake Pad Parking Brake Assembly ...

Страница 954: ...nt Disc Brake Tie rod end connection Lower arm connection Dust shield Knuckle Brake hose Brake caliper 2 way piston Air bleeder screw Upper arm connection Wheel bolt or hub bolt Brake disc Air bleeder screw Brake pad Brake caliper ...

Страница 955: ...5 4850 01 Rear Disc Brake Dust shield One way piston Brake hose Brake caliper Air bleeder screw Brake hub Brake disc Brake caliper Brake pad Air bleeder screw Wheel bolt or hub bolt Parking brake connection ...

Страница 956: ... 4 HYDRAULIC CIRCUIT with ABS Brake booster Brake fluid reservoir and master cylinder HECU Hydraulic Electric Control Unit 1 2 3 Front disc brake and caliper Rear disc brake and caliper 3 way connector 4 5 6 ...

Страница 957: ...06 27 4850 01 5 CIRCUIT DIAGRAM OF STOP LAMP ...

Страница 958: ...Operating temperature 40 150 Operating frequency 1 2 500Hz Tightening torque Front 7 8 11 7 Nm Rear 7 8 11 8 Nm Description Specification Remark ABS HECU Clock frequency 28 MHz CPU MCU60 32bit Memory 128 256 kb Switch orifice Wheel speed sensor Active type Output 7 14 mA Steering wheel angle sensor None Sensor cluster None Longitudinal G sensor 4WD only integrated in ABS HECU Pressure sensor None ...

Страница 959: ...aintain directional stability and control of the vehicle ABS is designed to secure more safety and increase the control of steering wheel during emergency braking situation But ABS does not guarantee perfect safety beyond its physical limit ABS in this vehicle contains EBD function In normal driving conditions the brake system operates without ABS function ABS effect according to braking condition...

Страница 960: ......

Страница 961: ... Master Cylinder and Booster ABS Warning Lamp EBD warning lamp ABS warning lamp and Brake warning lamp ON together 2 COMPONENTS AND LAYOUT Front Active Wheel Speed Sensor It is installed on the front hub assembly ...

Страница 962: ...07 7 4892 01 Diagnostic Connector HECU Hydraulic Electronic Control Unit Rear Active Wheel Speed Sensor It is installed on the rear axle ...

Страница 963: ...g the speed information from 4 wheel speed sensors when the vehicle is being driven For example when the comparison of the reference speed with front right wheel speed shows a slip the control signal is determined according to whether it s deceleration or acceleration If the control conditions are met the brake for the front right wheel will be got under control ...

Страница 964: ...es on for 3 seconds for self diagnosis and goes off if the system is OK initialization mode When the system is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected the warning lamp comes on ABS is not available during lamp ON In this condition Only normal brake system without ABS function is available When the c...

Страница 965: ...07 10 5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Страница 966: ...ing process cannot be described sufficiently accurately with the brake forces calculated The values calculated only apply if the wheel is not locked In the case of a locking wheel the static friction turns into lower sliding friction with the result that the stopping distance is increased This loss of friction is termed slip in specialist literature The stopping distance depends on the vehicle wei...

Страница 967: ...ture is shown by the curve for freshly fallen snow for this curve increases at 100 slip In a vehicle without ABS the wheel locks on braking and therefore pushes a wedge before it This wedge of loose surface or freshly fallen snow means and increased resistance and as a result the stopping distance is shorter This reduction in stopping distance is not possible with a vehicle with ABS as the wheel d...

Страница 968: ...in the circle the vehicle is stable to drive If a force exceeds the circle the vehicle leaves the road Brake and cornering force Brake force When depressing the brake pedal the brake force increases to the maximum then the brake force decreases until the wheel locks Cornering force The cornering force is a maximum when the wheel is turning freely with zero slip When braking the cornering force fal...

Страница 969: ...imation Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previously determined reference speed In that case the control cycle is initiated ag...

Страница 970: ...ed with each wheel speed Firstly it is determined whether the vehicle is in the deceleration or acceleration state using the wheel speed change ratio Then a signal is transmitted to the valve Finally the brake pressure is adjusted via the signal V Vehicle speed Vref Reference speed Vw Wheel speed ...

Страница 971: ...t 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 6 HYDRAULIC CIRCUIT DIAGRAM ...

Страница 972: ... valve At this moment the normally closed outlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases At th...

Страница 973: ...ressure changer and the wheel speed increases again The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises 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...

Страница 974: ...07 19 4892 01 8 ELECRTRIC CIRCUIT DIAGRAM ...

Страница 975: ...Unit Description Specification ABS ESP HECU Clock frequency 28MHz Clock frequency 33MHz CPU MCU60 32bit CPU MCU6 32bit Memory 128 256KB Memory 256 512KB Switched Orifice Switched Orifice Wheel speed sensor Active type Active type Output 7 14mA Steering wheel angle sensor None Max detection angle speed 1500 sec Operating voltage 9 12V Sensor cluster None Yaw rate sensor lateral G sensor longitudina...

Страница 976: ...rating temperature 30 75 Supplying voltage 9 to 16 V battery voltage Output voltage HI approx 3 50 V 3 0 to 4 1 V Output voltage LO approx 1 50 V 1 3 to 2 0 V Pulses rev 45 pulses rev 3 Specification of Sensor Cluster Description Specification Remark Supplying voltage approx 5V 4 75 5 25V Output voltage at standstill approx 2 5V IGN ON Operating range 0 2 4 8V Initial velocity 4 s ...

Страница 977: ...ution ESP Electronic Stability Program ABD Automatic Braking Differential ASR Acceleration Slip Regulation AYC Active Yaw Control HBA Hydraulic Brake Assistant ARP Active Rollover Protection HDC Hill Descent Control 2 Functions Function ABS EBD ESP ABS Available Available EBD Available ABD Not available ASR AYC HBA ARP HDC ...

Страница 978: ...udinal G sensor ESP warning lamp indicator ESP OFF switch and indicator Steering wheel angle sensor 4 Operation of Components ABS ESP ARP 2WD 4WD 2WD 4WD Wheel speed sensor 4 sensors 4 sensors 4 sensors 4 sensors Sensor cluster Not applied Not applied Applied Applied G sensor Not applied Applied Not applied Not applied 2H G sensor Operable 4H G sensor Operable 4L G sensor Operable 2H sensor cluste...

Страница 979: ...SP operating ESP warning lamp ESP malfunctioning ABS warning lamp Amber ABS malfunctioning EBD warning lamp Amber Red EBD malfunctioning HDC indicator Red Green Red HDC operating Green HDC switched ON 3 WARNING LAMPS 1 ABS warning lamp 2 Brake warning lamp 3 ESP OFF indicator 4 ESP warning lamp indicator 5 EBD warning lamp ...

Страница 980: ... the self diagnosis and when it detects the malfunction of EBD system However the brake warning lamp comes on regardless of EBD when the parking brake is applied EBD warning lamp ON When turning the ignition switch to ON position ABS warning lamp and the brake warning lamp comes on for 4 seconds for self diagnosis and goes off if the system is OK initialization mode When applying the parking brake...

Страница 981: ... in meter cluster the warning lamp comes on A B C D 4 ESP OFF Switch If ESP OFF switch is pressed ESP function is deactivated and the ESP OFF indicator in the instrument cluster comes on To resume the ESP function press the switch again At this time ESP OFF indicator goes out ESP warning lamp ON 3 ESP OFF Indicator When turning the ignition switch to ON position ESP warning lamp comes on for 4 sec...

Страница 982: ...perations in a very short period of time And keep in mind that the output and vehicle speed could be decreased without rpm increase due to the ASR function that controls the engine power ARP Operation During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle speed decreases rapidly so the driver must ...

Страница 983: ...d braking force HDC Hill DescentControl System Allows the vehicle to go down the steep hill slowly For example when the brakes are applied during cornering at the speed of 100 km h the ABS will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 degree seconds the ESP system is activated to apply ...

Страница 984: ...ation of Components and Layout Brake Oil Pressure Sensor ESP only Brake Master Cylinder ESP only ABS ESP HECU ESP ABS ESP OFF indicator ESP warning lamp indicator ABS warning lamp Parking brake warning lamp HDC indicator EBD warning lamp 3 4 1 2 3 4 5 ...

Страница 985: ...07 13 4892 01 ESP OFF HDC Switch ESP only ESP OFF Switch HDC Switch Rear Wheel Speed Sensor 4WD Brake Booster Assembly Front Wheel Speed Sensor 4WD Steering Wheel Angle Sensor ESP only ...

Страница 986: ...he centrifugal force increases the tires can easily lose the traction and the vehicle tends to slip outward when the curve angle gets bigger and the speed increases What is understeering ESP controls during understeer The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction durin...

Страница 987: ... braking force to the front outer wheel to compensate the yaw moment value In this way the vehicle does not lose its driving direction and the driver can steer the vehicle as intended Oversteer is a term of a condition in which the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction Compared to understeering vehicles it is hard to control the...

Страница 988: ...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 bef...

Страница 989: ...e directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeer with the yaw rate sensor and lateral sensor Then the ESP system applies the braking force to the rear inner wheel to compensate the yaw moment value In this way the vehicle does not lose its driving direction and the driver can steer...

Страница 990: ...07 18 4 Input and Output Diagram of ESP unit ...

Страница 991: ...rimary circuit and in secondary circuit When the vehicle brakes are not applied during engine running or when applying the non ABS operating brakes the normally open separation valve and the inlet valve are open whereas the normally closed shuttle valve and the outlet valve are closed When the ESP system is operating the normally open separation valve will be closed by the solenoid valve operation...

Страница 992: ...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 ...

Страница 993: ...creases just before the wheel speed drops and the wheels The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump operates to allow fast oil drainage ...

Страница 994: ... will be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens ...

Страница 995: ...le valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Страница 996: ...nsors under the master cylinder When the ESP ECU system determines that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depress the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated...

Страница 997: ...ergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the brake pressure sensor ...

Страница 998: ...sure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the wheel starts to lock the H...

Страница 999: ...ne must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns ...

Страница 1000: ...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 ...

Страница 1001: ...indicator goes off When the HDC is operating on a steep downhill When the HDC is operating on a steep downhill the HDC indicator in meter cluster blinks with heavy operating sound Sensor Cluster The G sensor in sensor cluster detects the gradient of the roads When the HDC is ready by HDC switch G sensor sends the HDC request signal to ESP HECU if the vehicle is driving on a downhill with over 10 g...

Страница 1002: ...riving 7 km h Reverse driving 7 km h automatic transmission 8 5 km h manual transmission A B Vehicle position control function in ESP and HBA function are not in operation The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden e The gradient of downhill should be over 10 When the gradient of d...

Страница 1003: ... the vehicle speed is out of the specified values Below 7 km h When the ESP related functions e g vehicle position control HBA ARP is activated during HDC operation When the internal temperature of HDC system goes over 450 C due to long downhill driving on a steep hill with HDC operated There is no specific temperature sensor in the system but a programmed logic inside the HECU predicts the temper...

Страница 1004: ... during HDC operation If the slope level is between 10 and 20 HDC is deactivated If the slope level exceeds 20 HDC function is still activated and the brake pressure is added Longitudinal acceleration sensor When the HDC operates HECU turns on the stop lamp by supplying 12V power separate relay HECU sends the signals regarding HDC Ready Operating and other warning conditions to the meter cluster v...

Страница 1005: ...odes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Initial ignition ON HDC system error occurs Brake system overheat Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warni...

Страница 1006: ...refore avoid using the HDC system on level roads If the HDC system is used frequently the internal components of ESP HECU and related parts could be damaged Place the HDC switch at OFF position while the vehicle is driving on level roads As mentioned earlier the HDC system is operable even when the vehicle is driving on level roads This could cause the driver to lose control of the vehicle resulti...

Страница 1007: ...07 35 4892 01 5 CIRCUIT DIAGRAM Wheel speed sensor Stop lamp switch Self diagnosis connector Warning lamps ABS ESP ...

Страница 1008: ...07 36 Brake pressure sensor Steering wheel angle sensor Sensor cluster ESP OFF switch ...

Страница 1009: ...mum turning radius m 5 7 Steering oil Type PSF 3 Capacity L 1 1 Service interval Daily check and add if necessary Type Double cardan CV joint type Angle 62 68 Components CV joint upper Hook joint lower Elastic sleeve 1 SPECIFICATIONS Lower shaft Description Specification Steering wheel Type 4 spoke type Outer diameter mm 390 Steering gear box Type Rack and pinion type Steering angle Inner 38 2 Out...

Страница 1010: ...r box and gear box cross member mounting bolt 98 0 127 4 Steering gear box and lower shaft connection bolt 24 5 29 4 Steering gear box and lower shaft connection nut 34 3 44 1 Tie rod end lock nut 63 7 78 4 Steering gear box and pressure hose connection nut 11 8 17 6 Steering gear box and return line connection nut 11 8 17 6 Power steering pump Eye bolt for oil supply pipe to power steering pump 1...

Страница 1011: ...RVICE TOOLS Part Number Name Description 661 589 00 33 00 L 99 46 001 0A Steering wheel puller Removing the steering wheel 661 589 13 33 00 W 99 44 002 0A Ball joint puller Removing the upper and lower end from front suspension ...

Страница 1012: ...e 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 ...

Страница 1013: ...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...

Страница 1014: ... lift Unscrew the adjusting plug lock nut Measure the torque of the adjusting plug A B C D If the torque is excessive or too low adjust to the specified torque E Place the rack gear to the center position Tighten the adjusting plug to 10 2 Nm Turn the pinion gear so that the rack gear is turned to lock to lock 5 times Unscrew the adjusting plug Tighten the adjusting plug to 4 6 to 5 6 Nm Unscrew t...

Страница 1015: ...a paved and flat ground and place the front wheels at straight ahead direction Start the engine and let it run around 1 000 rpm Install the spring scale on the circumference of the steering wheel and measure the steering effort in both directions A B C Steering effort in standstill below 3 0 kg The difference between both sides should be within 0 6 kg Steering Angle Check Place the front wheel on ...

Страница 1016: ...ight ahead direction Check the oil level in the power steering oil reservoir Adjust the oil level between MAX and MIN A B C D Oil Change If the difference between two measurements is below 5 mm and the level is between MAX and MIN level it s normal If it is over 5 mm bleed air from the system Open the power fluid reservoir cap and drain the fluid completely with oil suction device To make it easy ...

Страница 1017: ...r Periodically crank the starting motor and turn the steering wheel to its both ends without any interruption Check the oil level again If the oil level is fluctuated repeat the procedures from step 3 to step 5 Start the engine Turn the steering wheel to its both ends until any bubble can be found in the steering oil reservoir Perform the test drive and check the steering wheel for normal operatio...

Страница 1018: ...auge between the power steering pump and the power steering oil pressure line Place the shift lever to neutral position Apply the parking brake Open the valve in pressure gauge Start the engine and let it run at idle speed Turn the steering wheel several times so that the oil temperature reaches to normal operating level A B C D E Fully close the valve in pressure gauge and measure the oil pressur...

Страница 1019: ...fully open G Pressure at no load 3 5bar If the pump pressure is in specified range the pump is normal If not replace the power steering pump H Turn the steering wheel righ or left until it stops with the engine idling ans valve fully open I Oil pressure 78 83Bar ...

Страница 1020: ...re 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...

Страница 1021: ...ng oil from the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Linkage gear box Power steering pump tank Return hose tube High pressure hose Column shaft Steering wheel Lower shaft Return line High pressure line Steering pump Steering return pipe Steering cylinder ...

Страница 1022: ...08 16 Oil Flows during Right Turn Steering pump Oil reservoir in To piston pipe From piston pipe Piston Piston pipe ...

Страница 1023: ...12 3 4620 01 1 SPECIFICATIONS 1 Specifications Description Specification Voltage Rating DC 12V Current Rating 1 0A Resistance 6 7 1Ω ...

Страница 1024: ...he driving pressure of drivers No matter for steering parking or reversing it becomes much easier The adjustable safety steering column attached possesses the functions of electrically adjusting height and transverse position has brought much more abundant and comfortable spaces for legs and has provided the great convenience to get in or out the car The Speed Sensitive Power Steering SSPS unit co...

Страница 1025: ...12 5 4620 01 SSPS Warning Lamp SSPS Control Unit Location of Power Steering Pump Location of SSPS Solenoid Valve Location of SSPS Control Uni SSPS Solenoid Valve 2 COMPONENTS Power Steering Pump ...

Страница 1026: ...12 6 Steering Gear Box SSPS Solenoid Valve Tie rod end Tie rod Bellows SSPS solenoid valve Valve assembly Feed tube Mounting bracket Cylinder tube Rack housing Adjusting plug 1 2 3 4 5 6 7 8 9 10 ...

Страница 1027: ...20 01 3 OPERATING PROCESS 1 Input Output of ECPS Control Unit Meter Cluster Vehicle Speed SSPS Control Unit Solenoid Valve Meter cluster SSPS warning lamp Trouble Diagnosis 2 ECPS Configuration Ground IG Power ...

Страница 1028: ...alve SSPS control unit controls the current to solenoid valve according to the vehicle speed Based on this current the solenoid valve changes the position of valve spool to control the hydraulic pressure to the reaction plunger Accordingly the SSPS system can get the desired steering force according to the vehicle speed During parking and low speed driving SSPS control unit outputs nearly maximum ...

Страница 1029: ...m SSPS control unit The coil spring pulls the PCV spool toward solenoid valve to open it The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to reaction plunger At this time the reaction plunger transmits the reaction force to V groove in input shaft to provide heavy steerability 1 2 3 4 ...

Страница 1030: ...lity with low current as the vehicle speed increases And it provides light steerability with high current as the vehicle speed decreases During parking and low speed driving During parking and driving in low speed the control unit supplies approx 1 A of electric current to solenoid valve Then the spool located in PCV compresses the upper spring and elevates upward and the working pressure from oil...

Страница 1031: ...ric current to solenoid valve Then the spool located PCV moves from top to bottom and the working pressure A port from oil pump is applied to reaction plunger C port through B port As a result the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier ...

Страница 1032: ...12 12 4 CIRCUIT DIAGRAM ...

Страница 1033: ...ure measuring tolerance 5 40 10 2 10 70 5 70 100 Temperature measuring range 50 205 Temperature measuring tolerance 5 40 10 2 10 70 5 70 100 Transmit frequency 433 92 MHz Battery life Lithium battery approx 3 0 3 2V 160 000 km or 10 years Subject to operating conditions Tire pressure 32psi 1 SPECIFICATIONS 1 Wheel Module ...

Страница 1034: ...g Installing Valve Body 2 SPECIAL SERVICE TOOLS The tightening torque for wheel module is 1 4 Nm To tighten the bolts for wheel module without any damage you must use the special service tool as below Torque wrench 0 1 5 0 Nm Torx socket T 10 Tire valve remover installer ...

Страница 1035: ...s Rear Tire Pressures Front Tire Pressures Rear Tire Pressures If the vehicle is moving around electric power supply cable or radio transmitter which can interferewith normal operation of TPMS the TPMS may not work properly After replacing the low pressure tirewith the spare tire without TPMS the TPMSmalfunction indicator will illuminate afterrestarting and about 20 minutes ofcontinuous driving be...

Страница 1036: ...ment wheel has same size with factory installed wheel TPMA may not be usable due to interference on rim External View for Wheel Module Internal View for Wheel Module Do not use any tire sealant if the vehicle is equipped with a TPMS The liquid sealant can damagethe tire pressure sensors ...

Страница 1037: ......

Страница 1038: ...auses the tire to overheat and canlead to tire failure Under inflation alsoreduces fuel efficiency and tire treadlife and may affect the vehicle s handlingand stopping ability The wheel module is located under valve body in each tire and periodically sends the data to TPMS ECU with radio frequency TPMS ECU converts the signals and sends them to the meter cluster through CAN line so that the driver...

Страница 1039: ...11 9 4190 00 Location of TPMS ECU Location of Wheel Module Wheel Module Sensor Wheel Module Assembly TPMS ECU ...

Страница 1040: ...11 10 3 BLOCK DIAGRAM ...

Страница 1041: ...ays on when there is a problem with the TPMS For details refer to 5 WARNING This warning lamp comes on when the ignition switch is turned to ON and should go off in 4 seconds This warning lamp blinks 0 4s ON OFF for 70 seconds and then stays on when one or more tires is significantly under inflated or flat tire For details refer to 5 WARNING This warning lamp comes on when the ignition switch is t...

Страница 1042: ...obal Warning Failure Warning ON Conditions Warning Lamp Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Error in TPMS system Defective wheel module Error in TPMS system Low tire pressure Flat Tire Yellow Comes on immediately Yellow Affected tire symbol Yellow Comes on immediately Yellow Blinks 0 4s ON OFF for 70 seconds and the stays on Yellow Affected tire symbol ...

Страница 1043: ...ormal tire comes on in yellow In tire pressure display mode the symbol for abnormal tire comes on in yellow and the other symbols come on in green Tire Pressure Indicator Yellow Blinks 0 4 s ON OFF for 70 seconds and then stays on Specified tire pressure 32 psi 10 minutes of continuous driving over 20 km h The tire pressure should be measured at 18 C in CVW Comes on in green 10 15 s and then goes ...

Страница 1044: ...ressure P2 P3 range Meets the warning lamp ON condition 1 P3 Warning lamp ON P4 Warning lamp OFF Hysteresis range Condition 1 continuous driving for 10 minutes tire pressure 24 26 psi low vehicle speed 20 km h or higher A C B B Blinks 0 4 s ON OFF for 70 seconds and then stays on ...

Страница 1045: ...11 15 4190 00 6 TIRE PRESSURE DISPLAY LCD display Trip switch A B ...

Страница 1046: ...its own ID Identification to TPMS ECU at every 30 seconds However in emergency situation e g pressure drop of 1 psi a second it sends the data to TPMS ECU at every one second In this case the batter current consumption increases dramatically Have the system check immediately Tire Pressure Indication Procedure Simultaneously processed Wheel module check Auto Learning TPMS ECU identifies ID for each...

Страница 1047: ...f the vehicle A Carefully explain the TPMS system and its usage to customers The tire pressure can be changed frequently due to driving conditions passengers internal temperature changes and loads If there is another vehicle equipped with the TPMS keep the distance from this vehicle at least 5 m to prevent interference of wheel module transmitting Unload the cargo if not necessary Even though you ...

Страница 1048: ... Pressure B Inflate the air into the tire according to the specified procedure Inflate the air into tire 32 psi Drive the vehicle for more than 10 minutes over 20 km h Normal Abnormal Check if TPMS warning lamp or Global warning lamp comes on If there is no indication and adjust the tire pressure to the specified value Normal tire pressure Completed ...

Страница 1049: ...90 00 Caution When Inflating If the tire pressure is 10 psi lower than the specified value remove the valve insert from the wheel module valve body and replace it with new one Then inflate the air into the tire ...

Страница 1050: ...dherence type Tightening torque of wheel bolt 127 4 156 8 Nm Description Specification Tire EU GEN 16inch 18inch EU GEN 235 75R 16 255 70R 16 255 60R18 255 60R18 BR Tire inflation pressure 32psi Wheel EU GEN 16inch 18inch EU GEN 7 0J 16 7 5J 18 TYPE A 7 5J 18 DIAMOND CUT 1 SPECIFICATIONS 2 WHHEL DESIGNS 18 inch 255 60R 18 18 inch 255 60R 18 18 inch 255 60R 18 Type A Sputtering Diamond cut ...

Страница 1051: ...d interval Incorrect toe adjustmen Adjust Incorrect wheel bearing preload adjustment Adjust Malfunction of brake syste Replace Tire squeal vibration Too low tire pressure Adjust Unbalanced wheel or tire Adjust Heavy vibration of wheel or tire Replace Uneven tire wear Check and adjust Premature tire wear Too high tire pressure Adjust Fast driving with low pressure tire Adjust Overload Adjust ...

Страница 1052: ...at tread center Excessive tire inflation pressure Excessive wear in the outer side of the tread than in the inner side Excessive camber or deflection of knuckle arm Excessive wear in the inner side of the tread than in the outer side Insufficient camber or deflection of knuckle arm Inside Outside Inside Inside Inside Outside Outside Outside ...

Страница 1053: ...ce in tie rod length between left and right sides Blade type wear from inner side toward outer side of the tread Excessive toe in Deflection of knuckle arm Difference in tie rod length between left and right sides Corrugation wear of tread Poor wheel balance Loose wheel bearing poor wheel alignment Inside Outside Inside Outside Inside Outside ...

Страница 1054: ...the groove at the point with mark which is the indicator of the tread wear limit The limit of the tread wear for all season tires are 1 6 mm which is the same as the general tires but the wear limit mark is indicated as Higher than recommended pressure can cause hard ride tire bruising or damage and rapid tread wear at the center of the tire Excessive tire wear over the limit of the tread wear 1 6...

Страница 1055: ...out on the tire tread Specified value 2 03mm If any measurement exceeds the above specifications replace the applicable tires or wheels Tire inflation pressure 3 Specified value 32psi Maintaining the specified tire ressure is essential for comfortable riding driving safety and long tire life Incorrect inflation pressures will increase tire wear and will impair safety vehicle handling comfortable d...

Страница 1056: ...by 5 g There are two types of weight balance tape type and adhesion type Make sure to read the manual of the manufacturer thoroughly before using wheel balance tester Change tire location To avoid uneven wear of tires and to prolong tire life inspect and rotate your tires every 5 000 km 6 Mixing tires could cause the driver to lose control while driving Be sure to use the same size and type tires ...

Страница 1057: ...ower to propel brake and steer on the road It also functions to maintain a vehicle s movement In order to complete such tasks a tire must be structured to be a resilient vessel of air There is wear limit mark on the tire which protrudes as a strip shape located approximately 1 6 mm from the groove bottom This wear limit mark is not seen from the outside so there is additional mark on the shoulder ...

Страница 1058: ...09 11 4170 34 Tools Location of Components Spare Tire Jack Jack connection Wheel wrench Warning Triangle ...

Страница 1059: ...nd enhances the ride A tire s type size structure pattern manufacturing company product name and various characters are indicated here Bead The bead attaches the tire to the rim and wraps the end of the cord fabric Comprised of the bead wire core flipper and other parts the bead is generally designed to be slightly tight around the rim so that in the case of a sudden drop in inflation pressure the...

Страница 1060: ...xcessive so a lot of heat is generated and the tire is worn out unevenly and abnormally The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire faces the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly ...

Страница 1061: ... in a short period of time If the standing wave symptom occurs on the tire rubber on the tread comes off and eventually the tire can be blown out which is very dangerous When driving at high speed the inflation pressure should be increased to decrease heat generation due to extension and contraction motion to decrease hydroplaning and to prevent standing wave To prevent this symptom it is recommen...

Страница 1062: ...water It causes brake failure lower traction force and losing the steering performance To prevent this increase the tire inflation pressure use tires with leaf shape tread which is not worn However it is a best measure to drive slowly Hydro Planing Vehicle speed 60 km h No Hydro planning Vehicle speed 80 km h Partial Hydro planning Vehicle speed 100 km h Full Hydro planing ...

Страница 1063: ...1 add the balance weight of a weight corresponding to unbalanced weight from B to A to maintain the static balance If the static balance is not maintained tramping up and down vibration of the wheels occurs Dynamic Balance The static unbalance of the wheel creates the vibration in the vertical direction but the dynamic unbalance creates the vibration in the lateral direction As shown in the figure...

Страница 1064: ...eel 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 ...

Страница 1065: ...ance 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 The fo...

Страница 1066: ...CTIONS OF TIRE Supporting the Vehicle Weight Even friction coefficient road Uneven friction coefficient road Driving Force Braking Force Transferring the Driving Force Braking Force to Road Absorbing the Impact from Road ...

Страница 1067: ...escription FATC Air conditioner control panel Rated voltage DC 12V Operating voltage DC 9 16V Current consumption 2A Operating temperature 30 75 Output current from air mix door motor 0 4A Output current from high relay 0 5 Base current for power transistor 1A Output current from air source motor 0 55A Output current from mode motor 0 55A Dark current Below 2 mA Below 1 1 mA Compressor Pulley diam...

Страница 1068: ...01 4 Description FATC PTC Heating type Air heating type Material BaTiO3 Weight 500g ...

Страница 1069: ......

Страница 1070: ... Valve Controls the refrigerant volume and sends it to evaporator Condenser Installed on the front of vehicle and converts the gaseous refrigerant to liquid refrigerant by condensing it PWM Electric Fan Cools the radiator and condenser down ...

Страница 1071: ...ensor Absorbs the moisture from the refrigerant and accumulates it for supplying AQS Sensor Ambient Temperature Sensor Measures the air contamination value and ambient temperature and sends the data to FATC controller A C Compressor A C Hose Pipe Lines ...

Страница 1072: ...01 8 Mode Door Actuator Air Mix Actuator Heater A C Module Sun Sensor A C Control Automatic Control 2 SYSTEM LAYOUT INTERNAL ...

Страница 1073: ...01 9 6822 11 Duct Temperature Sensor Thermo Amplifier A C Filter Blower Motor Power Transistor Air Source Actuator PTC ECU ...

Страница 1074: ...01 10 3 VENTILATION SYSTEM 1 Location 2 Duct Layout ...

Страница 1075: ...ping between the components of FATC A C and A C controller briefly A C Compressor OFF Conditions Coolant temperature 20 or lower Coolant temperature 115 or higher For approx 4 seconds after starting the engine Engine speed 650 rpm or lower Engine speed 4 500 rpm or higher ...

Страница 1076: ...emperature for easier evaporation 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 f...

Страница 1077: ...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...

Страница 1078: ...01 14 Air Conditioner Compressor PWM Electric Fan Air Mix Motor Sun Sensor Coolant Temperature Sensor AQS Sensor Thermo Amplifier ...

Страница 1079: ...01 15 6810 18 2 2 Motor Mode Fresh Recirculation ...

Страница 1080: ...01 16 ...

Страница 1081: ...e air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation The seat belt and air the bags are the most effective when you are sitting well back and upright in the seat A child restraint system must not be placed on the front seat The infant or child can be severely injured by an air bag inflation in case of an accident Do not carry your child on your lap whi...

Страница 1082: ... Do not place your face or chest near the steering wheel and dashboard Also do not allow anyone to place their hands leg or face on the dashboard The air bag cannot work properly Do not hold and operate the steering wheel by crossing your arms You could get seriously injured when the air bag deploys When the air bag inflates it makes a loud noise and smoke However the smoke is a non toxic nitrogen...

Страница 1083: ......

Страница 1084: ...ir bag module side air bag module and seat belt pretensioner are installed for each seat The pretensioner operates with the front seat The side air bag operates according to the signal from the lateral G sensor longitudinal G sensor and side air bag sensor The front air bags operate independently 2 COMPONENTS STICS Passenger s Air Bag Module Air Bag Unit SDM ...

Страница 1085: ...02 7 8810 00 Air Bag Warning Lamp Meter Cluster Seat Belt Pretensioner Driver s Air Bag Module Side Air Bag Sensor Assembly Side Air Bag Module ...

Страница 1086: ...lls into a drainage or a puddle The front of the vehicle crashes into high impact point vehicle such as a truck The hood is hit by falling stones The air bag warning lamp is on The vehicle rolls over or tips over sideward or a side rear collision occurs the impact of the collision is low enough for the seat belt to protect the occupant properly Underbody impact from the road surface impact against...

Страница 1087: ...sion occurs with low speed A rear collision occurs The impact of the collision is low enough for the seat belt to protect the occupant properly the vehicle rolls over or tips over sideward with a severe impact The vehicle is stationary or a front collision occurs with low speed A rear collision occurs The impact of the collision is low enough for the seat belt to protect the occupant properly a se...

Страница 1088: ...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 Ssangyoung Motors ...

Страница 1089: ...02 11 8810 00 ...

Страница 1090: ...e Driver side Ignite Air bag module Passenger side Ignite Seat belt pretensioner Driver side Ignite Seat belt pretensioner Passenger side Ignite Side air bag module Driver side Ignite Side air bag module Passenger side Ignite Impact to Left direction Right direction Side air bag module Driver side Ignite Not ignite Side air bag module Passenger side Not ignite Ignite Seat belt pretensioner Driver ...

Страница 1091: ...m outputs the air bag deployment signal to STICS to unlock the doors automatically Automatic Door Unlock Crash unlock unlock when colliding The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to ON position After this period the door lock system outputs UNLOCK for all doors for 5 seconds from 40 ms after receiving the air bag collision signal Even ...

Страница 1092: ...ons for Door Lock Unlock Control 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 ...

Страница 1093: ... have been detected When the Air Bag Unit Detects Any Malfunctions in Unit When the Air Bag Unit Detects Any Intermittent Failure When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second Then the waning lamp stays on When due to an error from outside the system the intermittent failure signal...

Страница 1094: ...02 16 8 CIRCUIT DIAGRAM 8810 01 Air Bag including Side Air Bag ...

Страница 1095: ...lates against the heat such as a blanket or cushion Make sure that the head restraints are in place and secured properly Never drive the vehicle with the head restraint removed To minimize the injuries in a collision or an abrupt stop make sure the seatback is in the upright position before driving If the seatback is reclined too much the occupant could slide under the seat belt in a collision or ...

Страница 1096: ...Headrest 2 Front Seat Assembly Front Seat Assembly Old New Changed the design of seatback and seat cushion Changed the design of headrest Front Headrest Old New Swing type tilting Sliding type tilting Changed the design of headrest ...

Страница 1097: ...t Back Board 4 Front Seat Cover Shield Front Seat Cover Shield Old New Integrated type Split type Changed the design of seat cover shield Front Seat Back Board Old New Changed the design of seat back board and seat back pocket ...

Страница 1098: ...nt Seat Frame Cover Front Seat Frame Cover Old New Changed the design of seat frame covers front rear 6 Rear Center Armrest Assembly Rear Center Armrest Old New Changed the location and appearance of armrest band ...

Страница 1099: ...k and push the headrest down The headrest can be adjusted forward to three different positions by pulling the headrest forward To adjust the headrest backward pull it fully forward to the farthest position and release it Adjust the headrest so that it properly supports the head and neck How to operate How to operate Height Adjustment of Headrest Forward and Backward Adjustment of Headrest ...

Страница 1100: ...and move the seat as desired Then release the lever To change the seatback angle lean forward slightly and push the seatback reclining switch to desired direction To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever After adjusting make sure the lever is returned to its original position and the seatback is locked How to o...

Страница 1101: ...ounterclockwise To adjust the seat cushion angle raise or lower the seat cushion angle adjusting switch to desired direction Turn the lever forward to increase the amount of lumbar support To decrease it turn the lever backward How to operate How to operate How to operate How to operate Seat Cushion Angle Adjustment Power Seat Seat Height Cushion Angle Adjustment Manual Seat Lumbar Support Adjustm...

Страница 1102: ... operation for cranking period How to operate The seat heater has 5 heating levels Turning clockwise Higher heating level Turning counterclockwise Lower heating level Operating process The seat heating unit under the passenger s seat controls the seating process according to the signals from the seat heater switch The unit turns ON and OFF the seat heating element to keep the set heating level ...

Страница 1103: ...eted a buzzer sounds twice Operating process The SPWM unit under the driver s seat controls the driver s seat position sensor and outside rearview mirror position sensor to recall the set position appointed to respective button To recall the memory settings Press and hold one of the position buttons you want until the buzzer sounds The driver s seat and outside rear view mirrors start to move to t...

Страница 1104: ...OFF with the Easy Access switch pressed in The SPWM unit operates the seat sliding motor to slide backward the driver s seat The moving distance of the seat is based on when the seat is located at its front end It varies according to the initial position There could be some differences when the seat moves back to its original position The difference of the passenger weights and electrical loads ca...

Страница 1105: ...e button A on top of the seatback and push the headrest down The headrest can be adjusted forward to three different positions by pulling the headrest forward To adjust the headrest backward pull it fully forward to the farthest position and release it Adjust the headrest so that it properly supports the head and neck How to operate How to operate Forward and Backward Adjustment of Headrest ...

Страница 1106: ...an forward slightly and push the seatback reclining switch to desired direction To change the seatback angle lean forward slightly and raise the lever Then lean back to the desired angle and release the lever After adjusting make sure the lever is returned to its original position and the seatback is locked How to operate How to operate How to operate How to operate Seat Slide Adjustment Power Sea...

Страница 1107: ...ops the operation for cranking period How to operate The seat heater has 5 heating levels Turning clockwise Higher heating level Turning counterclockwise Lower heating level Operating process The seat heating unit under the passenger s seat controls the seating process according to the signals from the seat heater switch The unit turns ON and OFF the seat heating element to keep the set heating le...

Страница 1108: ...eturned to its original position and the setback is securely locked Second Row Seat Heating switch The heating switches for the rear seats are located on the rear door trims During heating the seats the seat heater indicator comes on Headrest Adjustment To raise the headrest pull it up without pressing the release button To lower the headrest press the release button A on top of seatback and push ...

Страница 1109: ...adrest Adjustment To raise the headrest pull it up without pressing the release button To lower the headrest press the release button A on top of seatback and push the headrest down Seatback Folding Pull up the folding lever to fold down the third row seat ...

Страница 1110: ...06 18 5 CIRCUIT DIAGRAM Power Seat Seat Position Memory ...

Страница 1111: ...06 19 4170 00 Outside Rearview Mirror Folding ...

Страница 1112: ...06 20 ...

Страница 1113: ...06 21 4170 00 ...

Страница 1114: ...06 22 ...

Страница 1115: ...06 23 4170 00 ...

Страница 1116: ...06 24 ...

Страница 1117: ...mpleted release the switch Keeping pressing the switch can result in malfunction Especially in winter never operate the sunroof if operation areas are iced Wait until melted To prevent a theft make sure that the sunroof is completely closed when leaving the vehicle In addition rain or snow can get into the vehicle through the open sunroof When the sunroof is fully open wind buffeting symptom can b...

Страница 1118: ...04 4 3 MAJOR CHANGES 1 Sunroof Switch Sunroof Switch Old New Changed the appearance of sunroof switch ...

Страница 1119: ...04 5 7340 01 Sunroof Assembly 1 COMPONENTS AND LAYOUT OPEN TILT Overhead Console Assembly Sunroof Switch Sunroof Motor Assembly Sunroof Control Unit ...

Страница 1120: ...cluded in the overhead console assembly CLOSE Closes the sunroof OPEN Opens the sunroof Sunroof glass The sunroof glass can be opened automatically and can be tilted by the switch operation Sun shade blind The sun shade blind can be closed or opened manually to block sunlight when the sunroof function is not in use ...

Страница 1121: ... completely When the switch is operated while the sunroof is moving the sunroof stops sliding open Push up and hold the switch manual sliding open The sunroof is opened only as long as pushing up the switch Pull down the switch briefly auto sliding close When pulling down the switch briefly the sunroof is automatically closed To stop the closing sunroof operate the switch to either direction Pull ...

Страница 1122: ...Pull down the switch The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof closed Push up the switch The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted up ...

Страница 1123: ... operation mode and then resume its function 5 Emergency Operation If the sunroof becomes out of order while it is open or tilted the sunroof can be operated through the motor operating hole of the sunroof motor When you drive this vehicle with the window or sunroof open at a certain position you may feel some pressure upon your ears or hear some noises similar to those from a helicopter This happ...

Страница 1124: ...04 10 3 CIRCUIT DIAGRAM 7304 03 Sunroof ...

Страница 1125: ...05 3 7610 00 1 MAJOR CHANGES 1 Center Fascia Panel 2 Sun Visor Retainer Sun Visor Retainer Old model New model Changed design Center fascia panel Old model New model Changed design ...

Страница 1126: ...nt door glass 4mm Tailgate glass 4mm Tailgate Fixed glass 4mm Flip up glass 5mm Requirements for leak test stand Nozzle type Full jet spray nozzle 1 2 GG 25 or 60 Nozzle height 1 600 mm from ground Displacement 14 liters per minute Nozzle injection pressure 155 kPa 22 5 PSI Location of windshield A pillar test stand Down 30 Rear 45 at center of windshield corner Location of B pillar test stand Dow...

Страница 1127: ...09 4 2 MAJOR CHANGES Hood Insulator 후드 인슐레이터 Changed the design to eliminate the interference Hood Panel 후드 판넬 Changed the design 1 Hood Panel Old New Old New ...

Страница 1128: ...09 5 5110 00 Front Bumper Old New Changed the design Radiator Grille 라디에이터 그릴 Changed the design and location 2 Radiator Grille 3 Front Bumper Old New ...

Страница 1129: ... 6 Door Garnish 도어 가니쉬 Deleted the front and rear garnish 4 Outside Rearview Mirror Outside Rearview Mirror 아웃 사이드 미러 Introduced the LED side repeater and changed the design Old New 5 Door Garnish Old New ...

Страница 1130: ...09 7 5110 00 Wheel Arch Garnish 휠 아치 가니쉬 Changed the design 6 Wheel Arch Garnish Old Rear New Rear Old Front New Front Center Lower Step 센터 로어 스텝 Changed the design 7 Center Lower Step Old New ...

Страница 1131: ...09 8 Side Sill Garnish Old Split type New Integrated type 8 Side Sill Garnish 9 Side Outer Rear Panel Side Outer Rear Panel 변경후 Changed the design of rear combination lamp Old New ...

Страница 1132: ... Tailgate Glass 변경후 Added the window open lever for flip up glass and changed the location of rear wiper 10 Tailgate Glass Old New Rear Spoiler 리어 스포일러 Introduced the wing type rear spoiler 11 Rear Spoiler Old New ...

Страница 1133: ...09 10 Tailgate Lower Garnish 테일 게이트 로어 가니쉬 Changed the design 12 Tailgate Lower Garnish Old New Rear Bumper Old New Changed the design 13 Rear Bumper ...

Страница 1134: ...07 3 5110 01 Top view Side view Front view Rear view 1 MAJOR EXTERNAL DIMENSIONS Unit mm General dimensions ...

Страница 1135: ... Head lamp low Head lamp high Tail lamp Turn signal lamp Front fog lamp Stop lamp Tail lamp 1 2 3 4 5 6 7 Side repeater License plate lamp Turn signal lamp rear lamp Backup lamp Extra stop lamp Reflex reflector 8 9 10 11 12 13 ...

Страница 1136: ...07 5 5110 01 ...

Страница 1137: ...07 6 Front Double wishbone Rear 5 link 2 JACK POINTS ...

Страница 1138: ...07 7 5110 01 3 UNDER COATING APPLICATIONS ...

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