SSANGYONG ACTYON 2008.07, Manual

Page 1: ... 2 SPECIFICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE INTERVAL 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS DOTTED CIRCLES 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 STANDARD BOLTS SPECIFICATIONS GENERAL 3 4 6 7 11 12 13 14 16 ...

Page 2: ...0 2 undefined 0000 00 GENERAL ...

Page 3: ...0 3 GENERAL undefined 0000 00 4110 01 GENERAL GENERAL 1 DIMENSIONS ...

Page 4: ...0 4 undefined 0000 00 GENERAL 2 SPECIFICATIONS ...

Page 5: ...0 5 GENERAL undefined 0000 00 ...

Page 6: ...is stamped on the upper rear left hand side of the cylinder block The chassis number is stamped on the frame behind the front right tire The engine number is stamped on the lower area of cylinder block in the intake manifold side Certification Label The certification label is located on the driver s door sill B pillar Vin Label ...

Page 7: ... stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Check the engine oil level and leak every 3 000 km 2...

Page 8: ...fluid at any time occasionally then change every 60 000 km 6 Change automatic transmission fluid and every 60 000 km if the vehicle is mainly driven under severe conditions Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly 7 After completion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness...

Page 9: ...their related parts If necessary correct clean replenish adjust or replace Replace or change In order to secure engine long life and effective break in first oil factory filled would be recommended to drain with in 10 000 km I R 1 If vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition shorten the service interval 2 If vehicle is operated...

Page 10: ...0 000 km 6 Change automatic transmission fluid and every 60 000 km if the vehicle is mainly driven under severe conditions Inspect the leak of fluid at any time occasionlly 7 After completion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness 8 If necessary rotate and balance wheels 9 After completion of off road operation the ...

Page 11: ...5 RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels when adding or replacing the fluids ...

Page 12: ...0 12 undefined 0000 00 GENERAL 6 JACK UP POINTS ...

Page 13: ...0 13 GENERAL undefined 0000 00 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 14: ...0 14 undefined 0000 00 GENERAL 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 15: ...0 15 GENERAL undefined 0000 00 2 Components Locator ...

Page 16: ...0 16 undefined 0000 00 GENERAL 8 STANDARD BOLTS SPECIFICATIONS ...

Page 17: ...bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of above ...

Page 18: ...lied to the airflow direction control lever 1 MAJOR CHANGES 3722 02 Shift lever changed The appearance of the shift lever has been changed Hazard warning switch bezel Outside rearview mirror switch bezel Hazard warning switch bezel Outside rearview mirror switch bezel Parking brake lever changed The thickness and the appearance of the lever have been changed for grip comfort MODIFIED ITEMS ...

Page 19: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

Page 20: ......

Page 21: ...01 3 ENGINE GENERAL undefined 0000 00 0000 00 ENGINE GENERAL GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 22: ...01 4 undefined 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 23: ...FH L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 24: ...01 6 undefined 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 25: ...01 7 ENGINE GENERAL undefined 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 26: ... 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 27: ...ter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 28: ... undefined 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 29: ...TION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 30: ...KE SYSTEM Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 31: ...efined 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 32: ...01 14 undefined 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 33: ...will happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the in...

Page 34: ...01 16 undefined 0000 00 ENGINE GENERAL 6 LUBRICATION SYSTEM Cylinder Head Cover Oil Pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 35: ...pen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake sid...

Page 36: ...oolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 37: ...01 19 ENGINE GENERAL undefined 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 38: ...EM Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 39: ...01 21 ENGINE GENERAL undefined 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 40: ...sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decreas...

Page 41: ...pen Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very h...

Page 42: ...on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing cap...

Page 43: ... The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to sp...

Page 44: ...by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history faults 10 1...

Page 45: ...heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to ...

Page 46: ...ntenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity engi...

Page 47: ...ervice Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the br...

Page 48: ...by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Howev...

Page 49: ...contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of polari...

Page 50: ...oreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly M...

Page 51: ...ween HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance dr...

Page 52: ...cle and then support with chassis stand before service work Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 ...

Page 53: ...ase on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line bet...

Page 54: ... Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting Positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front of...

Page 55: ...These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignment ...

Page 56: ... cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Inspec...

Page 57: ... Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system includin...

Page 58: ...e glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the cool...

Page 59: ...01 41 ENGINE GENERAL undefined 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 60: ...ing bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ab...

Page 61: ...ally controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque Coolant reservoir FFH Engine oil dipstick Oil separator PCV valve Vacuum pump Air cleaner assembly HFM sensor VGT Turbo charger Engine Engine oil filler cap ...

Page 62: ...INE ASSEMBLY undefined 1212 01 EGR valve Vacuum modulator Brake fluid reservoir ABS ESP modulator Fuel filter priming pump Power steering oil reservoir PWM electric fan fan shroud Washer fluid reservoir Battery ...

Page 63: ... VGT Turbo charger 5 EGR pipe 6 Water pump pulley 7 Alternator 8 Crankshaft pulley 9 Oil pan 10 Auto tensioner 11 Air conditioner compressor 12 Auto tensioner pulley 13 Power steering pump pulley 14 Power steering pump 15 EGR valve 16 Idle pulley 17 Viscos clutch pulley 1 Engine Structure Front View 12 1 7 Nm ...

Page 64: ...over 10 1 0 Nm 180 20 3 Oil pipe 4 Fuel pressure sensor 5 Water outlet port 6 EGR valve 7 Oil filler 8 Booster pressure sensor 9 Common rail 10 Vacuum pump 11 Glow plug 12 Cylinder head cover 13 VGT Turbo charger Top View 10 1 0 Nm 40 4 0 Nm 25 2 5 Nm 10 1 0 Nm 15 3 Nm ...

Page 65: ...HP pump assembly 6 Air conditioner compressor 7 Engine mounting bracket 8 Vacuum modulator for VGT turbocharger actuator 9 Flywheel 10 Crank position sensor 11 Vacuum modulator for EGR valve 12 Oil filter oil cooler 13 Vacuum pump 14 Booster pressure sensor 15 Intake manifold 0 8 0 4 Nm Gap 0 7 1 5 mm Right Side View 20 2 6 Nm ...

Page 66: ... 1212 01 1 Cylinder head jack valve screw 2 VGT Turbo charger assembly 3 Cylinder block assembly 4 Engine mounting bracket 5 Oil pan 6 Alternator 7 Water pump 8 EGR pipe 9 Oil dipstick gauge 10 Oil separator with PCV Left Side View ...

Page 67: ...02 8 undefined 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 68: ...02 9 ENGINE ASSEMBLY undefined 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 69: ...02 10 undefined 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 70: ...02 11 ENGINE ASSEMBLY undefined 1212 01 ...

Page 71: ...02 12 undefined 1212 01 ENGINE ASSEMBLY ...

Page 72: ... Element Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2321 01 ENGINE INTAKE SYSTEM ...

Page 73: ... chamber and the air temperature Major Functions It controls the EGR feedback It controls the pressure control valve for the turbocharger booster 1 Plug in sensor 2 Cylinder housing 3 Protection grid 4 Hybrid cover 5 Measuring duct cover 6 Housing 7 Hybrid 8 Sensor 9 Mounting plate 10 O ring 11 Temperature sensor Turbocharger actuator Intake air cleaner Com pressed air intercooler Exhaust gas Exha...

Page 74: ...red or the knocking may happen as the intake air is heated and the density of air is lowered The intercooler is the device which cools the supercharged air Intake manifold Intake air Exhaust gas Exhaust gas Intake manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum pump EGR valve IP interior fuse RH No 63 7 5A Engine ECU No 96 Intake Manifold Intake air ...

Page 75: ...04 6 undefined 2313 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 76: ...al and helical port which increases the swirl ratio in mid low operating range improves acceleration fuel consumption and decreases particle materials However there are some differences in the form of the EGR valve and 4 cylinder engine The inlet port and coolant outlet port is integrated together Therefore be careful not to let the residual coolant in the manifold enter the inlet port when removi...

Page 77: ... valve 4 Intake air intercooler Intake Manifold Incoming of intake air and exhaust gas Operation of EGR valve Incoming of intake air No operation of EGR valve Coolant emission port Coolant emission port The SUS Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect Intake air Intake air Exhaust gas ...

Page 78: ...sion process in the turbocharger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine from high temperature 100 110 C to maintain the turbocharging efficiency Thus more air is entered the cylinder than the engine only with the turbocharger to give more power Intercooler For removal and installation procedures refer to the Cooling syste...

Page 79: ...04 10 undefined 2313 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 80: ...s complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to r...

Page 81: ... the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing input signal from the related sensors such as acceleration pedal sensor and engine RPM rec...

Page 82: ...lve and Installation Location 1 EXHAUST SYSTEM LAYOUT OVERVIEW AND OPERATION PROCESS Intake manifold Intake manifold EGR pipe Intake manifold Intake air intercooler EGR pipe LH To turbo charger To EGR valve Exhaust manifold Diesel catalytic converter Muffler EGR pipe RH ...

Page 83: ...05 6 undefined 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 84: ...s than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature 40 140 C Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH GENERAL 1533 01 LUBRICATION SYSTEM ...

Page 85: ...oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Inlet port Blow by gas air duct ho...

Page 86: ...06 5 LUBRICATION SYSTEM undefined 1533 01 Cylinder Head Cover Oil pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil Filter Oil Cooler Oil cooler Oil filter ...

Page 87: ...BRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 ...

Page 88: ...ndefined 1533 01 2 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 89: ...07 3 COOLING SYSTEM undefined 2112 01 9210 05 ENGINE COOLING SYSTEM GENERAL 1 ENGINE COOLING SPECIFICATIONS ...

Page 90: ...07 4 undefined 2112 01 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING OVERVIEW AND OPERATION PROCESS ...

Page 91: ...PTC Engine Coolant Flows FFH Engine Coolant Flows 2 COOLING SYSTEM FLOW Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 92: ... in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley Cylinder head Intake manifold Coolant outlet port Improved shape and gasket material to prevent coolant from leaking It prevents co...

Page 93: ...08 3 ENGINE ELECTRIC DEVICES undefined 1451 01 1461 01 ENGINE ELECTRICAL SYSTEM GENERAL 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 94: ...uel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF ELECTRIC IN ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 95: ...NGINE ELECTRIC DEVICES undefined 1451 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 96: ...08 6 undefined 1451 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 97: ...08 7 ENGINE ELECTRIC DEVICES undefined 1451 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 98: ...S GENERAL Water Pump and Pipe Coolant Port Engine Oil Filter and Cooler Cylinder block Reservior coolant inlet hose Radiator Thermostat inside Coolant outlet port Oil cooler Oil filter Oil cooler Oil Filter cap Oil pressure switch Radiator Coolant outlet hose Return hose Coolant reservoir Coolant inlet hose ...

Page 99: ...09 4 undefined 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 100: ...09 5 ENGINE CONTROL SYSTEM undefined 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 101: ...ock sensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preh...

Page 102: ...ange of ECU is normally 40 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circuit divides current applying time i...

Page 103: ...mplete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined acco...

Page 104: ...ng advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liable ...

Page 105: ... made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a function o...

Page 106: ... flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order t...

Page 107: ...re As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel acc...

Page 108: ...s the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and choos...

Page 109: ...ke emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the...

Page 110: ... the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The di...

Page 111: ...ot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection and...

Page 112: ... be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled and t...

Page 113: ...sion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors I...

Page 114: ... optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number 16 ...

Page 115: ...mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 116: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 117: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 118: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 119: ... is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never us...

Page 120: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 121: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 122: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 123: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 124: ...OR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The electronically controlled advanced D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque D20DT EURO D20DT ...

Page 125: ...01 4 undefined 1114 00 ENGINE ASSEMBLY 1 Engine Assembly Structure Front View Top View Touch idler equipped for A T ...

Page 126: ...01 5 ENGINE ASSEMBLY undefined 1114 00 Right Side View Left Side View ...

Page 127: ...01 6 undefined 1114 00 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 128: ...01 7 ENGINE ASSEMBLY undefined 1114 00 2 Engine Performance Curve 1 Output and Torque General EU4 2 Oil Temperature Pressure and Boost Pressure General EU4 ...

Page 129: ...01 8 undefined 1114 00 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 130: ...01 9 ENGINE ASSEMBLY undefined 1114 00 ...

Page 131: ...01 10 undefined 1114 00 ENGINE ASSEMBLY ...

Page 132: ... head bolt changes of the DI engine D20DT Cylinder head bolt wrench Tightening Torque A Removal order Remove the bolts in the order as shown in the figure Installation order Based on the number in the picture B 10 9 8 7 6 5 4 3 2 1 14 13 12 11 Reverse order of removal W9912 003 0B I D of head bolt head 14 5 mm O D of head bolt wrench 13 3 mm ...

Page 133: ...14 00 ENGINE ASSEMBLY 4 MAJOR CHANGES IN D20DT EURO IV ENGINE COMPARED TO D20DT 1 Engine Assembly D20DT EURO 4 Engine D20DT Engine Front Side View Top Side View Right Side View Left Side View Touch idler equipped for A T ...

Page 134: ... due to the increased capacity D20DT EURO4 Added damping orifice Orifice is added to fuel inlet outlet ports in order to dampen the pulsation in fuel flow caused by multi injections E EGR valve ECU controls the EGR valve directly without any media It provide more precise EGR control by transmitting the electric signal of EGR valve operating position Injector Fuel pipe Fuel high pressure pipe Commo...

Page 135: ... to intake manifold is blocked by closed flap when the engine is switched off To enhance EGR function coolant EGR cooler is adopted to reduce the temperature of exhaust gas into the intake manifold Reason of changes To satisfy the emission regulation E EGR valve and EGR cooler are adopted And the layout also has a great difference from D27DT HFM 6 0 HFM 5 0 Throttle body EGR cooler EGR center pipe...

Page 136: ...mounting location of booster pressure sensor is changed For D20DT EURO4 engine Additional connecting port for EGR cooler hose For D20DT EURO4 engine Additional port for coolant of EGR cooler Coolant outlet port Water pump Intake manifold PCV oil separator PCV valve Cylinder head cover oil gas Oil To oil gage pipe Oil separator Blow by gas To air duct hose PCV valve Oil separator Oil To oil gage pi...

Page 137: ...digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D20DT engine the injector MDP minimum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running However for the D20DT EURO 4 engine it is learned when the vehicle is in motion and the engine is at idle speed 2 Common Rail The orifice is added to the co...

Page 138: ...ail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail ...

Page 139: ......

Page 140: ...Rail Orifice for Preventing Fuel Pulsation Added OVERVIEW AND OPERATION PROCESS 1 COMPONENTS OF FUEL SYSTEM Injector 7 way Injection and C3I Coding C3I Fuel nozzle holes 7 Orifice Orifice for HP pump fuel outlet Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ...

Page 141: ...ng Pump Fuel filter Priming pump Connector Fuel from HP pump Fuel filter HP pump Fuel tank Fuel tank Fuel return port Low pressure fuel supply port Venturi Fuel return port Fuel temperature sensor IMV connector High pressure fuel supply port orifice included IMV valve ...

Page 142: ...02 8 undefined 1881 09 ENGINE FUEL SYSTEM 2 FUEL FLOW OF D20DT EURO 4 ENGINE ...

Page 143: ...throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased OVERVIEW AND OPERATION PROCESS ...

Page 144: ...ined 2321 01 ENGINE INTAKE SYSTEM 2 INTAKE SYSTEM LAYOUT Uncompressed air Compressed air Ambient air Air cleaner VGT Turbo Chargera HFM Sensor ver 6 0 Air coeaner Turbo charger Temperature sensor Pretension graph ...

Page 145: ... Intercooler Turbo charger Intake manifold Throttle body Coolant port Compress ed air EGR gas To corresponding cylinders Booster Pressure Sensor Ground Supply power Output voltage Throttle body Normal flap open Engine stopped flap closed Intake duct Intake duct ...

Page 146: ...lve electrically and sends the valve location signal to ECU vacuum modulator control has been deleted EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe EGR cooler E EGR valve To EGR cooler Exhaust manifold E EGR valve Coolant Intake manifold Intake manifold EGR gas From EGR cooler Turbocharger intercooler Intake compressed air Exhaust manifold ...

Page 147: ... oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase PCV valve Oil separator PCV valve Oil separator Blow by gas T...

Page 148: ...erlapped in normal driving mode These are the cause of oil and carbon accumulated in the intake pipe When the EGR system is operated the particulate material in the exhaust gas is drawn into the intake pipe and the oil not filtered in the PCV oil separator is also drawn into the intake pipe However unless the particulate material or oil are accumulated excessively in the pipe they do not affect th...

Page 149: ...ENGINE COOLING SYSTEM 2112 00 1520 00 ENGINE COOLING SYSTEM COOLING SYSTEM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE WATER PUMP 1 OVERVIEW 3 4 ...

Page 150: ...06 2 undefined 0000 00 ENGINE COOLING SYSTEM ...

Page 151: ...EM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT EURO4 engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block 1 Cooling System for Engine ...

Page 152: ...and a belt pulley The impeller is supported by a completely sealed bearing The water pump is serviced as an assembly and therefore cannot be disassembled The capacity of water pump has been increased due to the EGR cooler increased engine power and additional coolant port in the cylinder block For D20DT EURO4 engine For D20DT engine Port to EGR cooler ...

Page 153: ...06 5 ENGINE COOLING SYSTEM undefined 0000 00 1 Structure of Water Pump for D20DT Engine ...

Page 154: ......

Page 155: ...NO DATA ...

Page 156: ...P and D27DT engines including its components Kyron Actyon Same CDPF system for D27DT and D20DT engines including its components The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their mounting layout but their front rear exhaust temperature sensors and differential pressure sensors are same 3 System Met with EURO IV Regulations The Ssangyong vehicles...

Page 157: ...anifold As it is installed in front of the VGT turbocharger it also monitors the exhaust gas tempera ture coming to the turbocharger If the temperature of the exhaust gas flowing to the turbocharger is higher than the specification the engine lowers the exhaust gas temperature Rear Exhaust Gas Tempera ture Sensor Measures the increased ex haust gas temperature after the oxidation process of DOC If...

Page 158: ...ap to block the intake air when the engine is stopped Duty control controls the valve inside the throttle body to burn more EGR gas in the EGR valve operating range VGT Turbocharger and Front Exhaust Gas Temperature Sensor Turbocharger may become weaker if high tem perature exhaust gas passes through the tur bocharger for DPF regeneration process The front exhaust gas temperature sensor moni tors ...

Page 159: ...e amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is anintegrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter Comparison of throttle body functions based on exhaust emission regulation Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soot in...

Page 160: ...ure 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 Norm...

Page 161: ...ion patterns pilot injection pre injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temperature of exh...

Page 162: ...gine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume engine load and effective combustion of EGR gas according to the Euro 4 regulations It has following functions by the engine type ...

Page 163: ...nge with two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environmental regulations in the future the soot is filt...

Page 164: ...l pressure snesor When the soot is accumulated the pressure difference be tween the front and the rear side occurs Then the engineECU performs the post injec tion to raise the exhaust gas temperature and burn the collected soot at approx 600 C The exhaust gas enters intoCDPF assembly after passing through the exhaust manifold Normal temperature of ex haust gas approx 250 C When the exhaust gas ent...

Page 165: ...ing style Then the engine ECU performs the CDPF regeneration operation However the driver is not in formed with this operation by any engine warning lamp or vehicle signal so he she may not detect this operation The control logic at the post injection dur ing the regeneration process is to increase the fuel injection volume and control the intake air volume by the throttle body in order to increas...

Page 166: ...is case perform the step 2 1 2 3 If the vehicle is driven at a speed of 5 to 10 km h for an extended period of time the soot accumu lated in the CDPF cannot be burnt as the CDPF cannot reach the regeneration temperature Then an excessive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp c...

Page 167: ...tion and Location Differential Pressure Sensor Engine compartment RH Rear exhaust gas temperature sensor Throttle Body Front Exhaust Gas Temperature Sensor Front exhaust gas temperature sensor Rear pressure port CDPF assembly Front pressure port Differential pressure sensor ...

Page 168: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 169: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 170: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 171: ... is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never us...

Page 172: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 173: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 174: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 175: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 176: ...as during assembly to protect and lubricate the surfaces on initial operation Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever valve train components are removed for service they should be kept in order They should be installed in the same locations and with the ...

Page 177: ...sed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Any time the air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the en...

Page 178: ...01 5 ENGINE ASSEMBLY undefined 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 179: ...01 6 undefined 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 180: ...01 7 ENGINE ASSEMBLY undefined 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 181: ...ng Rod 6 Fuel Distributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan NO FUNCTION NO FUNCTION 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywhe...

Page 182: ...cation of the leak by the drippings on the paper Visually check around the suspected component Check around all the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well Dry the area Operate the vehicle for sev...

Page 183: ...urce the cause of the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check for the following conditions and correct them as they may cause a leak Repairing the Leak Gaskets The fluid level pressure is too high The c...

Page 184: ...ompression pressure tester A9912 0012B 001 589 76 21 00 and install it into the spark plug hole Crank the engine approx eight revolutions by using the start motor Compare the measurements of compression pressure tester A9912 0012B 001 589 76 21 00 with the specifications Measure the compression pressure of the other cylinders in the same way If measured value is not within the specifications perfo...

Page 185: ...re LeakageTest Permissible Pressure Leakage At Whole Engine Max 25 At Valve and Cylinder Head Gasket Max 10 At Piston and Piston Ring Max 20 OT TDC 1 4 UT BDC 180 2 3 Cylinder Number Cylinder Number Cylinder Pressure Leakage Tester Bosch EFAW210A Sun CLT 228 ...

Page 186: ...ressure line and adjust the scale of tester Install the connecting hose to spark plug hole Position the piston of No 1 cylinder at TDC by rotating the crankshaft Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable Perform the p...

Page 187: ...01 14 undefined 1113 01 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 188: ...01 15 ENGINE ASSEMBLY undefined 1113 01 General Diagnosis Cont d ...

Page 189: ...01 16 undefined 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 190: ...01 17 ENGINE ASSEMBLY undefined 1113 01 General Diagnosis Cont d ...

Page 191: ...01 18 undefined 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 192: ...01 19 ENGINE ASSEMBLY undefined 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 193: ...01 20 undefined 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 194: ...01 21 ENGINE ASSEMBLY undefined 1113 01 Fastener Tightening Specifications Cont d ...

Page 195: ...01 22 undefined 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 196: ......

Page 197: ...02 3 ENGINE INTAKE SYSTEM undefined 1713 08 0000 00 ENGINE INTAKE SYSTEM GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 198: ...03 3 ENGINE EXHAUST SYSTEM undefined 2420 01 2420 01 ENGINE EXHAUST SYSTEM GENERAL 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 199: ...damage the catalytic converter Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter 1 2 Catalytic Converter Structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith Washer c...

Page 200: ...rmal range of temperature CO purification rate becomes the best near the temperature of 450 C and NOx does so near the temperature of 400 to 500 C Purification of Catalytic Converter Adhesion of soluble organic fraction SOF below 180 C Purification of soluble organic fraction SOF over 180 C Chemical reaction formula SOF HC O2 CO2 H2O 2CO O2 2CO2 2C2H6 7O2 4CO2 6H20 By catalytic action of two prima...

Page 201: ...actor are high EGR valve can decrease NOx 30 to 35 decrease by making temperature of combustion chamber fall by means of exhaust gas re circulation EGR valve is installed on the diesel engine of Musso Korando Istana and Rexton And micro switch is installed together to control EGR valve The setting method of micro switch is identical with the existing one ...

Page 202: ...04 3 ENGINE COOLING SYSTEM undefined 2112 01 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 203: ...04 4 undefined 2112 01 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 204: ...OPERATION PROCESS 1 COMPONENT LOCATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 4 Outlet Hose 5 3 way Hose 6 Clamp 7 Clamp 8 Bolt M6 2 piece 9 Radiator 10 Lower Radiator Insulator 11 Plate 12 Clip 13 Upper Radiator Insulator 14 Bracket 15 PWM Electric Fan ...

Page 205: ... correct coolant level The cooling system for this vehicle has no radiator cap or filler neck The coolant is added to the cooling system through the coolant reservoir 2 Radiator This vehicle has a lightweight tube and fin aluminum radiator Plastic tanks are mounted on the upper and the lower sides of the radiator core On vehicles equipped with automatic transaxles the transaxle fluid cooler lines ...

Page 206: ...ng of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits The wax pellet in the thermostat is hermetically sealed in a metal case The wax element of the thermostat expands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the engine coolant temperature increases When th...

Page 207: ...ooling fan relay and a cooling fan motor relay The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C 203 F and at high speed when the coolant temperature reaches 105 C 221 F The ECM will change the cooling fans from high peed to low speed at 100 C 212 F and will turn the cooling fans off at 90 C 194 F A C On The ECM will turn the cooling fans on at low speed ...

Page 208: ...DULATION ELECTRIC FAN OPERATION 1 Function The PWM Pulse Width Modulation high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise 2 Mounting Location PWM Fan shroud Electric fan PWM unit ...

Page 209: ...Modulation Unit It controls the time of the output voltage to control the fan motor speed independently Internal functions Motor power shutting off function when overcurrent is applied Adverse voltage prevention function Detection function for the motor lock Temperature detecting function The electric fan operates at FULL speed to cool down the PWM unit when the interior temperature of PWM unit is...

Page 210: ...or 4 seconds after engine starting abrupt acceleration and A C refrigerant pressure sensor detecting the followings A C compressor is turned off when the refrigerant pressure is below 2 0 kg cm2 and then is turned on when the refrigerant pressure is over 2 4 kg cm2 A C compressor is turned off when the refrigerant pressure is over 30 kg cm2 and then is turned on when the refrigerant pressure is be...

Page 211: ...05 3 ENGINE ELECTRICAL SYSTEM undefined 1452 01 0000 00 ENGINE ELECTRIC DEVICES GENERAL 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 212: ...05 4 undefined 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 213: ...riods of time More power available in a lighter smaller case The battery has three major functions in the electrical system First the battery provides a source of energy for cranking the engine Second the battery acts as a voltage stabilizer for the electrical system Finally the battery can for a limited time provide energy when the electrical demand exceeds the output of the generator 2 Ratings A...

Page 214: ...p the battery cable terminals clean and tight or a loose battery hold down clamp Mechanical problems in the electrical system such as shorted or pinched wires 3 Charging Time Required The time required to charge a battery will vary depending upon the following factors Size of Battery A Completely discharged large heavy duty battery required more than twice the recharging time as a completely disch...

Page 215: ... may not have enough voltage to activate this circuitry even though the leads are connected properly making it appear that the battery will not accept charging current Therefore follow the specific charger manufacturer apos s instruction for by passing or overriding the circuitry so that the charger will turn on and charge a low voltage battery Continue to charge the battery until the charge curre...

Page 216: ... not attach the cable directly to the neg ative terminal of the discharged battery Doing so could cause sparks and possible battery explosion Clamp one end of the second cable to the negative terminal of the booster battery Make the final connection to a solid engine ground such as the engine lift bracket at least 450 millimeters 18 inches from the discharged battery Start the engine of the vehicl...

Page 217: ...l loads the on time may be 90 percent and the off time 10 percent 7 Charging System Generators use a new type of regulator that incorporates a diode trio A Delta stator a rectifier bridge and a rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan are used There is no test hole 8 Starter Wound field starter motors have pole pieces arranged a...

Page 218: ...ll the related wiring Diagnostic tables will aid in troubleshooting system faults When a fault is traced to a particular component refer to that component section of the service manual The starting system circuit consists of the battery the starter motor the ignition switch and all the related electrical wiring All of these components are connected electrically ...

Page 219: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 220: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 221: ...06 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 222: ... is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never us...

Page 223: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 224: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 225: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 226: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 227: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 228: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 229: ...06 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 230: ... is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never us...

Page 231: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 232: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 233: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 234: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 235: ...odel and is installed to the back of the STICKS As the ICM box is newly installed the following relays are integrated into the ICM box Door lock relay previously installed to STICKS bracket Windshield de icer relay previously installed next to floor on the driver side Turn signal lamp relay previously installed to passenger side fuse relay box Some relays have been integrated into the ICM box PREV...

Page 236: ...S is integrated with the door lock relay windshield de icer relay and turn signal lamp relay There are four fuse relay units 2 FUSE RELAY MOUNTING LOCATION 1 In engine compartment Fuse Relay Box InEngine Compartment Interior Fuse Relay Box On The Driver Side RH 2 In vehicle Interior Fuse Relay Box On The Driver Side LH Mounting Location of ICM ...

Page 237: ...IN ENGINE COMPARTMENT The label attached on each fuse box indicates only major fuses and relays Therefore there are more fuses and relays than indicated For details about the connection of fuses and relays refer to the power distribution circuit diagram on the following pages ...

Page 238: ...0 6 undefined 8210 01 FUSE AND RELAY 4 CAPACITY AND NAME OF INTERIOR FUSE AND RELAY 1 Interior Fuse and Relay Box On the Driver Side ...

Page 239: ...0 7 FUSE AND RELAY undefined 8210 01 2 Interior Fuse and Relay Box On the Passenger Side ...

Page 240: ...M box is newly installed the following relays are integrated into the ICM box Door lock relay previously installed to STICKS bracket Windshield de icer relay previously installed next to floor on the driver side Turn signal lamp relay previously installed to passenger side fuse relay box 2 Mounting Location Relays in the ICM box cannot be replaced respectively so if the components on the PCB are d...

Page 241: ...S 6 pin 15 pin it operates the door actuator 11 pin 13 pin through its door lock relay to lock unlock the door In order to check the operation of the relay measure the voltage at the connector of the ICM box and check the output through the ICM box after operating the corresponding door Of course the components for the corresponding system should be checked in advance ...

Page 242: ...mp blinks 10 times at an interval of 0 35 seconds This function is only available when the ignition key is in the ON position If the ignition key is turned to the OFF position during this function is activated this function is immediately deactivated If the system receives signals for the turn signal lamp operation during this function is activated this function is immediately deactivated While th...

Page 243: ...r operation Pressing the windshield de icer switch activates the de icer for 12 minutes and pressing the switch again deactivates the de icer At this time pressing the switch again activates the de icer for 12 minutes from the time the switch is pressed again ...

Page 244: ... door ajar warning light in the instrument cluster does not come on even though the deck tailgate is opened Rear Wiper and Washer System Eliminated Tailgate Open Switch Eliminated Opening Closing of the deck tailgate is not related to the operation condition of the theft deterrent mode The deck tailgate can be controlled as lock unlock status depending on the operation of central locking system by...

Page 245: ...erformance Characteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 246: ...02 5 STICS undefined 8710 01 Rated Load ...

Page 247: ...02 6 undefined 8710 01 STICS Input Signals ...

Page 248: ...each function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time from s...

Page 249: ...me Integrated Control System is almost the same as that of ACTYON in terms of its function and role Due to the removal of tailgate opening switch and rear wiper and washer system the circuit layout is slightly changed compared to ACTYON Door Lock Relay RK STICS REKES key OVERVIEW AND OPERATION PROCESS ...

Page 250: ...perates automatically according to the vehicle speed or the amount of rain Continuous wipe slow operation Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position Fast Fast interval Slow Slow interval Continuous wipe fast operation MIST AUTO OFF LO HI Front wiper...

Page 251: ...erate only while holding the switch When releasing the switch it returns to the rear wiper operate position Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch OFF the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times after then the washer fluid is sprayed and the wiper sweeps off 3 times again Rear Washer and Wiper The rear washer...

Page 252: ... on for 0 1 to 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 ...

Page 253: ... washer switch is turned on for more than 0 6 seconds during the wiper operation by INT switch the operation in step 2 is performed When it is turned on for a certain period of time 0 1 to 0 59 seconds the operation in step 1 is performed 3 ...

Page 254: ...ar washer motor relay output gets ON from the time when the rear washer switch is turned on It gets OFF when the rear washer switch is turned off This control is not available while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation 1 2 3 Rear Washer Motor Control ...

Page 255: ...ON and the INT switch OFF the washer motor output gets ON for 1 second If the system recognizes the output signal the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second Then the wiper relay output gets OFF after 3 cycles 1 4 Auto Washer and Wiper Switch AFW ...

Page 256: ...the auto washer operation stops and the auto INT operation is activated 2 3 4 5 Priorities in Washer Operations he rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden du...

Page 257: ...02 16 undefined 8710 01 STICS 5 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 258: ...wiper switch is turned to the ON position again from other positions the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal 1 2 Rain sensing unit AUTO light integrated type A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting ...

Page 259: ... switch input with the ignition switch ON and the auto INT switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 260: ...tivity is increased while the ignition key is in the ON position the wiper 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 If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 1 ...

Page 261: ...the ignition key is in ON position and the wiper switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is fixed to IGN the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal The wiper motor runs only when the rain sensor requires the wiper operation 2 ...

Page 262: ...ng the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 1 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 wiper switch is in ON position 2 ...

Page 263: ... in the ICM box It rains but the system does not work in the AUTO position Symptom 2 Check whether the multifunction wiper switch is in the AUTO position Check the power to the sensor Check the conditions of the pin 3 Ground and the pin 4 IGN Check the wiper relay for defective Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage...

Page 264: ...iper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 265: ...d headlamp If it rains heavy which requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 2 3 Emitter lense Auto light senso...

Page 266: ...itch positioned to ON Intermittent interval at 0 km h 3 0 5 19 2 seconds Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 60 km h X 60 sec 637 X 4 PULSE 1 41 km h The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis VOLUME calculation Pause time...

Page 267: ...FF Resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is ON INT switch ON or Washer switch ON The output stops immediately after turning off the switch The output sto...

Page 268: ... WARNING The chime buzzer sounds continuously when opening the driver s door while the ignition key is in ignition switch When removing the ignition key or closing the driver s door during chime buzzer operation the buzzer stops This function is not available when the ignition switch is in ON position 1 2 3 PAS buzzer Chime buzzer ...

Page 269: ...system outputs UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK the system does no...

Page 270: ...s open When the door is closed during the UNLOCK output the UNLOCK output stops immediately When the ignition key is inserted during the 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 ...

Page 271: ...n and the ignition key is removed The chime 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 ...

Page 272: ...ng light goes 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 ...

Page 273: ...turning the ignition switch to the OFF position The chime buzzer 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 buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is ON position 1 2 3 4 Seat Bel...

Page 274: ...ile the 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 buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on The warning light goes off and the chime buzzer stops when tu...

Page 275: ...y during the dimming operation The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and the center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remote c...

Page 276: ...a door is opened and goes off when the door is closed The front and center room lamps come on when pressing the room lamp main switch 3 Center Room Lamp If the switch is at the door coupled position the center room lamp comes on when a door is opened The lamp always comes on while the switch is at the other position Driver s seat Tailgate Center Room Lamp Lamp ON Center Room Lamp Door coupled oper...

Page 277: ... the ignition key is turned to the ON position The output stops when receiving the lock signal from the remote control key under armed mode 1 2 3 4 20 Ignition Key Hole Illumination Key cylinder with key hole illumination For diesel and gasoline engine equipped vehicle Without immobilizer With key hole illumination For diesel engine equipped vehicle With immobilizer With key hole illumination For ...

Page 278: ...hen opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 21 Tail Lamp Auto Cut Battery Saver The front defogger output is ON when turning ON the front defogger switch while the ignition switch is ON with engine running The output stops when turning on the defogger switch again during its operation The output is ON only for 6 minutes when tu...

Page 279: ...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 23 Rear Defogger Timer ...

Page 280: ...em outputs UNLOCK signal for 0 5 seconds when positioning the driver s or passenger s door lock switch to the unlock position LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK signal by other functions All door lock signals are UNLOCK for 0 5 seconds just for once when receiving the LOCK signal within 0 5 seconds after closing the driver s or passenger s door whi...

Page 281: ...nds while LOCK switches in all doors are in UNLOCK position and the vehicle speed is 0 Km h STICS operates the tailgate relay for 0 5 seconds to unlock the tailgate If any LOCK switch is switched to LOCK position or vehicle speed exceeds 3 Km h while operating the tailgate open relay the output of the tailgate relay gets OFF 1 2 ...

Page 282: ...tem outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 283: ...oor LOCK UNLOCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Page 284: ... 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 The door lock system outputs UNLOCK automatically if the LOCK output condition...

Page 285: ...ut continues on for remaining period The function is erased when turning OFF the IGN switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or ...

Page 286: ...mode during its extended operation period of 30 seconds 1 2 3 31 Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN Any of all door switches including hood and tailgate is in OPEN position DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 The door lock unlock operation does not affect the engine hood DOOR LOCK Indicates that all door lock switches including tailg...

Page 287: ...trol key while any of doors is not closed only the LOCK output can be done and then activates the armed ready mode without theft deterrent horn and hazard warning flasher At this moment if the ignition key is inserted or the door lock switch is unlocked it cancels the armed mode and activates the normal mode When the door is opened or the ignition key is not inserted into ignition switch within 30...

Page 288: ...nd hazard warning flasher output is ON for 27 seconds at the interval of 1 second Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation 2 Cancels warning after 27 seconds remaining time while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activat...

Page 289: ...efly press below 0 5 sec Door unlock and theft deterrent mode is deactivated Press and hold over 2 sec Panic function 1 Door unlock Briefly press If the unlock button on the remote control is pressed the door will be opened and the theft deterrent mode will be activated If the door coupled switch of front room lamp is pressed the lamp will come on for 30 seconds It will turn off immediately after ...

Page 290: ...OCK switch on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 1 2 ...

Page 291: ... 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 36 Auto Door Lock in 30 Seconds after Pressing Door Unlock 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 ...

Page 292: ...02 51 STICS undefined 8710 01 3 CIRCUIT DIAGRAM The circuit diagram below shows the input and output of STICS 1 STICS Input Singnals and Others ...

Page 293: ...02 52 undefined 8710 01 STICS 2 STICS Output Signals and Others ...

Page 294: ...2 53 STICS undefined 8710 01 3 Circuit Diagram of Wiper Rear wiper and washer system is not applied the circuit related to rear wiper and washer is removed from the STICS circuit regarding wiper control ...

Page 295: ...on key reminder is a convenience function to prevent the driver from leaving the vehicle with the tail lamps ON or without removing the key As shown in the figure STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions For details refer to following information ...

Page 296: ...iring Circuit of STICS Related to Seat Belt Parking Brake Warning STICS monitors the seat belt fastening status and the parking brake engagement status and warns the driver with the warning light on the instrument panel or chime buzzer ...

Page 297: ...he door s opening and closing status and UNLOCK signal of the remote controller The operating time control and dimming functions of room lamp have been introduced for user convenience The ignition key reminder warning signal in the circuit is related to the dimming function Refer to the detailed information in this manual for the control logic ...

Page 298: ...02 57 STICS undefined 8710 01 7 Wiring Circuit of STICS Related to Tail Lamp Auto Cut Battery Saver ...

Page 299: ...pressing this switch 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 Tailgate window and outside rearview mirror heated glass switch The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch ...

Page 300: ...02 59 STICS undefined 8710 01 9 Circuit Diagram of STICS Related to Remote Controller and Door Lock Unlock ...

Page 301: ......

Page 302: ...cle theft by allowing only the authorized key to start the engine The transponder 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 Transponder Battery ...

Page 303: ... of front room lamp is pressed the lamp will come on for 30 seconds It will turn off immediately after the lock button of the remote control is pressed 2 Panic function activated in the theft deterrent mode If you press and hold the door unlock and panic buttons the buzzer will sound for 27 seconds The function is inactivated if any button of remote control is pressed Door Lock Function Briefly pr...

Page 304: ......

Page 305: ...lizer unit transmits the encrypted code to the transponder Immobilizer Unit The transmitted code is changed to an encrypted signal in the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit 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 t...

Page 306: ... the challenge message to the immobilizer unit to verify whether the key is valid Only when the two signals are identical it recognizes the key as the authorized one and transmits the positive message to the 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 register an extra key let the own...

Page 307: ...ol key for less than 0 5 seconds all doors are locked The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key If the vehicle is locked while all doors including tailgate and engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice 1 2 ...

Page 308: ...witch on the remote control key for more than 0 5 seconds all doors are unlocked When receiving the DOOR UNLOCK message from the remote control key the door unlock relay is turned on for 0 5 seconds The hazard warning lamps blink once only when the doors are successfully unlocked 1 2 3 ...

Page 309: ...03 10 undefined 7010 06 IMMO 5 CIRCUIT DIAGRAM ...

Page 310: ...OR DISPLAY The instrument cluster sends and receives the signals to and from the relevant control units through CAN communication The HDC warning light and the engine hood open warning light are newly introduced OVERVEIW AND OPERATION PROCESS 8010 01 CLUSTER ...

Page 311: ...cator 21 ABS warning light 7 4WD HIGH indicator 22 Engine oil pressure warning light 8 4WD CHECK warning light 23 Glow indicator 9 Water separator warning light 24 Low fuel level warning light 10 Seat belt reminder 25 Engine hood open warning light 11 Speedometer 26 Over temperature warning light 12 ODOmeter Trip odometer 27 Power mode indicator 13 Coolant temperature gauge 28 Winter mode indicato...

Page 312: ...05 4 undefined 8010 01 CLUSTER 2 WARNING INDICATOR PANEL ...

Page 313: ...05 5 CLUSTER undefined 8010 01 ...

Page 314: ...ped with gasoline engine the indicator shows up to 7 000 rpm and 8 000 rpm The tolerance at 7 000 rpm is 100 Connect the tachometer for tune up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds abn...

Page 315: ...abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range Perform the speedometer test regarding the tolerance as described However it is not similar simp...

Page 316: ...to instrument panel TCU TCCU and engine ECU via CAN communication If the speedometer gauge vibrates stops at a certain range or makes an abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications This table shows the tolerance and resistance value changes by f...

Page 317: ...ure is as shown below Measurement of coolant temperature sensor resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range Resistance value by coolant temperature When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal op...

Page 318: ...1 CLUSTER 2 TRIP ODOmeter TRIP A TRIP B and ODOmeter Odometer Trip Odometer When pressing the TRIP RESET switch on the center panel the odometer trip odometer is converted and the meter resets to 0 0 km in Trip A and Trip B ...

Page 319: ...s two modes green function lamp and red warning lamp The HDC switch is a push self return type switch When you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON HDC system e...

Page 320: ...he ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ESP s...

Page 321: ...ch returns to normal position when the OFF switch is released 3 The ESP system will be resumed after approx 150 ms When turning the ignition switch off while the ESP system is activated the ESP system will be resumed when ignition switch is turned on again When the vehicle is controlled by ESP system during driving the ESP OFF switch does not operate The ESP OFF switch operates when it is pushed f...

Page 322: ...es it as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESP unit resets the ESP OFF switch for approx 3 5 seconds ...

Page 323: ...ditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compensate the vehicle stability posture during ESP operation ...

Page 324: ...05 16 undefined 8010 01 CLUSTER 4 CIRCUIT DIAGRAM ...

Page 325: ...05 17 CLUSTER undefined 8010 01 ...

Page 326: ...AMP undefined 8310 01 Front Fog Light Side Repeater Headlamp 8310 01 LAMP OVERVEIW AND OPERATION PROCESS 1 LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Position lamp and Turn Signal Lamp Push Push ...

Page 327: ...06 4 undefined 8310 01 LAMP High Mounted Stop Lamp License Plate Lamp Rear Fog Light Rear Combination Lamp Stop lamp Tail lamp Back up lamp Turn signal lamp ...

Page 328: ... However the front lamps are turned on when opening a door and turned off when closing it The front room lamps and center lamp are turned on when pressing the room lamp main switch 3 Center Room Lamp When this switch is pushed towards the rear of the vehicle the lamp comes on when opening a door and goes off in 30 seconds If the switch is pushed to the opposite direction the lamp stays on Toward t...

Page 329: ...ould stop immediately after turning on the ignition key during decaying operation The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The ...

Page 330: ...ors press it again Rear Fog Lamp Switch ESP OFF Switch If you press the ESP OFF switch the ESP function stops and the indicator lamp in instrument panel comes on Press this switch again to resume the ESP function At this time the indicator lamp goes out Driver s Power Window Switch Driver can controls all door windows Open Close Lock Unlock and doors Lock Unlock with this switch unit ...

Page 331: ...o choose a desired driving distance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO Auto light position Front Wiper and Washer Coupled Operation Pull the lever briefly below 0 6 seconds One wiping cycle Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer fl...

Page 332: ...o Remote Control Switch POWER MODER SEEK SEEK MUTER VOL VOL Sun roof switch Main room lamp switch Front room lamp spot switch 1 2 3 Passenger s Heated Seat Switch Driver s Heated Seat Switch 4WD Control Switch Head Lamp Leveling Switch ...

Page 333: ... basic functions of manual wiper are as follows 1 Wiper Function Coupled Auto Washer When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 3 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times 2 Integrated Auto Light Sensor in Rain Sensor Unit The rain sensor unit is installed on a...

Page 334: ...ystem uses the front washer fluid reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 335: ...to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle The water may be entered into the engine compartment if the curved area of the engine hood and the nozzle is not adhered clo...

Page 336: ...08 6 undefined 7810 01 WIPER 2 SYSTEM LAYOUT OF WIPER AND WASHER WITH RAIN SENSOR ...

Page 337: ...08 7 WIPER undefined 7810 01 ...

Page 338: ...08 8 undefined 7810 01 WIPER 3 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 339: ... 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch 2 ...

Page 340: ...s the operation in step 1 is performed 3 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced Fa...

Page 341: ...the auto washer operation stops and the auto INT operation is activated 3 4 5 6 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden d...

Page 342: ...08 12 undefined 7810 01 WIPER 4 WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM ...

Page 343: ...ntegrated Type Multifunction Wiper Switch AUTO and Sensitivity Control A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor refer to the below picture AUTO Wiper operates automatically by rain ...

Page 344: ...er operation mode washer MIST AUTO then sends the information to the rain sensor STICS Engine Compartment Fuse Box Wiper relay HI Rear washer relay Front washer relay Wiper relay LO 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 c...

Page 345: ... the wipers to operate automatically under the rain sensing mode multifunction switch wiper AUTO mode The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor F...

Page 346: ...2 are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rai...

Page 347: ...dless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the INT auto switch to ON position from OFF position for the first tiime while the ignition key is in ON position When the wiper switch is turned to ON position again from OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor detec...

Page 348: ...he washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation 1 2 ...

Page 349: ... AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 1 stage within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating with ...

Page 350: ...is in ON position and the INT switch is in ON position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position 2 The wiper moto...

Page 351: ...ceiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 1 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 2 ...

Page 352: ...quires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 353: ...ncreases as the obstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle 2 Parking Aid Sensor 1 Type Piezo ceramic element 2 Frequency 40 KHz 2 KHz 3 Detecting range 13 5 V Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5...

Page 354: ...our parking operation Always keep the safety precautions Do not press or shock the sensors by hitting or high pressure water gun while washing or the sensors will be damaged If the system is in normal operating condition a short beep sounds when the gear selector lever is moved into R position with the ignition key ON If the system is in abnormal operating condition a beep sounds for 3 seconds whe...

Page 355: ... braking noises from heavy commercial vehicles When a high power radio is turned on 3 Narrowed sensing area When the sensing portion is partially covered by snow or mud operates normally after cleaned Surrounding temperature of sensor is too high approx over 80 C or too low approx below 30 C 4 Not defective but may occur improper working When driving on the rough roads gravel road hill and grass W...

Page 356: ...nts to measure vertical and horizontal distance to obstacles When placing the gear selector lever to R position the designated unit PAS unit in the rear right quarter panel activates the parking aid sensors to measure the distance to obstacles PAS Related Devices Gear Selector Lever R Position PAS buzzer STICS PAS piezoelectric buzzer OVERVIEW AND OPERATION PROCESS ...

Page 357: ...10 7 PAS undefined 8790 03 Left Right Center Sensor Location Side Sensor Center Sensor PAS Sensor Parking Aid Unit The PAS unit is installed in the rear right section of the rear quarter panel ...

Page 358: ...display changes according to the distance as below While reversing if obstacles are within stage 1 the warning beep sounds with long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously ...

Page 359: ... the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions conditions for warning beep due to failure 1 2 Sensor failure conditions conditions for warning beep Open in sending circuit Open in receiving circuit Open in power c...

Page 360: ...10 10 undefined 8790 03 PAS 4 CIRCUIT DIAGRAM ...

Page 361: ...0 3 AUDIO SYSTEM undefined 4610 00 8930 01 AUDIO SYSTEM OVERVIEW AND INSTALLATION 1 AUDIO SYSTEM OVERVIEW Audio System 6 Speakers ...

Page 362: ...02 3 ION 4 SPEED ACTYON 2010 01 3410 01 3640 01 ION 4 SPEED GENERAL 1 SPECIFICATIONS ...

Page 363: ...02 4 ACTYON 2010 01 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 364: ...Transfer Case The TCU utilizes throttle position rate of throttle opening engine speed vehicle speed transmission fluid temperature gear selector position and mode selector inputs and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects The ou...

Page 365: ...02 6 ACTYON 2010 01 3410 01 ION 4 SPEED 2 APPEARANCE 1 4WD Automatic Transmission 2 2WD Automatic Transmission Torque converter Oil cooler return Servo Inhibiter switch Adapter housing Oil cooler outlet ...

Page 366: ...02 7 ION 4 SPEED ACTYON 2010 01 3410 01 3 SHIFT PATTERN DIAGRAM 1 Normal Mode WINTER mode has same shift pattern with NORMAL mode except 2nd gear drive off 2 Power Mode ...

Page 367: ...ugh the transmission in Neutral But the final drive is not locked by the parking pawl so thewheels are free to rotate D Overdrive range is used for all normal driving conditions 4th gear overdrive gear reduces the fuel consumption and the engine noise Engine braking is applied with reduced throttle First to second 1 2 first to third 1 3 second to third 2 3 second to fourth 2 4 third to fourth 3 4 ...

Page 368: ...ifts will occur to give maximum performance and the POWER mode indicator light is switched ON When WINTER mode is selected starting in second gear is facilitated the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF 3 Indicator Light The indicator light is located on the instrument panel Auto shift indicator light comes ON when the ignition switch ON and...

Page 369: ... electromagnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn ON and OFF the two regulator valves that control the shift feel The seventh solenoid is the proportional or Variable Pressure Solenoid VPS which works with the two regulator valves to control shift feel 1 Transmission Control Modul...

Page 370: ...djusts the variable pressure solenoid ramp pressure then executes the shift The TCU continuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends upon the failure detected with ...

Page 371: ...the output shaft speed signal to the Engine Control Module ECM The information is then transferred to the TCU via the CAN Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission This sensor is a typical Negative Temperature Coefficient NTC resistor with low temperatures producing a high r...

Page 372: ...02 13 ION 4 SPEED ACTYON 2010 01 3410 01 ...

Page 373: ...Sensor 10 White Temperature Sensor 4 Gear Position Sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case The gear position sensor is a multi function switch providing three functions Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is selected Ind...

Page 374: ... Battery Voltage Monitoring Input The battery voltage monitoring input is connected to the positive side of the battery This signal is taken from the main supply to the TCU If the battery voltage at the TCU falls below 11 3 V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may not occur because of the reduce...

Page 375: ...N S4 switches the front band regulator valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pressures S5 also provides the signal pressure for the converter clutch...

Page 376: ...02 17 ION 4 SPEED ACTYON 2010 01 3410 01 Solenoid Operation during Gearshifts ...

Page 377: ...n gear state and engine speed S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures VPS pressure is multiplexed to the clutch regulator valve the band regulator valve and the converter clutch regulator valve during automatic gearshifts A variable pressure solenoid produces a hydraulic pressur...

Page 378: ...lectrically controlled for each gearshift Mode indicator light Depending on the application the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists The mode indicator light is usually located on the instrument cluster 9 Communication Systems 1 CAN The Controller Area Network CAN connects various control modules by using a twisted pair of ...

Page 379: ...and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to return to stand by pressure The primary regulator valve is l...

Page 380: ...02 21 ION 4 SPEED ACTYON 2010 01 3410 01 1 Hydraulic Control Circuit ...

Page 381: ... into the PRND fluid circuits 1 2 shift valve The 1 2 shift valve is a two position valve that must be switched to the 2 3 and 4 position in order to get any forward gear other than first gear It is used for all 1 2 and 2 1 gearshifts The switching of this valve is achieved by using S1 and or S2 During a 1 2 gearshift drive oil from the manual valve passes through to the second gear circuit During...

Page 382: ...S1 which is located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve Exhausts the front band release B1R circuit thereby allowing the application of the front band B1 Connects the inner apply area of the front servo B1AI to the Band Apply Feed BAF circuit thus allowing greater apply forces to the front band Exhausts the Overrun Clutch OC circuit which allows the C4 clutch t...

Page 383: ...noid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids S1 to S7 Line pressure is used as the feeding oil to this regulator and the output is termed line 500 Line pressure control valve Line pressure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primary Regulato...

Page 384: ...re of 2 25 times the S5 signal pressure when S3 is ON When S3 is OFF the output pressure is 2 25 times the line 500 pressure Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio 1 4 1 valve It provides a regulated pressure to the front servo and controls the change rate of the front band B1 state to give the desired shift quality Second gear oil supplied to the valv...

Page 385: ...conditions are satisfied In P or N vehicle speed 3 km h In R vehicle speed 10 km h Engine speed 1600 rpm Throttle position 12 Under these conditions the TCU switches solenoids S1 and S2 to OFF The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston applying B2...

Page 386: ...ecause all shifting pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slippage This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and S6 pressure T...

Page 387: ...clutch The switching of this valve is governed by the signal pressure from S7 When the valve is in the OFF or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the ON or applied position regulated o...

Page 388: ...t permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the needto force the oil back from the front servo through the valve body and through the 3 4 shift valve The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa ...

Page 389: ...e operation of the Power Train System is detailed below First gear is engaged by applying the C2 clutch and locking the 1 2 One Way Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3 4 OWC Reve...

Page 390: ...02 31 ION 4 SPEED ACTYON 2010 01 3410 01 ...

Page 391: ...er and piston assembly en ables the torque converter to lock up under favorable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted slippage W...

Page 392: ...y occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting Clutch packs Bands The transmission utilizes two bands the B1 band sometimes known as the 2 4 band and the B2 band sometimes known as the low reverse band The B1 band is a flexible band which is enga...

Page 393: ...etween the C4 and the C2 clutch assemblies This allows the C2 clutch to drive the forward sun gear in first second and third gears but unlocks in fourth gear and during overrun The B2 band is a solid band which is engaged by the rear servo piston B2 is activated in Park Reverse Neutral and Manual 1 When activated B2 prevents the planet carrier assembly from rotating In Manual 1 only the inner area...

Page 394: ...wer Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a ret...

Page 395: ...02 36 ACTYON 2010 01 3410 01 ION 4 SPEED 1 Park and Neutral ...

Page 396: ... 2 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regulator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by the soleno...

Page 397: ...02 38 ACTYON 2010 01 3410 01 ION 4 SPEED 2 Reverse ...

Page 398: ... valve Reverse oil is routed from the manual valve to the C3 clutch Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value All other clutch and band apply circuits are open to exhaust The elements of the transmission function as follows The C3 clutch is engaged and drives the reverse sun gear in a clock wise direction ...

Page 399: ...02 40 ACTYON 2010 01 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 400: ... the inner apply area of the rear servo piston for B2 band application In Manual 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The B2 band is engaged to hold the planetary gear carrier stationary The forward sun gear drives the short pinion anticl...

Page 401: ...02 42 ACTYON 2010 01 3410 01 ION 4 SPEED 4 Drive 1 ...

Page 402: ...h In Drive 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under reaction forc...

Page 403: ...02 44 ACTYON 2010 01 3410 01 ION 4 SPEED 5 Drive 2 and Manual 2 ...

Page 404: ...tch In Drive 2 and Manual 2 transmission drive is via the input shaft and forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under r...

Page 405: ...02 46 ACTYON 2010 01 3410 01 ION 4 SPEED 6 Drive 3 and Manual 3 ...

Page 406: ... sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed The C4 clutch is applied to bypass the 3 4 OWC and provide engine braking on overrun The outer apply area of the front servo The 1 2 shift valve to provid...

Page 407: ...02 48 ACTYON 2010 01 3410 01 ION 4 SPEED ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 3 and Manual 3 x x x x ...

Page 408: ...02 49 ION 4 SPEED ACTYON 2010 01 3410 01 7 Drive 3 Lock Up and Manual 3 Lock Up ...

Page 409: ...N S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converte...

Page 410: ...02 51 ION 4 SPEED ACTYON 2010 01 3410 01 8 Drive 4 Overdrive ...

Page 411: ...he reverse sun gear stationary As the planet carrier tuns the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i e in overdrive ratio The forward sun gear is also driven faster than the input shaft and overruns the 3 4 OWC The C2 clutch is e...

Page 412: ...02 53 ION 4 SPEED ACTYON 2010 01 3410 01 ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 4 Overdrive x x x ...

Page 413: ...02 54 ACTYON 2010 01 3410 01 ION 4 SPEED 9 Drive 4 Lock Up ...

Page 414: ... valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converter clutch control valve Converter ...

Page 415: ... Two hydraulically controlled brake bands Three multi plate clutches All hydraulic functions are directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications The TCU receives input signals from certain transmission related sensors and switches The TCU also uses these signals when determining transmission operating strategy U...

Page 416: ... mode is selected starting in second gear is facilitated and the WINTER mode indicator light is switched ON To prevent wheel spin on slippery surfaces the transmission will not allow first gear unless manually overridden Standard Mode is selected when the lever is in the D position with the mode switch in the standard S position and the transmission is within normal temperature ranges Shift schedu...

Page 417: ...0 4 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 1 Specifications 2 STRUCTURE CHARACTERISTICS AND SPECIFICATIONS ...

Page 418: ...5 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 4WD Automatic Transmission 2 Appearance 2WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Adapter housing Inhibiter switch ...

Page 419: ...0 6 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 3 Internal Assembly Figure 2WD 4WD ...

Page 420: ...0 7 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 4 Shift Pattern ...

Page 421: ...0 8 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 3 TIGHTENING TORQUE ...

Page 422: ...ing Modulated torque converter clutch applications The transmission contains fully synthetic automatic transmission fluid ATF and is filled for life therefore it does not require periodic servicing Engine power reaches the transmission via a torque converter with integral converter lock up clutch The six forward gears and one reverse gear are obtained from a single planetary set followed by a doub...

Page 423: ...ions Drive and Reverse engagements from either Park or Neutral are performed in less than 2 2 seconds There is no drive engagement prevention strategy implemented on the transmission system as there is sufficient engine strategy to protect the system However reverse engagement is prevented until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12 and vehicle speed...

Page 424: ...ooler 3 Shift Strategy Transmission gear change is controlled by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change Gear Hold Going Uphill Downhill Coastdown Coastdown downshifts occur at 0 pedal when the vehicle is coasting down to a stop Torque Demand Torque ...

Page 425: ...he attempt To shift into any other positions from the P position after stopping the vehicle you have to depress the brake pedal with the ignition switch ON 2 Selection of Manual Automatic Shift Function Shift from the P Position D Automatic shift according to the driving condition M Manual shift 3 Mode Switch W Winter mode S Standard mode Use the standard mode in normal driving c 4 Gear Position P...

Page 426: ... gear state will display on the instrument cluster Unlike the normal 1st gear engine braking will be available in this manual 1st state 2st Gear State 3st Gear State 4st Gear State 5st Gear State 6st Gear State The 2nd gear state will display on the instrument cluster 2 1 automatic kick down shifts are available 2nd gear has engine braking available The 3rd gear state will display on the instrumen...

Page 427: ...p home mode for service The TCU monitors all factors which can af The TCU enters the limp home mode when the batter voltage drops below 8 V If the transmission is overheated the shift pattern is changed to the hot mode to cool the transmission more efficiently While the transmission is overheated the selector lever symbol and engine temperature warning lamp on the instrument cluster blink until th...

Page 428: ...om certain transmission related sensors and switches The TCU also uses these signals when determining transmission operating strategy Using all of these input signals the TCU can determine when the time and conditions are right for a shift or when to apply or release the torque converter clutch It will also determine the pressure needed to optimise shift feel To accomplish this the TCU operates si...

Page 429: ... switch ON process checking for the above faults The gear ratio diagnostic checks if each gear ratio is correctly engaged Also following a gear shift the diagnostic checks if the transmission has engaged the target gear within the allowed time The TCU checks if the torque converter can be locked correctly If torque converter lock up does not occur correctly the TCU performs the appropriate fail sa...

Page 430: ...peration High and Low range operation has different parameters to optimise shift quality 4 Shift Map Selection The driver can manually select between normal S and winter modes W via the mode switch Depending on the transmission temperature uphill and downhill grades and altitude shift maps will be selected by the TCU to suit the driving conditions The following maps are available Normal Mode Norma...

Page 431: ...converter As additional assistance to the hot mode the following are activated Above 110 C the electrical radiator fans are switch ON Above 130 C the engine torque will be reduced and the WINTER light on the instrument cluster will flash Above 145 C the transmission will neutralise until the fluid temperature falls below 120 C as a final protection Activation of the hot mode inhibits other transmi...

Page 432: ...dy during manufacture The EMM is integrated into the input speed sensor which is mounted on the valve body in the transmission The EMM data contains transmission specific characterisation information Upon installation the TCU will upload the data from the EMM and utilise this data in the operation of the transmission Selector lever position Selected gear state Manual mode activation Output torque ...

Page 433: ...er train of the transmission is as follow Gear States Summary Power train M 1st gear Power train D 1st gear Power train D 2nd gear Power train D 2nd gear lockup Power train D 3rd gear Power train D 4th gear D 4th gear limp home mode Power train D 5th gear Power train D 6th gear ...

Page 434: ...0 21 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 Overall Hydraulic Circui ...

Page 435: ...lenoids S9 is also a variable bleeding solenoid It controls Line Pressure Solenoid S10 is a variable bleeding solenoid as well and is used for controlling the application of the Torque Converter lock up clutch ON OFF Solenoids Gear States Summary S1 controls apply release of the C1 Clutch S2 controls apply release of the C2 Clutch S3 controls apply release of the C3 Clutch B2 Band S4 controls appl...

Page 436: ...S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch S1 ON moves B2 Shift Valve to its left end position allowing an application of the B2 Band S7 must be ON as well C2 Shift Valve S2 OFF is open allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 Connecting Components Manual 1st is not achieved by moving the Manual Valv...

Page 437: ...0 24 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Manual 1st C2 B2 ON 3 536 ...

Page 438: ...C2 applied drives FSG Rear Planet Carrier held via 1 2 OWC Control Connecting Components S1 is ON S2 is OFF S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch C2 Shift Valve S2 OFF is open allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 ...

Page 439: ...0 26 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Auto 1st C2 OWC ON 3 536 ...

Page 440: ...onents S1 is ON S2 is OFF S4 is ON S1 ON moves C1 Shift Valve to its left end position not allowing the application of the C1 Clutch C2 Shift Valve is OPEN S2 OFF allowing drive oil to engage C2 Clutch Drive oil that engages C2 Clutch is regulated by VBS S6 S4 ON moves B1 Shift Valve to its left end position allowing engagement of B1 Band Drive oil that engages B1 Band is regulated by VBS S8 ...

Page 441: ...0 28 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Auto 2nd C2 B1 ON 2 143 ...

Page 442: ...0 29 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 4 Power Train D Drive 2nd Lockup Power flow diagram Connecting Components ...

Page 443: ...0 30 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 2nd Lockup C2 B1 TCC ON ...

Page 444: ...ual to the ratio of the Front Gear Set Control Connecting Components S1 ON moves C1 Shift Valve to the left end not allowing the application of the C1 Clutch C2 Shift Valve is open allowing drive oil to engage C2 Clutch S2 OFF S3 S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch Connecting Components C3 Clutch cannot be engaged without S7 being ON and supplying press...

Page 445: ...0 32 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 3rd Gear C2 C3 ON 1 478 ...

Page 446: ...pplied drives Rear Planet Carrier Control Connecting Components S1 is OFF S2 is OFF C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch C2 Shift Valve is OPEN S2 OFF allowing drive oil to engage C2 Clutch Drive oil that engages C1 C2 Clutches is regulated by S5 S6 VBS respectively for each clutch 4th GEAR is used as a LHM state Connecting Components ...

Page 447: ...0 34 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 4th 4th LHM C1 C2 ON 1 156 ...

Page 448: ...rrier C3 applied drives RSG Control Connecting Components S1 is OFF S2 is ON S3 is ON S2 ON moves C2 Shift Valve to its left end position not allowing the application of the C2 Clutch C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch S3 ON and with S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutc ...

Page 449: ...0 36 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 5th Gear C1 C3 ON 0 866 ...

Page 450: ...t Carrier B1 applied to hold RSG Control Connecting Components S1 is OFF S2 is ON S4 is ON S2 ON moves C2 Shift Valve to its left end position not allowing the application of the C2 Clutch C1 Shift Valve is OPEN S1 OFF allowing drive oil to engage C1 Clutch S4 ON moves B1 Shift Valve to its left end position allowing the engagement of B1 Band ...

Page 451: ...0 38 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T 6th Gear C1 B1 ON 0 677 ...

Page 452: ...ves RSG B2 applied holds Rear Planet Carrier stationary Control Connecting Components S1 is ON S2 is ON S3 is ON Line pressure is directed via Manual Valve to apply B2 Band directly S3 ON allows ramping and regulating pressure supplied to the C3 S1 S2 are ON not allowing engagement either C1 or C2 Clutch at any circumstances ...

Page 453: ...0 40 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Reverse C3 B2 ON 3 094 ...

Page 454: ...0 41 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 10 Power Train Reverse Limp Home Mode Power flow diagram Connecting Components ...

Page 455: ...0 42 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Reverse at LHM C3 B2 ON ...

Page 456: ...0 43 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 11 Power Train Parking Power flow diagram Connecting Components ...

Page 457: ...0 44 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Park ...

Page 458: ...0 45 DSI M78 6 SPEED A T ACTYON 2010 01 3650 01 12 Power Train Neutral Power flow diagram Connecting Components ...

Page 459: ...0 46 ACTYON 2010 01 3650 01 DSI M78 6 SPEED A T Neutral ...

Page 460: ...0 95 DSI M78 6 SPEED A T ACTYON 2010 01 3110 01 1 WIRING DIAGRAM DIAGNOSIS AND TESTING ...

Page 461: ...0 96 ACTYON 2010 01 3110 01 DSI M78 6 SPEED A T 1 Transmission Control Unit 2 WIRE HARNESS CONNECTOR CHART Connector Front View 3 UNIT CONNECTOR DESCRIPTION Connector J1 A ...

Page 462: ...0 97 DSI M78 6 SPEED A T ACTYON 2010 01 3110 01 Connector J2 B Connector J3 C ...

Page 463: ...0 98 ACTYON 2010 01 3110 01 DSI M78 6 SPEED A T 2 Transmission Connector J4 Connector Front View ...

Page 464: ...0 99 DSI M78 6 SPEED A T ACTYON 2010 01 3110 01 3 Inhibitor Switch Connector J5 ...

Page 465: ...0 100 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T 1 DIAGNOSTIC TROUBLE CODE LIST TROUBLE CODE DIAGNOSIS ...

Page 466: ...0 101 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 ...

Page 467: ...rent draw typically being less than 4 amps but reaching as high as 10 amps during gear shifts As the mechanical components of the transmission change due to wear etc the TCU adapts its shift data to accommodate these changes and maintain shift quality over the life of the vehicle If a transmission component degrades to a point whereby the TCU is unable to adapt its shift data to maintain shift qua...

Page 468: ...0 103 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 Schematic Connector Details ...

Page 469: ...0 104 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 470: ...d enables reverse light operation when the TGS lever is in the reverse position The inhibitor switch has an individual circuit for each of these functions with only the gear lever position circuit being connected directly to the TCU The TCU supplies a 5 V reference signal to the gear lever position circuit inhibitor switch and measures the voltage drop in the circuit to determine the gear lever po...

Page 471: ...0 106 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T Resistance Values DTC Details Gear Lever Position Sensor Specifications ...

Page 472: ...0 107 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Clearing ...

Page 473: ...nable to maintain a satisfactory transmission oil temperature the TCU will take precautionary measures to prevent damage to the transmission and other vehicle components The TCU also monitors the rate of temperature change according to current operating conditions performance If the temperature sensor performance is outside a pre determined set of values DTC P0711 will set DTC Details DTC Clearing...

Page 474: ...n the valve body harness tray The TFT sensor is a negative coefficient thermistor The transmission control unit TCU supplies a 5 V reference signal to the sensor and measures the voltage drop in the circuit When the transmission fluid is cold the sensor resistance is high with the sensor resistance decreasing as the fluid temperature increases Schematic Connector Details ...

Page 475: ...0 110 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T Resistance Values ...

Page 476: ...0 111 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Details DTC Clearing ...

Page 477: ...e sensor and is mounted on the valve body in the transmission The EMM is matched to the transmission valve body during manufacture The EMM is integrated into the input speed sensor The hall effect sensor drives the signal low The TCU then pulls the signal up to 5 V via a resistor 36 times per revolution of the C2 cylinder ...

Page 478: ...0 113 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 Schematic Connector Details ...

Page 479: ...0 114 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 480: ...0 115 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Clearing ...

Page 481: ...I M78 6 SPEED A T 6 Transmission Gear Select Lever DTC Description The transmission gear select lever contains the mode switch manual mode active switch and up down switches These switches are connected directly to the TCU Schematic ...

Page 482: ...0 117 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 Connector Details Resistance Values Transmission Gear Select Lever Resistance Values ...

Page 483: ...0 118 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 484: ...n The OSS sensor is a Hall Effect type sensor and is mounted at the rear of the transmission main case The hall effect sensor drives the signal low The TCU then pulls the signal up to 5 V via a resistor 22 times per revolution of the transmission output shaft Schematic Connector Details ...

Page 485: ...0 120 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details DTC Details ...

Page 486: ...Engagement DTC Description Transmission gear change is controlled by the TCU The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch TCC operation at each gear change ...

Page 487: ...0 122 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details ...

Page 488: ...0 123 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Clearing ...

Page 489: ...raulic control system Pressure at the torque converter lock up clutch piston is determined by an electronic variable bleed solenoid VBS During operation the TCU evaluates torque converter slip speed and compares this against what is expected If torque converter slip is not within predefined parameters a DTC will set to indicate a torque converter lock up problem ...

Page 490: ...0 125 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Details DTC Clearing ...

Page 491: ...D A T 10 Steering Wheel DTC Description The steering wheel contains transmission gear select TGS up down switches and are directly connected to the TCU These switches operate in parallel with the TGS lever switches directly to the TCU Schematic ...

Page 492: ...0 127 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 Connector Details Resistance Values DTC Details ...

Page 493: ...0 128 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 494: ...CU is able to vary the amount of torque applied to the clutch elements by controlling the current to the variable bleed solenoid windings The clutch element torque transfer is directly related to the current applied to the solenoids During operation the TCU evaluates the actual current delivered to the solenoid and compares this against what is expected If the current is not within predefined para...

Page 495: ...0 130 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Description Schematic Connector Details ...

Page 496: ...0 131 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Details ...

Page 497: ...0 132 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T ...

Page 498: ...0 133 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 ...

Page 499: ...0 134 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 500: ...ween different clutch elements within the transmission During operation the TCU evaluates the actual current delivered to the on off solenoid and compares this against what is expected If the current is not within predefined parameters a DTC will be set to indicate the load on the TCU is abnormal DTC Description ...

Page 501: ...0 136 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T Schematic Connector Details ...

Page 502: ...0 137 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Details ...

Page 503: ...0 138 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T ...

Page 504: ...0 139 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 DTC Clearing ...

Page 505: ...share vehicle system information between the control units connected to the bus The TCU obtains the majority if its information via this network If the TCU does not receive information at regular intervals from the electronic control units connected to the bus the TCU will set a communication DTC DTC Description ...

Page 506: ...0 141 DSI M78 6 SPEED A T ACTYON 2010 01 3110 00 Schematic Connector Details DTC Details ...

Page 507: ...0 142 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Clearing ...

Page 508: ...TCU software or calibration may be upgraded at service These DTC뭩 protect the TCU against corrupted files being loaded into the TCU They also ensure only the correct calibration parameters are used with the software version currently loaded into the TCU DTC Description ...

Page 509: ...0 144 ACTYON 2010 01 3110 00 DSI M78 6 SPEED A T DTC Details DTC Clearing ...

Page 510: ...of driving power Replenish oil if the engine is completely warmed up and there is no loss of driving power but there is still a problem with the vehicle speed Oil Check and Replenishment When replenishing or changing transmission oil a genuine recommended oil must be used If non approved oil is used it will have fatal impacts on the transmission s performance and life Never use such oil Wrong oil ...

Page 511: ...filler pump to the oil inlet After attaching the filler pump to the transmission lower this vehicle and replenish oil 1 2 3 4 When the transmission torque converter has no oil 9 5 ℓ When the transmission torque converter is filled with oil 4 5 ℓ a b Engage the parking brake start the engine while the selection lever is engaged to P and depress the foot brake Then start shifting the selection lever...

Page 512: ...ngine torque without slipping Stall testing should be performed for a period no longer then 10 seconds Apply Hand Brake Start Engine Press Brake Pedal Shift to DRIVE Press Accelerator Pedal to 100 for 6 seconds Observe Engine speed Release Accelerator Pedal Shift To Reverse Press Accelerator Pedal to 100 for 6 seconds Observe Engine speed If engine speed is observed 3000 rpm transmission hardware ...

Page 513: ...ting the scan tool With the transmission gear select TGS lever in Park turn the ignition key to the ON position engine not running Using the scan tool set the parameter Set Km Travelled to 0Km Run the task Activate Adaptive Green Offset Turn the ignition key to the OFF position Start the vehicle and check for normal operation 1 2 3 4 5 6 Adaptive Reset Procedure To perform an adaptive reset proced...

Page 514: ...til fluid starts to drain from the level hole and reinstall the plug Drive the vehicle for approximately five minutes Connect the vehicle s diagnostic scan tool to the vehicles diagnostic connector Refer to the vehicle repair manual for information on connecting the scan tool With the gear select lever in the Neutral position start the engine and allow to run at idle until the transmission fluid t...

Page 515: ... 3 Connect one end of a rubber hose to the end of the rear cooler line and place the other end in a suitable container to collect the transmission fluid as it is pumped out Start the engine and run for approximately 30 seconds at idle With ATF at 50 C temperature a minimum of 2 5litres oil flow after 30 seconds Whist the engine is running have an assistant pump transmission fluid into the transmis...

Page 516: ...0 151 DSI M78 6 SPEED A T ACTYON 2010 01 3680 01 7 TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE NEW TRANSMISSION ...

Page 517: ...r safety and convenience are limited Sometimes the vehicles gears can be changed unexpectedly or unintentionally by various factors Therefore two tip switches are installed to prevent such changes from happening For instance when a vehicle is running on a severely curved road the driver must hold the steering wheel with two hands Shifting gears or using the engine brake while driving on the road w...

Page 518: ...p or towing the vehicle When towing the is vehicle the towing speed should be 50 km h or less and the towing distance should not exceed 50 kilometers It is more recommended to load this vehicle on a flat bed towing vehicle 4 D 1 6 Gears This position is for normal driving on paved roads or high speed driving The gear ratio of the 6th gear is 0 68 1 5 M Manual Mode This allows the driver to define ...

Page 519: ...lay on the instrument cluster 4 3 4 2 and 4 1 automatic kick down shifts are available 4th gear has engine braking available 9 3 1 3 gears only available in the M position The 3rd gear state will display on the instrument cluster 3 2 and 3 1 automatic kick down shifts are available 3rd gear has engine braking available 10 2 1 2 gears only available in the M position The 2nd gear state will display...

Page 520: ...hed from the D position to the M mode the M mode sensor detects this change and sends a signal to the TCU and the TUC shifts down one or two gears without any jerking This means the newly engaged gear in the M mode is the one level lower gear from the D position For example when the selector lever is pushed from the D position to the M mode the transmission will automatically switch the 3rd gear t...

Page 521: ... the vehicle s smooth driving off With the Winter mode 2WD and AWD models have fast up shifts and slow down shifts to increase gas mileage When these models use the full throttle the Winter mode automatically switches to the Standard mode However in case of 4WD models the Winter mode will stay on even with the full throttle In spite of the Winter mode being selected the transmission will use only ...

Page 522: ...0 8 ACTYON 2010 01 3722 01 TGS LEVER 2 Electric Circuit ...

Page 523: ...the selector lever unit so that the system detects the brake switch operation signal for allowing shift from the P to other positions This system is a safety measure to prevent the selector lever from moving unless the brake pedal is depressed 1 Selector Lever 2 Shift Pattern Display 3 Selector Lever Handle 4 Parking Lock Release Flap 5 Selector Lever Control Unit Internally Installed 6 Mode Switc...

Page 524: ...0 10 ACTYON 2010 01 3722 01 TGS LEVER 3 Shift Lock Solenoid Function ...

Page 525: ... the brake pedal is pressed the Selector Lever Unit does not activate the P Locking solenoid and the Selector Lever 1 stays locked In this situation the lock lever 4 is engaged to the P Lock position and the Locking Lever Tap 3 holds the Lock Lever 2 Therefore the Selector Lever cannot be shifted to other positions ...

Page 526: ...itch in ON please apply the following instruction Apply the parking brake firmly and turn the ignition off Depress the brake pedal and push down the shift lock release lever with a stick such as a pen Then shift the lever to other positions 1 2 Do not push down the shift lock release lever excessively The internal parts could be damaged Shift lever lock release ...

Page 527: ...s used to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift 2 3 The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 4 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement The clutch rele...

Page 528: ...03 4 ACTYON 2010 01 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 529: ...03 5 M T ACTYON 2010 01 3170 01 2 Tightening Torque ...

Page 530: ...03 6 ACTYON 2010 01 3170 01 M T Inside N Switch OVERVIEW AND OPERATION PROCESS 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch 0 5mm 0 5mm ...

Page 531: ...etection The gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm When the gea...

Page 532: ...itch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Neutral Signal Input None Wire CAN Wire Actyon Kyron models with manual transmission New...

Page 533: ......

Page 534: ...04 3 CLUTCH ACTYON 2010 01 3010 01 GENERAL 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE 3020 01 CLUTCH ...

Page 535: ...system which adjusts the clutch freeplay according to the wear of clutch disc 2 Operation description Internal Components of Clutch Cover Disc wear Free play Diaphragm spring 1 Adjusting equipment 2 3 Pressure plate 4 Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear ...

Page 536: ...the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the c...

Page 537: ...04 6 ACTYON 2010 01 3010 01 CLUTCH Components of Clutch Assembly Concentric Slave Cylinder Clutch Assembly 3 Functions Adapter Pipe Assembly ...

Page 538: ...04 7 CLUTCH ACTYON 2010 01 3010 01 Cross Sectional View of Clutch Assembly 1 Transmission housing 4 Bolt 2 Clutch disc assembly 5 Washer 3 Clutch disc cover assembly 6 Bolt ...

Page 539: ...05 3 AXLE ACTYON 2010 01 4120 01 4120 01 AXLE GENERAL 1 SPECIFICATIONS OF AXLE 1 Front View 2 Rear View 3 Specifications ...

Page 540: ...2010 01 4120 01 AXLE 4 Specifications of Front and Rear Axle The specification below is for front and rear axles equipped in Actyon including gear ratio and specific specifications For details refer to each section ...

Page 541: ...05 5 AXLE ACTYON 2010 01 4120 01 OVERVIEW AND OPERATION PROCESS 1 OVERVIEW OF AXLE 1 Front Axle 2 Rear Axle ...

Page 542: ...ve big difference in comparison to the conventional part time transfer case but the changes in comparison to the conventional transfer case are as follows No additional coding is required when replacing TCCU Delete the devices tone wheel speed sensor wiring etc related to the speed sensor in the transfer case This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS ...

Page 543: ...FER CASE OVERVIEW AND OPERATION PROCESS 1 STRUCTURE Front axle Front locking hub system IWE Power steering assembly Front propeller shaft ION 4th gear automatic transmission Part time transfer case TCCU Rear propeller shaft Rear axle ...

Page 544: ...Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper ...

Page 545: ...0 6 ACTYON 2010 01 3240 01 TRANSFER CASE 2 SYSTEM LAYOUT AND OPERATION 1 System Layout ...

Page 546: ... locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Atmosphere Atmosphere Electrical signal Booster Vacuum modulator for engine ...

Page 547: ...hub gear In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve Hub actuator LH 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released ...

Page 548: ...0 9 TRANSFER CASE ACTYON 2010 01 3240 01 4 POWER FLOW 1 Components of Power Flow Part time transfer case Transfer case Engine Rear 2WD Rear wheel side Front 4WD Front wheel side ...

Page 549: ...0 10 ACTYON 2010 01 3240 01 TRANSFER CASE 2 Flow Layout ...

Page 550: ...0 11 TRANSFER CASE ACTYON 2010 01 3240 01 3 2H Mode Rear Wheel Drive 1 Layout ...

Page 551: ...0 12 ACTYON 2010 01 3240 01 TRANSFER CASE 4 4H Mode 4 Wheel Drive High speed 1 Layout ...

Page 552: ...0 13 TRANSFER CASE ACTYON 2010 01 3240 01 4 4L Mode 4 Wheel Drive Low speed 1 Layout ...

Page 553: ...07 3 SUSPENSION ACTYON 2010 01 4411 01 4510 01 SUSPENSION GENERAL 1 SPECIFICATIONS OF SUSPENSION 2 WHEEL ALIGNMENT ...

Page 554: ...it differ between ABS ESP system equipped vehicle and non ABS ESP equipped vehicle The drum type brake is installed on non ABS equipped vehicle while the solid disc thickness approx 10 4 mm is installed on ABS ESP equipped vehicle 3 Parking Brake Ventilated disc type Solid disc type Front Ventilated Disc and Caliper 2 internal Cylinders Piston Rear Disc and Caliper 1 Internal Cylinder For the park...

Page 555: ...08 4 ACTYON 2010 01 4892 01 ESP 2 SECTIONAL DRAWING 1 Front Disc Brake 2 Rear Disc Brake ...

Page 556: ...o signal the vehicle speed to the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication 1 Location of the wheel speed sensor rear right wheel Connector Appearance In vehicle...

Page 557: ...08 6 ACTYON 2010 01 4892 01 ESP 3 SPECIFICATIONS Description Item NON ABS ABS ESP Brake pedal Brake master cylinder Brake booster Front brake Rear brake Parking brake Brake fluid ...

Page 558: ...does not imply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disc and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is...

Page 559: ...ary device for comfortable driving When the vehicle exceeds its physical limits it cannot be controlled Do not rely on the system Keep on the safe driving Feeling when ESP is working When the ESP system activates the feeling can be different depending on vehicle driving conditions For example you will feel differently when the ESP system is activated during the ABS is operating with the brakes app...

Page 560: ...s and prevents the vehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic ...

Page 561: ...itch ESP warning lamp comes on ESP is activated by pressing the switch again ESP warning lamp goes off HDC is activated by pressing the switch Green HDC indicator comes on HDC is deactivated by pressing the switch again Green HDC indicator goes off Detects the angle of the steering wheel and sends it to HECU Detects lateral acceleration longitudinal acceleration and yaw rate ...

Page 562: ...892 01 Wheel Speed Sensor FOR 4WD Rear Wheel Speed Sensor LH RH HECU Receives the signals from wheel speed sensor steering wheel angle sensor sensor cluster and pressure sensor and perform the vehicle stability control function ...

Page 563: ... during cornering by controlling the vehicle stability using the input values from the sensors and applying the brakes independently to the corresponding wheels The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering is when the steering wheel is steered to a certain angle during ...

Page 564: ...ain angle during driving and the rear tires slip outward losing traction When compared with under steering vehicles the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases 2 Over steering ...

Page 565: ...er the vehicle as he or she intends 2 ESP Control As the single track vehicle model used for the calculations is only valid for a vehicle moving forward ESP intervention never takes place during backup The ESP system includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the brakes are applied during cornering at ...

Page 566: ...08 15 ESP ACTYON 2010 01 4892 01 The following figure shows the operating range according to driving conditions Operating range Turning Turning ...

Page 567: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 568: ...ng is required under emergency The BAS System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the...

Page 569: ... that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions Pressure over 20 bar Pressure changes over...

Page 570: ... needed One must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sha...

Page 571: ...equently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off however the ARP function is also deactivated when the ESP function is not operatable due to system malfunction ...

Page 572: ...lope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation When you press the HDC switch the green HDC indicator comes on and when the HDC operates the green HDC indictor flashes at 0 5 second of interval The G Sensor within the sensor cluster detects the steepness...

Page 573: ...rmination slope level when it reaches 5 2 HDC target speed in 2H 4H mode The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches 7 km h but is converted to the stand by mode When the vehicle speed increases again as a result of the increase of the road steepness etc the HDC goes into operation Forward driving 7 km h Reverse driving 7 km h automatic tra...

Page 574: ...10 and 20 during the HDC operation When depressing the accelerator pedal or brake pedal HDC system is changed to stand by mode When releasing the pedal HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by depressing and releasing the pedal When the slope level exceeds 20 during the HDC operation When depressing the accelerator pedal HDC system is cha...

Page 575: ...s overridden When the internal temperature of HDC system goes over 450 C due to long downhill driving on a steep hill with HDC operated 5 There is no specific temperature sensor in the system but a programmed logic inside the HECU predicts the temperature based on the operating times and conditions of HDC The red HDC warning lamp blinks when the internal temperature goes over 350 C When reaches 45...

Page 576: ...TYON 2010 01 4892 01 4 Input Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function ...

Page 577: ...ment panel has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON...

Page 578: ...in HDC operation The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the H...

Page 579: ...pressure sensor Active Wheel Speed Sensor 7 Components and Locations There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system However the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied ...

Page 580: ... 29 ESP ACTYON 2010 01 4892 01 Steering Wheel Angle Sensor HDC Switch Sensor Cluster Yaw Rate Lateral Sensor Longitudinal Sensor ESP OFF Switch HDC Indicator ABS ESP Indicator 1 Comparison with ABS System ...

Page 581: ...08 30 ACTYON 2010 01 4892 01 ESP 7 INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input Output of ESP System ...

Page 582: ...08 31 ESP ACTYON 2010 01 4892 01 8 HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ...

Page 583: ...in primary 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 opera...

Page 584: ... 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 The pressure decreases just before the wheel speed drops and the wheels are locked The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the ...

Page 585: ...sing 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 The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuou...

Page 586: ...king depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the whee...

Page 587: ...Speed Sensor Front Wheel Speed Sensor for 4WD 11 COMPONENTS OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor Valve body B Plunger C Cam bushing Motor pump ...

Page 588: ...08 37 ESP ACTYON 2010 01 4892 01 1 Input and Output Diagram Of ABS System ...

Page 589: ...ont wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 590: ... to close the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This procedure helps the wheel to maintain a stable hydraulic pressure 2 3 Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable the wheel can be locked as the wheel speed decreases This is when the ABS ECU detects the wheel spee...

Page 591: ...lates to the wheel by the pump no pressure increase in wheel Therefore when depressing the brake pedal the pressure generated in the master cylinder is transferred to the disc and then the outlet valve decreases this pressure intermittently This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels When the ABS hydraulic pressure control takes place there...

Page 592: ...c pressure to operate the power steering system The pressure relief valve in the pump controls the discharging pressure The rotary control valve in the rack and 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 ...

Page 593: ...09 4 ACTYON 2010 01 4610 01 POWER STEERING OVERVIEW AND OPERATION 1 SYSTEM LAYOUT ...

Page 594: ...09 5 POWER STEERING ACTYON 2010 01 4610 01 ...

Page 595: ...09 6 ACTYON 2010 01 4610 01 POWER STEERING 2 COMPONENTS ...

Page 596: ...09 7 POWER STEERING ACTYON 2010 01 4610 01 ...

Page 597: ...r bags deploy and the seat belt pretensioners of the driver s and passenger s seat belts retract seat belts 1 2 Curtain air bag G sensors These are located inside the left and right B pillar panel bottoms When a collision occurs the air bag at the side of collision deploys accordingly Please pay attention to that in the case of the curtain air bag only the air bag at the side of collision deploys ...

Page 598: ...side STICS 40 ms after receiving the air bag deployment signal at the vehicle speed 3 km h or higher it sends out the door UNLOCK signal for 5 seconds Inflator Gas guide Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner 1 LOCATIONS AND RELATED COMPONENTS Curtain air bag DAB Driver Air Bag ...

Page 599: ... driver s and passenger s air bags and or the driver s and passenger s seat belt retensioners When the front collision G sensor sends out only the air bag deployment signal the signal deploys the two front air bags and ctivates their seat belt pretensioners LH RH Connector Inflator Gas guide Curtain air bag Gas guide Inflator Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner ...

Page 600: ...ON PROCESS The overall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyoung Motors 1 Air Bag System Block Diagram Functions and Roles Included ...

Page 601: ...02 7 AIR BAG ACTYON 2010 01 8810 03 ...

Page 602: ... from vehicle collision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver Rear View 1 Components Air bag cover Air bag housing Air bag cushion approx 50 liters Inflator approx 190 Kpa ...

Page 603: ...e to operate together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and inflates the air bag cushions curtain air bags independently operate in case of the side collisions Rear View Front Vi...

Page 604: ...ic of the curtain air bag is slightly different from the one of the front air bag including pretensioner but it is the same as the conventional side air bag A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B pillar The signal is transmitted to the air bag unit The air bag unit instantly inflates the necessary air bag necessary by sendin...

Page 605: ...02 11 AIR BAG ACTYON 2010 01 8810 03 1 Components ...

Page 606: ...the front air bags deploy When a collision occurs or when brakes are applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat Belt Pretensioner Driver Side Belt Pretensioner Passenger Side 35 55 Nm Belt pretensioner LH Curtain air bag G sensor Belt pretensioner RH ...

Page 607: ...tensioner reel assembly Reel bracket Ring upper stay D ring Bending tongue Tongue stopper Mini anchor D bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D bolt Label D bolt Spacer Bush Mini anchor cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 608: ...CTYON 2010 01 8810 03 AIR BAG 5 Air Bag Unit Air Bag Unit Connector The sensor that detects collision is integrated into the air bag unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 609: ...s seats that is around the pretensioner reel The body panel has guiding holes to ensure its correct installation But incorrect tightening torque may break the sensor or make it insecure As a result the sensor may have inaccurate judgment and have the air bag deployed inaccurately Connector Driver s Side Passenger s Side 9 Nm 1 Nm Signal terminal Ground ...

Page 610: ...ch fires the detonator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for firing Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag re...

Page 611: ...ned off in the middle of the unlock signal being sent out the unlock signal continues for the remaining time This function cancels when the ignition key is withdrawn 1 2 3 4 Reminder for door lock unlock control The unlock function by the air bag signal takes priority over any other lock unlock operations While or after the automatic unlock is made by the air bag system any lock or unlock request ...

Page 612: ...lashing it six times the air bag warning lamp will turn off if no malfunction have been detected 2 When the Air Bag Unit Detects Any Malfunctions in Unit 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 3 When the Air Bag Unit Receives Any Malfunction Sig...

Page 613: ...02 19 AIR BAG ACTYON 2010 01 8810 03 10 Electrical Wiring Diagram ...

Page 614: ...ESS 1 Front Seat 1 COMPOSITION OF SEAT 1 Driver Seat Reclining Motor Seat Cushion Rear Area Up Down Motor Seat Cushion Front Area Up Down Motor Lumbar Support Lever Seat cushion rear area up down bar Sliding rail Seat cushion front area up down bar Sliding motor Sliding rail ...

Page 615: ...03 4 ACTYON 2010 01 7410 01 SEAT 2 Passenger Seat Reclining Motor Power Seat Switch Sliding rail Sliding rail Sliding motor Reclining Switch Sliding lever No seat height control function ...

Page 616: ...n moves up or down 2 Seat Cushion Angle Adjustment When moving the front side of the seat cushion switch up or down the front side of the seat cushion moves up or down When moving the rear side of the switch up or down the rear side of the seat cushion moves up or down 3 Seatback Reclining Adjustment When moving the upper side of the reclining switch forward or rearward the seatback moves forward ...

Page 617: ...e headrest pull it up without pressing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down To change the seatback angle push the lever rearward Then release the lever at the desired position The seat is locked at the position Seatback Reclining Lever Seatback Reclining Lever ...

Page 618: ...rotect occupant s face and chest when a strong frontal collision occurs Seat Belt in Front Seats 3 point type Seat Belt in Rear Seat 3 Point Type LH RH Seat Belt in Rear Seat 2 3Point Type Center Seat Belt Seat belt anchor Seat belt height adjustment lever Seat belt D ring Pre tensioner Seat belt anchor Seat Belt Seat belt D ring Buckle of 3 point type seat belt Buckle of 2 point type seat belt Bu...

Page 619: ...UNROOF ACTYON 2010 01 7340 01 7340 01 SUNROOF OVERVIEW AND OPERATION PROCESS 1 COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Front Drain Hose Rear Drain Hose ...

Page 620: ...itch clockwise OPEN direction for less than 0 5 seconds the sunroof slides back and opens until it reaches at the 1st stop position 330 mm Then if you continue to rotate the switch to its stop the sunroof is fully opened 420 mm To stop the operation while moving operate the sunroof switch to any direction 2 Close To fully close the sunroof briefly for approx 0 5 sec rotate the sunroof switch count...

Page 621: ... operation and the sunroof goes back to the original position However if the force against the sunroof is less than the specified value or the continuous resistance is detected the Anti Trap function doesn t operate Therefore make sure that there is no obstacle such as hand head or part of body before operating the sunroof 4 Hazard Manual Operation The sunroof can be operated by rotating the screw...

Page 622: ...04 6 ACTYON 2010 01 7340 01 SUNROOF 6 Circuit Diagram of Sunroof ...

Page 623: ...RATION PROCESS 1 LOCATIONS Instrument Panel Instrument Lower Panel Driver Side Glove Box and Instrument Lower Panel Passenger Side Sun Visor A Pillar B Pillar D Pillar C Pillar Quarter Panel Instrument Panel Assembly C Pillar D Pillar and Rear Quarter Panel Center Console Assembly ...

Page 624: ...05 3 BODY INTERIOR ACTYON 2010 01 7610 01 Interior Room Lamp Sun Visor Front Room Lamp A Pillar B Pillar Door Trim Front Door Rear Door Trim Headlining Assembly Roof Wiring Rear Washer Hose ...

Page 625: ...VIEW AND OPERATION PROCESS 1 COMPOSITION OF BODY EXTERIOR Hood Assembly Sunroof Assembly Front Door Assembly Front Bumper Assembly Cover Front end member lower Energy absorber Front bumper Front bumper fascia assembly Headlamp Front extension cover Front Fender Assembly ...

Page 626: ...XTERIOR Rear Door Assembly Tailgate Assembly Rear Bumper Assembly Side sill garnish Fog light type Dummy type Fog light type Rear bumper fascia assembly Rear bumper garnish Energy absorber Rear bumper Rear bumper beam Rear upper bracket ...

Page 627: ...07 3 BODY REPAIR ACTYON 2010 01 4110 01 4110 01 BODY REPAIR GENERAL 1 DIMENSIONS ...

Page 628: ...07 4 ACTYON 2010 01 4110 01 BODY REPAIR 2 JACK UP POINTS ...

Page 629: ...Dash Panel and Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision ...

Page 630: ... Body Panel Reinforcement Sealer to the Door Outer Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise BPR sealer to reinforce the body panel and reduce the noise Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 631: ...07 7 BODY REPAIR ACTYON 2010 01 4110 01 4 Applied BPR Body Panel Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise ...

Page 632: ...07 8 ACTYON 2010 01 4110 01 BODY REPAIR 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 633: ......

Page 634: ...OUT AND COMPONENTS This sensor is installed at the front bottom of engine compartment This changes the air source mode by detecting the air pollution and the ambient temperature Manual air conditioner FATCFATC Ambient temperature sensor It changes sun load coming through front windshield into current to input to FATC controller Type Air Conditioner Controller FATC Manual air conditioner ...

Page 635: ... Air conditioner filter Thermo AMP Main wiring connector Power transistor Blower Unit Side Heater Unit Side Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condition to control the air conditioner A sensor that detects coolant temperature and transmits it to engine ECU Condenser Installed i...

Page 636: ...01 4 ACTYON 2010 01 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM 1 Locations of Vents 2 Air Duct ...

Page 637: ...ensor Thermo AMP Power transistor Blower motor Air source door actuator Coolant temperature sensor Air mix door actuator Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Thermo AMP Air mix door actuator Main wire connector Active incar sensor interior temperature sensor and humidity sensor Mode door actuator ...

Page 638: ...rmo AMP Coolant Temperature Sensor Mode Door Actuator Power Transistor Blower Motor Air Conditioner Filter Air Source Door Actuator 3 AIR CONDITIONER MODULE AND SENSORS 1 Locations A C Controller Unit Active incar and humidity sensor Power transistor Blower motor Air mix door actuator ...

Page 639: ...01 7 AIR CONDITIONER ACTYON 2010 01 6810 20 2 Components ...

Page 640: ...01 8 ACTYON 2010 01 6810 20 AIR CONDITIONER 3 PTC Heater and FFH Heater Layout 1 PTC Heater Assembly Layout 2 FFH Heater Assembly Layout ...

Page 641: ...igerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below 20 C Coolant temperature over 115 C For approx 4 seconds after starting the engine When engine speed is below 650 rpm When engine spee...

Page 642: ......

Page 643: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 644: ......

Page 645: ...0 3 ECU GASOLINE ACTYON 2010 01 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 646: ...0 4 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 647: ...0 5 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 648: ...0 6 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 649: ...0 7 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 650: ...0 8 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 651: ...0 9 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 652: ...0 10 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 653: ...0 11 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 654: ...0 12 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 655: ...0 13 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 656: ...0 14 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 657: ...0 15 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 658: ...0 16 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 659: ...0 17 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 660: ...0 18 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 661: ...0 19 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 662: ...0 20 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 663: ...0 21 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 664: ...0 22 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 665: ...0 23 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 666: ...0 24 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 667: ...0 25 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 668: ...0 26 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 669: ...0 27 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 670: ...0 28 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 671: ...0 29 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 672: ...0 30 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 673: ...0 31 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 674: ...0 32 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 675: ...0 33 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 676: ...0 34 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 677: ...0 35 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 678: ...0 36 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 679: ...0 37 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 680: ...0 38 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 681: ...0 39 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 682: ...0 40 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 683: ...0 41 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 684: ...0 42 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 685: ...0 43 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 686: ...0 44 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 687: ...0 45 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 688: ...0 46 ACTYON 2010 01 0000 00 ECU GASOLINE ...

Page 689: ...0 47 ECU GASOLINE ACTYON 2010 01 0000 00 ...

Page 690: ......

Page 691: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 692: ......

Page 693: ...0 3 ECU DIESEL ACTYON 2010 01 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 694: ...0 4 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 695: ...0 5 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 696: ...0 6 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 697: ...0 7 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 698: ...0 8 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 699: ...0 9 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 700: ...0 10 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 701: ...0 11 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 702: ...0 12 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 703: ...0 13 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 704: ...0 14 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 705: ...0 15 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 706: ...0 16 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 707: ...0 17 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 708: ...0 18 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 709: ...0 19 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 710: ...0 20 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 711: ...0 21 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 712: ...0 22 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 713: ...0 23 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 714: ...0 24 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 715: ...0 25 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 716: ...0 26 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 717: ...0 27 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 718: ...0 28 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 719: ...0 29 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 720: ...0 30 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 721: ...0 31 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 722: ...0 32 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 723: ...0 33 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 724: ...0 34 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 725: ...0 35 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 726: ...0 36 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 727: ...0 37 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 728: ...0 38 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 729: ...0 39 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 730: ...0 40 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 731: ...0 41 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 732: ...0 42 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 733: ...0 43 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 734: ...0 44 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 735: ...0 45 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 736: ...0 46 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 737: ...0 47 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 738: ...0 48 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 739: ...0 49 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 740: ...0 50 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 741: ...0 51 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 742: ...0 52 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 743: ...0 53 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 744: ...0 54 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 745: ...0 55 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 746: ...0 56 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 747: ...0 57 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 748: ...0 58 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 749: ...0 59 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 750: ...0 60 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 751: ...0 61 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 752: ...0 62 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 753: ...0 63 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 754: ...0 64 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 755: ...0 65 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 756: ...0 66 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 757: ...0 67 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 758: ...0 68 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 759: ...0 69 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 760: ...0 70 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 761: ...0 71 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 762: ...0 72 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 763: ...0 73 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 764: ...0 74 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 765: ...0 75 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 766: ...0 76 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 767: ...0 77 ECU DIESEL ACTYON 2010 01 0000 00 ...

Page 768: ...0 78 ACTYON 2010 01 0000 00 ECU DIESEL ...

Page 769: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 770: ......

Page 771: ...0 3 BRAKE ACTYON 2010 01 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 772: ...0 4 ACTYON 2010 01 0000 00 BRAKE ...

Page 773: ...0 5 BRAKE ACTYON 2010 01 0000 00 ...

Page 774: ...0 6 ACTYON 2010 01 0000 00 BRAKE ...

Page 775: ...0 7 BRAKE ACTYON 2010 01 0000 00 ...

Page 776: ...0 8 ACTYON 2010 01 0000 00 BRAKE ...

Page 777: ...0 9 BRAKE ACTYON 2010 01 0000 00 ...

Page 778: ...0 10 ACTYON 2010 01 0000 00 BRAKE ...

Page 779: ...0 11 BRAKE ACTYON 2010 01 0000 00 ...

Page 780: ...0 12 ACTYON 2010 01 0000 00 BRAKE ...

Page 781: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 782: ......

Page 783: ...0 3 AIR BAG ACTYON 2010 01 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 784: ...0 4 ACTYON 2010 01 0000 00 AIR BAG ...

Page 785: ...0 5 AIR BAG ACTYON 2010 01 0000 00 ...

Page 786: ...0 6 ACTYON 2010 01 0000 00 AIR BAG ...

Page 787: ...0 7 AIR BAG ACTYON 2010 01 0000 00 ...

Page 788: ...0 8 ACTYON 2010 01 0000 00 AIR BAG ...

Page 789: ...0 9 AIR BAG ACTYON 2010 01 0000 00 ...

Page 790: ...0 10 ACTYON 2010 01 0000 00 AIR BAG ...

Page 791: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 792: ......

Page 793: ...0 3 CCCS ACTYON 2010 01 0000 00 0000 00 CCCS 1 CCCS ...

Page 794: ...0 4 ACTYON 2010 01 0000 00 CCCS ...

Page 795: ...0 5 CCCS ACTYON 2010 01 0000 00 ...

Page 796: ...0 6 ACTYON 2010 01 0000 00 CCCS ...

Page 797: ...0 7 CCCS ACTYON 2010 01 0000 00 ...

Page 798: ...0 8 ACTYON 2010 01 0000 00 CCCS ...

Page 799: ...0 9 CCCS ACTYON 2010 01 0000 00 ...

Page 800: ...0 10 ACTYON 2010 01 0000 00 CCCS ...

Page 801: ...0 11 CCCS ACTYON 2010 01 0000 00 ...

Page 802: ...0 12 ACTYON 2010 01 0000 00 CCCS ...

Page 803: ...0 13 CCCS ACTYON 2010 01 0000 00 ...

Page 804: ...0 14 ACTYON 2010 01 0000 00 CCCS ...

Page 805: ...0 15 CCCS ACTYON 2010 01 0000 00 ...

Page 806: ...0 16 ACTYON 2010 01 0000 00 CCCS ...

Page 807: ...0 17 CCCS ACTYON 2010 01 0000 00 ...

Page 808: ...0 18 ACTYON 2010 01 0000 00 CCCS ...

Page 809: ...0 19 CCCS ACTYON 2010 01 0000 00 ...

Page 810: ...0 20 ACTYON 2010 01 0000 00 CCCS ...

Page 811: ...0 21 CCCS ACTYON 2010 01 0000 00 ...

Page 812: ...0 22 ACTYON 2010 01 0000 00 CCCS ...

Page 813: ...0 23 CCCS ACTYON 2010 01 0000 00 ...

Page 814: ...0 24 ACTYON 2010 01 0000 00 CCCS ...

Page 815: ...0 25 CCCS ACTYON 2010 01 0000 00 ...

Page 816: ...0 26 ACTYON 2010 01 0000 00 CCCS ...

Page 817: ...0 27 CCCS ACTYON 2010 01 0000 00 ...

Page 818: ......

Page 819: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 820: ......

Page 821: ...ATC 1 SELF DIAGNOSIS 1 Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds Check LED segments on the vacuum fluorescent display VFD Press OFF switch more than 5 seconds ...

Page 822: ...he digit 2 is displayed implying step 2 on the display window and the trouble diagnosis for sensors is executed If no failure exists 20 is displayed If any failure exists the appropriate trouble code is displayed as below Trouble Code The symbol in front of step number 2 means a short circuit of the blinking sensor Short circuit in the ambient air temperature sensor ...

Page 823: ...EMP dial to the right to set in the trouble diagnosis step 3 Indication of Step 2 Starting self diagnosis Sensor failure code blinking 30 no failure Trouble Code 4 Set in Trouble Diagnosis Step 4 In this step check the position of actuator door check the fan speed and check the compressor operation Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window When pressing DE...

Page 824: ...mbient air temperature Interior air temperature Intake air temperature Press Press Press 6 Set in Trouble Diagnosis Step 6 In this step the temperature can be compensated within the range of 3 C to 3 C in the control process according to the temperature to air conditioner controller The step 6 initiates when slightly rotating the fan speed switch other than TEMP switch in step 5 Step 6 Min tempera...

Page 825: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 826: ......

Page 827: ...0 3 FFH ACTYON 2010 01 0000 00 0000 00 FFH 1 FFH ...

Page 828: ...0 4 ACTYON 2010 01 0000 00 FFH ...

Page 829: ...0 5 FFH ACTYON 2010 01 0000 00 ...

Page 830: ...0 6 ACTYON 2010 01 0000 00 FFH ...

Page 831: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 832: ......

Page 833: ...0 3 P TRUNK ACTYON 2010 01 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 834: ...0 4 ACTYON 2010 01 0000 00 P TRUNK ...

Page 835: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 836: ......

Page 837: ...erminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symptom 3...

Page 838: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 839: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 840: ......

Page 841: ...0 3 STICS ACTYON 2010 01 0000 00 0000 00 STICS 1 STICS ...

Page 842: ...0 4 ACTYON 2010 01 0000 00 STICS ...

Page 843: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 844: ......

Page 845: ...0 3 TC ACTYON 2010 01 0000 00 0000 00 TC 1 TC ...

Page 846: ...0 4 ACTYON 2010 01 0000 00 TC ...

Page 847: ...0 5 TC ACTYON 2010 01 0000 00 ...

Page 848: ...0 6 ACTYON 2010 01 0000 00 TC ...

Page 849: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 850: ......

Page 851: ...0 3 TCU ACTYON 2010 01 0000 00 0000 00 TCU 1 TCU ...

Page 852: ...0 4 ACTYON 2010 01 0000 00 TCU ...

Page 853: ...0 5 TCU ACTYON 2010 01 0000 00 ...

Page 854: ...0 6 ACTYON 2010 01 0000 00 TCU ...

Page 855: ...0 7 TCU ACTYON 2010 01 0000 00 ...

Page 856: ...0 8 ACTYON 2010 01 0000 00 TCU ...

Page 857: ...0 9 TCU ACTYON 2010 01 0000 00 ...

Page 858: ...0 10 ACTYON 2010 01 0000 00 TCU ...

Page 859: ...0 11 TCU ACTYON 2010 01 0000 00 ...

Page 860: ...0 12 ACTYON 2010 01 0000 00 TCU ...

Page 861: ...0 13 TCU ACTYON 2010 01 0000 00 ...

Page 862: ...0 14 ACTYON 2010 01 0000 00 TCU ...

Page 863: ...0 15 TCU ACTYON 2010 01 0000 00 ...

Page 864: ...0 16 ACTYON 2010 01 0000 00 TCU ...

Page 865: ...0 17 TCU ACTYON 2010 01 0000 00 ...

Page 866: ...0 18 ACTYON 2010 01 0000 00 TCU ...

Page 867: ...0 19 TCU ACTYON 2010 01 0000 00 ...

Page 868: ......

Page 869: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 870: ......

Page 871: ...0 3 TGS LEVER ACTYON 2010 01 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 872: ...0 4 ACTYON 2010 01 0000 00 TGS LEVER ...

Page 873: ...0 5 TGS LEVER ACTYON 2010 01 0000 00 ...

Page 874: ...0 6 ACTYON 2010 01 0000 00 TGS LEVER ...