SSANGYONG Korando 2012, Manual

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Page 96: ...MODIFIED ITEMS 1 EXTERIOR 2 INTERIOR 3 CHASSIS 2 4 6 ...

Page 97: ...01 2 Rear view Front view 1 EXTERIOR Old New Old New Old New Old New 7840 20 Rear glass Deleted the solar glass option 7910 01 Radiator grille Chrome plated ...

Page 98: ...iper arm blade Changed the blade design and arm pressure size is same with old version Arm pressure driver s 900 50g Front passenger s 600 50g Arm pressure driver s 950 50g Front passenger s 650 50g Old New Side view Old New ...

Page 99: ...ng indicator Rearranged warning lamps and indicators Added winter mode operating message 4610 01 Steering wheel heating system Added the heated wire and heating unit in the steering wheel 2 INTERIOR 6810 20 Manual type A C control Added the connector for ambient temperature sensor Old New Old New Added the connector Old New Steering wheel heating unit Smart key STD SVC ...

Page 100: ...k pocket 7752 04 Luggage compartment cover Added the lid hanger and changed the handle type Old New 8510 00 Lower switch cluster Added the steering wheel heating switch in the switch cluster Old New Lid hanger Steering wheel heating switch Old Hook Leather seat Fabric seat New 8710 01 BCM Changed the ESS Emergency Stop Signal logic Changed the SBR Seat Belt Reminder logic ...

Page 101: ... heating system 8910 02 Gear shift cable assembly M T Changed the connection and socket to the gear shift lever 3710 01 Gear shift lever M T Changed the gear shift lever bracket 8810 00 Contact coil Changed the contact coil design according to the newly adopted steering wheel heating system 3 CHASSIS Old New Old New Old New Old New Gear shift lever bracket ...

Page 102: ...GENERAL INSTRUCTIONS 1 GUIDELINES FOR SERVICE WORKS 2 JACK UP POINTS 3 STANDARD BOLTS SPECIFICATIONS 4 CODING AND SETUP SPECIAL SERVICE TOOLS 1 SPECIAL SERVICE TOOLS 2 NORMAL EQUIPMENTS 0000 00 SET UP THE ENGINE SUPPORT HANGER 3 4 6 11 12 13 14 23 26 ...

Page 103: ......

Page 104: ...01 3 0000 00 1 LAYOUT Right side view Left side view Rear view Front view ...

Page 105: ... pulley Water pump pulley Alternator pulley Idler pulley No 1 A C compressor pulley Auto tensioner Idler pulley No 2 Isolation damper Rear View E EGR valve Fuel temperature sensor Coolant temperature sensor Fuel HP pump assembly Crankshaft position sensor IMV valve Magnetic triggering Crankshaft position sensor ...

Page 106: ...E VGT turbocharger Post CDPF pressure port Oil drain plug Left side View Thermostat assembly Knock sensor 1 connector Variable swirl valve assembly Oil cooler assembly E EGR valve Knock sensor 2 connector E EGR solenoid valve EGR cooler Electronic throttle body T MAP sensor Oil level switch Front exhaust gas temperature sensor ...

Page 107: ... hazardous situation which if not avoided may result in minor or moderate injury or property damage However above references and cautions cannot be inclusive measures so should have habits of paying attentions and cautions based on common senses indicates information to assist maintenance and instructions 2 Equipment Korando is FF Front Engine Front Drive type vehicle and engine and powertrain sys...

Page 108: ...asher and self locking nut Replace them with new ones If reused normal functions cannot be maintained Store the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or mix the fasteners If necessary especially for inspection clean the removed parts completely Apply the oil or grease on the running and sliding surfeces before installation Use the spec...

Page 109: ...xhaust system including catalytic converter Inspect all the components and body frame near the exhaust system 4 Tires Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads may indicates the uneven tire inflation pressure or poor wheel balance 5 Steering and suspension system Inspect the front and rear suspension and the steering system for damage ...

Page 110: ...l the inlets with the plugs before removing the engine All the interference should be eliminated before removing the engine 3 Electric devices To prevent any damage to electric systems make sure to disconnect the negative cable from the battery and place the ignition switch to OFF position before servicing Use only the specified parts with same ratings when replacing the electric devices Check the...

Page 111: ...DI engine s fuel system there can be serious damages between 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 When working on the fuel line between priming pump and injector including return line always plug the openings with caps to p...

Page 112: ... UP POINTS Stand jack up points and installation status front side Jack up points for 2 post lift Jack up points for 2 post lift Supporting Jack up points and setup rear side Supporting Jack up points and setup front side ...

Page 113: ...uring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ...

Page 114: ...01 13 0000 00 4 CODING AND SETUP 1 Engine Variant Coding ...

Page 115: ...r T99410010A Name Belt tension adjuster Use to release tension without removing belt when replacing pulley or pump How to use on engine Part number T9911 0010A Name Flywheel fixing device Use to fix flywheel or drive shaft to prevent engine from rotating when removing crankshaft pulley ...

Page 116: ...rt Number Special tool Use Part number T99180010A Name EURO V injector remover Components of Injector Remover No Name Quantity Component 1 Injector remover set 1 2 Main bar 1 3 Cross bar 2 4 Main bolt holder 1 5 Ball bearing 1 ...

Page 117: ...1 16 No Name Quantity Component 6 Main nut A 1 7 Main bolt A 1 8 Injector holder A 1 9 Injector holder B 1 10 Injector holder cover 1 11 Bar holder assembly 2 12 Support mounting bolt 4 13 Main support 4 ...

Page 118: ...r bar holder assembly for Euro V Temporarily assemble the main bars A and cross bar B with the bar holder assembly C Assemble the main supports D and cross bar B and temporarily tighten the bolts E Install the sub supports F at the main supports 1 2 3 ...

Page 119: ...injector to be removed 1 Install the injector holder A Tighten the main bolt Install the injector holder B A B C Pay particular attention not to damage the injector return nozzle and thread of injector during setting up the injector holder A B C Secure the injector holder by inserting the injector holder cover on the main bolt 2 ...

Page 120: ...mpletely 2 Install the main bolt holder 3 Pay attention not to damage the other components when installing the main bar assembly Before setting up the injector remover check if the cylinder head bolts have been tightened with the specified tightening torque The sub supports should be positioned on the cylinder head cover bolts Align the slot on main bolt with the main bolt holder tab ...

Page 121: ...se with a torque wrench and socket 32 mm 6 Release the other injector on same clamp with same manner and remove two injectors with the clamp 7 To avoid any damage to cylinder head and head cover keep the specified tightening torque To avoid the damage to injector and engine the lifting should be below 15 mm Maximum lifting 15 mm ...

Page 122: ...Y9922 082B W9911 0230A Y9922 018 Name Valve spring complete Use Used to compress the valve spring Y9922 082B W99110230A Part number Y9922 018 Name Remover Use to remove the valve stem seal Part number Y9922 008 Name Installer Use to install the valve stem seal ...

Page 123: ...922 012 Name Dial gauge Use Used to measure the protrusion of piston Part number Y9922 0172B Name Piston install guide Use Used to slide the piston into cylinder Part number W9911 0120A Name Inserting guide Use Used to install the rear crankshaft oil seal ...

Page 124: ...when lowering engine and transmission mounted to sub frame at the same time replacing manual transmission Name Engine stand 1 tone or more Use Used to fix the removed engine or engine and transmission transaxle and can support at least 1 tone Name Engine crane 1 tone or more Use Used to move engine module including transaxle to working space or engine stand and can support at least 1 tonne ...

Page 125: ...t it from dropping when removing engine mounting RH insulator or sub frame Name Oil pan gasket remover Use Used to separate oil pan and minimize damage when removing oil pan Name Torque angle gauge Use Used to angle tighten correctly after torque tightening Name Fuel sender cover remover installer ...

Page 126: ...e Part number Tool How to use Name High pressure pump gear nut remover Use to remove install the high pressure pump sprocket Name Adapter gauge Use to measure the compression pressure by inserting it into glow plug hole ...

Page 127: ...01 26 Unscrew three screw rivets on each fender cover and remove both fender covers 1 Disconnect the negatice cable from the battery Disconnect the negative cable from the battery ...

Page 128: ...01 27 0000 00 Secure the hanger legs by turning the lever to arrow direction 3 Place the engine support hanger on the fender 2 ...

Page 129: ...t hangers with the engine hanger brackets 7 Chain up the rear engine hanger bracket 5 Engage it with the front hanger bracket directly However to avoid the interference between hanger hook and cowl engage the hook with the chain on rear hanger bracket Rear hanger bracket Front hanger bracket Long hanger hook Short hanger hook Chain Make sure that the hanger hook is out of contact with the rear cow...

Page 130: ...01 29 0000 00 Make the chain tight by turning the hook level adjusting lever to arrow direction 8 Remove the engine support hanger in the reverse order of installation 9 ...

Page 131: ......

Page 132: ... 2nd 링 엔드 갭 0 35 to 0 50mm 3rd 링 엔드 갭 0 2 to 0 40mm 옵셋 off set 0 3mm 헤드 가스켓 피스톤 돌출량 0 475 0 540 1 2t 0 541 0 649 1 3t 0 650 0 745 1 4t 1 SPECIFICATION Unit Description Cylinder head Height Flatness Valve protrusion Intake Valve Exhaust Valve Flatness on manifold side Intake manifold 0 08mm Exhaust manifold 0 08mm Mass balance shaft MBU Backlash Connecting rod End play Camshaft Axial end play Intak...

Page 133: ...1 200 20Nm 180 20 660 720Nm Not re usable Oil pan M6 20 18 10 1Nm M6 35 2 10 1Nm M6 85 2 10 1Nm M6 120 2 10 1Nm M8 40 2 25 2 5Nm HP pump main nut M14 1 5 8 1 1 650 5Nm HP pump mounting bolt M8 55 3 25 2 5Nm Cylinder head M13 150 12 85Nm 270 10 Camshaft cap M6 30 16 10 1Nm M8 60 4 25 2 5Nm Exhaust stud bolt 10 15 1 5Nm Exhaust sprocket bolt M11 40 1 30 3Nm Chain tensioner screw plug M38 1 5 1 25 2 ...

Page 134: ... 17 2 0Nm T C oil return pipe M6 16 turbo side 2 10 1Nm M6 16 block side 2 10 1Nm EGR valve M8 22 3 25 2 5Nm EGR pipe bolt Intake side M6 25 2 10 1Nm EGR pipe bolt EGR cooler side M8 16 2 25 2 5Nm Component Size Quantity Tightening torque Nm Remark Total torque Hot water inlet pipe M6 12 2 10 1Nm Alternator M10 90 1 25 2 5Nm Lower M10 116 1 46 4 6Nm Upper A C compressor M8 85 4 25 2 5Nm A C bracke...

Page 135: ... position sensor M5 14 1 8 0 4Nm Main wiring M6 16 5 10 1Nm Intake duct M8x25 3 25 2 5Nm Power steering pump M8 100 3 25 2 5Nm Mass balance shaft MBU M8 45 6 30 3Nm Cylinder head front cover M6 10 5 10 1Nm 품명 규격 볼트 수량 규정토오크 Nm 비고 총 토오크 Timing gear case cover M6 40 7 10 1Nm M6 45 1 10 1Nm M6 50 3 10 1Nm Cylinder head cover M6 35 21 10 1Nm Component Size Quantity Tightening torque Nm Remark Total to...

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Page 137: ...02 8 ...

Page 138: ...02 9 0000 00 ...

Page 139: ...02 10 ...

Page 140: ...tools and persons are keeping away from moving components of engine e g belt and cooling fan Park the vehicle on the level ground and apply the parking brake Do not allow anybody to be in front of the vehicle 2 Cylinder pressure leakage test If the measured value of the compression pressure test is not within the specifications perform the cylinder pressure leakage test Specified value Perform thi...

Page 141: ...02 12 Position the piston at TDC and measure the piston protrusion from crank case mating surface 3 Piston protrusion check Specified value 0 475 to 0 745mm Measure it at both ends of crankshaft ...

Page 142: ... valve 0 6 to 1 0 mm Exhaust valve Measure the cylinder head height A 1 If the height is less than the limit the cylinder head must be replaced Insert the valves into the valve guides and measure the recesses 2 If the measured value is out of the specified range machine the valve seat as much as necessary until the specified value is achieved Valve recess a 0 6 to 1 0 mm 2 Cylinder head pressure L...

Page 143: ...ning and aligning work areas Do not allow the foreign material get into the fuel injection system When removing the engine use only the safety hook on engine and engine hanger Do not support the bottom of oil pan with a jack Engine and accessories Completely drain the engine oil coolant and fuel from engine before removal Before disassembling assembling the engine components carefully read the wor...

Page 144: ...m Do not allow the fluid and engine oil to make contact with the body paintwork and hoses If work on the fluid system such as fuel and oil working area should be well ventilated and smoking should be prohibited Gasket or seal on the fuel lubrication system should be replaced with new ones and bolts and nuts should be tightened as specified After removal installation works be sure to check whether ...

Page 145: ...omponents on the oil filter housing as FEAD Front End Accessories Drive type Components HPS EPS 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pulley 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 NO 1 idler pulley 9 NO 2 idler pulley 10 Power steering pump with HPS hydraulic power steering ...

Page 146: ...m pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid This pump is single vane type and displacement is 210 cc rev The lubrication oil is supplied through the hole in hollow shaft Components Vacuum pump Pump capacity 210 cc rev Speed 375 to 3 000 rpm Lubrication temperature 40 to 155 C Oil 5W30 Drive type Driven by exhaust Camshaft sprocket Brake booster ...

Page 147: ...dy side member Location Front mounting Rear mounting assembly Location Rear side of transfer axle housing and front side of sub frame Location Front mounting 3 ENGINE MOUNTINGS D20DTF engine mounting is 4 point mounting type and supports the engine and transaxle Front and rear mountings are rubber type and support the torque reaction Left and right mountings support the power train rods and torque...

Page 148: ...ariable swirl valve is introduced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas 2 Exhaust Manifold Exhaust manifold is installed on the cylinder head with 10 stud bolts and nuts EGR port is integrated in cylinder head Components Intake manifold Exhaust manifold Components ...

Page 149: ...LINDER HEAD COVER AND OIL SEPARATOR The cylinder head cover is made by high strength plastic to reduce the weight The multi twist type oil separator improves the oil consumption Components Oil separator PCV valve ...

Page 150: ...s cam position sensor vacuum pump intake manifold exhaust manifold and valve assembly Vacuum pump and the high pressure HP pump are driven by Camshaft and valves are install in vertical direction This enables the compact layout in cylinder head assembly ...

Page 151: ...02 22 Vacuum pump drive Intake exhaust Camshafts Camshaft sprocket Finger follower HLA Components Cylinder head Camshaft position sensor HP pump drive gear Cylinder head gasket ...

Page 152: ...es single stage chain drive system Timing chain drives the exhaust side and gear drive the intake side Timing chain is single bush type Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke and lower chain drives oil pump to lubricate the engine And MBU Mass Balance shaft Unit drive gear drives MBU Components Chain lower bush Chain type single bush Chains 60 ...

Page 153: ...02 24 Intake exhaust Camshaft assembly Components Intake Camshaft HP pump drive gear Exhaust Camshaft Connected to vacuum pump ...

Page 154: ...02 25 0000 00 Timing gear cover case TGCC TGCC Oil seal Screw plug ...

Page 155: ...02 26 Mass Balance Unit MBU Fuel HP pump HP pump gear Crankshaft MBU drive gear MBU HP pump drive gear ...

Page 156: ...sor in oil pan monitors the oil level and turns on the oil level warning lamp on the meter cluster when the oil level goes down below the specified value And A C compressor bracket and the oil dipstick tube are mounted on the oil pan Components Oil drain plug Dust cover Oil dipstick tube hole A C compressor bracket Oil level sensor For details refer to Chapter Engine Control ...

Page 157: ...ALANCE SHAFT UNIT MBU The balance shaft in MBU Mass Balance shaft Unit improves the NVH performance by decreasing the unbalanced force Components Crankshaft drive gear Mass balance shaft unit Mass balance shaft unit ...

Page 158: ...e rating of the transmission The friction ring is the weak spot in the system and can wear out if excessive engine torque loads are applied through it The system also has a center support bearing that carries the load between the inner and outer flywheel and is fitted with damper springs to absorb shocks 2 Drive Plate Drive plate receives the power from the start motor when starting the engine Wit...

Page 159: ...LOCK This vehicle is FF driving type and the engine is installed in lateral direction The crankshaft and the cylinder block convert the compression pressure to the rotating energy Components Cylinder block Piston Connecting rod Crankshaft ...

Page 160: ...g capacity 200 cc Heater capacity 250W 13 5V Injector System pressure 1800 bar High pressure fuel pump Type Eccentric cam Plunger type Operating type Gear driven type Normal operating temperature 40 125 Operating pressure 1800 bar Operating temperature 30 120 Low pressure fuel pump Type Vane type Gear ratio pump engine 0 5 1 Pressure 6 bar Fuel tank Capacity 60 L Material Plastic Fuel sender Dual ...

Page 161: ...ystem Wash your hands and do not wear working gloves 1 2 3 Follow the below procedures before starting service works for fuel system If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in this manual At this point thoroughly clean the related area in engine compartment 4 Clean the engine com...

Page 162: ... Once installed the pipes have been deformed according to the force during installation therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to specified tightening torque as well If not the injection point may be deviated from correct position and it may cause engine disorder Plug the removed components with cle...

Page 163: ... Check the installed components again and connect the negative battery cable Start the engine and check the operating status With Scan Tool check if there are current faults and erase the history faults 8 9 ...

Page 164: ...check the low pressure and high pressure fuel systems before removing the components To run the system properly the electric system must be intact but for the DI engine the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device 2 Hydraulic system ...

Page 165: ...njector Excessive injector backleak Occurs when the injector control valve is not sealed due to the entry of the foreign materials Example Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector ...

Page 166: ... pressure flow Faulty fuel supply line or damaged or worn pump causes the lack of flow pressure and flow volume Example Air in fuel supply line Excessive load on fuel supply line 400 mBar Burned out and mechanical worn pump High temperature of fuel supply 85 ...

Page 167: ... high pressure line Tool kit for low pressure line 2 Pre inspection Connections in fuel supply line Fuel level in fuel tank Air in fuel supply line air bubbles in fuel supply line or fuel Fuel leaks from fuel supply line low high pressure line Used the specified Fuel filter contamination ...

Page 168: ...several DTCs are output simultaneously check the electric wiring for open or short circuit Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities Carry out the high pressure fuel system check ...

Page 169: ...03 12 4 Fuel System Check Procedure ...

Page 170: ...sor connector and then IMV connector 1 Connect the pressure tester to the fuel rail pressure sensor connector 2 Crank the engine 2 times for 5 seconds 3 Read the highest pressure value displayed on the tester display If the highest pressure value is 1 050 bar or less refer to the section Fuel System Check Process ...

Page 171: ...n on the tester to check if the message TEST is displayed If the button is pressed again at 4 seconds after starting engine cranking the highest pressure is displayed on the tester 1 2 The fuel rail pressure value can be checked using a diagnostic device ...

Page 172: ... for low pressure test and clean it thoroughly to prevent foreign materials from entering 1 2 Disconnect the key connector for fuel filter connection and connect both connectors to the fuel filter and hose 3 Start the engine and check visually for clogged low pressure fuel system excessive air or air entry If the fuel flow is not sufficient or air is in the fuel repair the leak area 4 5 ...

Page 173: ...nipple of the injector prevent air entry to the low pressure line 2 Disconnect the IMV connector of the high pressure pump and then fuel pressure sensor connector 3 The connector of the injector can be easily contaminated Always keep it clean Crank the engine for 5 seconds Check the flow volume of injector backleak 4 5 If the value is out of the specified range replace the injector Flow volume of ...

Page 174: ...t the hose of the container for measuring backleak to the return nipple of the injector Start the engine again and let the engine idle for 30 seconds Perform backleak test of fuel system with a diagnostic device after 30 seconds 3 4 5 This test consists of 4 cycles and the engine rpm reaches 3 500 rpm for 18 seconds in each cycle Check the amount of backleak collected into the container and confir...

Page 175: ...ld be over 60 C Check the conditions of sensors and components in fuel system with scan tool Perform the diagnostic test as follows 1 2 3 Select the Vehicle Model and go to Diagnosis Mode Select Pressure Leak Test in Fuel System in Diagnosis Menu If the conditions are OK press Start The pressure leak test procedure is performed in 4 cycles The engine speed goes up to 3 500 rpm and down again four ...

Page 176: ...il to the fuel rail for test 3 Disconnect the return hose for HP pump and connect the clear hose and connect its the other end to the return port of the fuel rail for test 4 Connect the digital tester connector to the sensor connector of the fuel rail for test Crank the engine 2 times for 5 seconds after removing the IMV connector and fuel rail pressure sensor connector Read the pressure value dis...

Page 177: ...ed to protect the system It reduces the driving force restricts the engine speed rpm and stops engine operation Refer to Diagnosis section in this manual Engine CHECK Warning Lamp 3 The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or major electronic systems of the engine are not working properly As a result the engine s power output may decrease or the engine may sta...

Page 178: ...ains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The below figure shows the clearance between internal operating elements The core elements of fuel system has very ...

Page 179: ...tem 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 poor lubrication of pump c...

Page 180: ...hich supplies low pressure fuel to the low pressure pump includes high pressure pump high pressure line which connected to the injector and the engine control unit ECU which calculates the accelerator pedal position and controls the overall performance of vehicle based on the input signals from various sensors HP fuel pump Common rail and Injector Fuel filter Priming pump Fuel supply tube Fuel ret...

Page 181: ...injection order Injector C3I Pre injection main injection after injection by signals from ECU Fuel tank Fuel metering by dual sender Supply the fuel in main fuel tank and sub fuel tank through fuel inlet tube 2 SYSTEM LAYOUT AND OPERATION 1 Layout Fuel supply line Fuel return line For sensor and actuator control logic refer to Chapter ENGINE CONTROL ...

Page 182: ...emperature Engine ECU D20DTF Engine control by various signals Fuel filter assembly Supply clean fuel fuel heating water separation by priming pump Accelerator pedal position sensor Detects driver s intention for speed up down High pressure pump Generates the high pressurized fuel and supply it Plunger type HP pump 1 800 bar Vane type transfer pump 6bar ...

Page 183: ...y the injectors according to the injection signals The injection method is the same with the conventional method Fuel return by backleak which operates the needle valve The major difference is that the fuel return line is connected to the fuel filter inlet port not the HP pump venturi The pressure from the high pressure pump is increased to 1 800 bar from 1 600 bar and the pump is now installed to...

Page 184: ...03 27 0000 00 3 Input Output devices ...

Page 185: ...accelerator pedal depressed driver s will by receiving the electrical signals from the accelerator pedal sensor The mass air flow sensor detects the volume of intake air and sends the value to the ECU The major function of the ECU is controlling air fuel ratio to reduce the emission level EGR valve control by detecting instantaneous air flow change with the signals from the mass air flow sensor Al...

Page 186: ...03 29 0000 00 4 Flow Diagram of Fuel Supply System ...

Page 187: ...03 30 5 Circuit Diagram ...

Page 188: ...e conditions GEN Change every 15 000 km But shorten the service interval under severe conditions Air cleaner assembly Weight 1 13 kg Operating temperature 30 100 Capacity 6 5 L Intercooler Core material Aluminum Size 510 x 110 x 70 W x H x T Core size 510 x 110 x 63 W x H x T Tank material Plastic Molding Efficiency 80 Shorten the service interval under severe conditions such as driving on a dusty...

Page 189: ...ing the intake hoses and pipes which were disconnected to check the system or replace the air cleaner If the intake system is free of any faults check the EGR and PCV oil separator connected to the intake system The figure may be different from the actual engine Therefore read thoroughly below before replacing the parts 2 Abnormal Noise Caused by Poor Tightness of Intake System When the DI engine ...

Page 190: ...ke system is an open circuit system Therefore any malfunction may occur due to dust and dirt Most of the connections consist of hoses so the system cannot withstand high temperature and pressure Also it can be deformed or loosened easily because it is a clamp mounting system Thus when checking the engine basic inspections such as tightened status check and visual inspection for hose etc should be ...

Page 191: ...ld the swirl valve and dual type port have been adopted And the improved HFM sensor has been adopted to control the intake air volume more precisely 2 COMPONENTS 1719 02 Swirl control valve Operates variably in accordance with the engine load and rpm For more information refer to Chapter Engine Control 1719 01 Intake manifold Passage for intake air during the operation of variable swirl valve 1719...

Page 192: ...04 7 0000 00 2313 15 HFM Hot Film Air Mass sensor HFM sensor version 6 For more information refer to Chapter Engine Control 2313 01 Air cleaner assembly and resonator ...

Page 193: ...04 8 3 INPUT OUTPUT OF INTAKE SYSTEM ...

Page 194: ...04 9 0000 00 4 OPERATING PROCESS Work Flow ...

Page 195: ...eates the bowl type squish 2 Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizontal ...

Page 196: ...efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl and EGR To reduce Nox it is essential to increase EGR ratio However if EGR ratio is too high the PM also could be very higher And the exhaust gas should be evenly mixed with newly aspired air Otherwise PM and CO are dramat...

Page 197: ...04 12 5 CIRCUIT DIAGRAM ...

Page 198: ...05 3 0000 00 1 TROUBLESHOOTING 1 Work Flow ...

Page 199: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 200: ...exhaust pipe No 3 muffler pipe 1 OVERVIEW This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion 2 COMPONENT Fore details about the CDPF assembly refer to Chapter CDPF System ...

Page 201: ...05 6 3 OPERATING PROCESS 1 Exhaust Gas Flow 2 Input Output Devices ...

Page 202: ...00 1 SPECIFICATION Component Item Specification Turbocharger Max expansion coefficient 5 0 Max turbine speed 215 000 rpm Max temperature of turbine housing 800 Weight 7 2 kg E Actuator Operation duty cycle 300 Hz ...

Page 203: ...nute allowing oil to circulate to the turbocharger after the replacement When the engine is stopped abruptly after driving at high speed the turbocharger continues to rotate in condition where the oil pressure is at 0 In such condition an oil film between the journal bearing and the housing shaft journal section gets broken and this causes abrasion of the journal bearing due to the rapid contact T...

Page 204: ...ust gas opening Problems in turbocharger In case where the oil is smeared on only at the exhaust gas outlet section When problem occurs with the turbocharger it could cause engine power decline excessive discharge of exhaust gas outbreak of abnormal noise and excessive consumption of oil Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and...

Page 205: ...gas energy compared to the time where great amount of air is required during idling conditions of the engine Therefore amount of air in the compressor inlet increases but the turbocharge pressure is not high which makes negative pressure at the compressor section causing the oilleakage within the center housing a b No problem will occur with the turbocharger if above conditions are found in early ...

Page 206: ...erstand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects In case where oil pan oil pipe has been contaminated oil filter is defected and where adhesive of gaskets has been contaminated into the oil line 1 ...

Page 207: ...06 8 Oil Pump Defect Rapid over loaded driving after replacing oil filter and oil and clogging of oil line 2 ...

Page 208: ...06 9 0000 00 Turbine Side Inflow of foreign materials from engine Compressor Side such as air filter muffler and nut 3 ...

Page 209: ...06 10 Defects caused by reasons other than that of the turbocharger 4 ...

Page 210: ...here is possibility of dampness in the areas related with air cleaner and engine or engine block and turbocharger And it could affect the smooth supply of engine oil and discharge Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in connecting area of the duct When the engine rotates or in case where there is change in noise level check for ...

Page 211: ...06 12 2 Work Flow for Troubleshooting ...

Page 212: ...06 13 0000 00 ...

Page 213: ...06 14 ...

Page 214: ...06 15 0000 00 ...

Page 215: ...06 16 ...

Page 216: ...ume efficiency Also the exhaust efficiency improves as the exhaust turbine rotates The turbocharger is often referred to as the exhaust turbine turbocharger The E VGT system installed to the D20DTF engine variably controls the passages of the turbine housing to regulate the flow rate of the exhaust gas The actuator of E VGT is a DC motor actuator E Actuator which controls more quickly and precisel...

Page 217: ... 1 Performance for EURO V Has a faster response time than the conventional vacuum actuator 2 Improved low speed torque high speed power and fuel economy Improved acceleration performance with rapid response time of vane 1 Features Features Benefits Folding and unfolding of the vane is controlled electrically Easy to get low speed air volume Rapid response time Electric control Improved low speed t...

Page 218: ...ne ECU D20DTF E VGT duty control Accelerator pedal position sensor Transfers accelerating demand to ECU Atmospheric pressure RPM signal HFM sensor Improves the engine power Coolant temperature sensor Operates the VGT according to engine warm up For more information about control logic refer to Chapter Engine Control ...

Page 219: ...06 20 3 INPUT OUTPUT DEVICES ...

Page 220: ...s by controlling the turbine as follows 1 How it Works at Low Speed Normal turbocharger cannot get the turbo effect because the amount of exhaust gas is not enough and the flow speed is slow in a low speed zone but VGT allows the flow passage of exhaust to narrow resulting in increasing the flow speed of exhaust gas and running the turbine quickly and powerfully Therefore as VGT can intake more ai...

Page 221: ...dant exhaust gas can deliver a more increased energy to the compressor The output will increase in submission to the increase of intake air volume Control range Turbocharger driving mechanism Control method Effect Improved performance At high speed Expands the flow passage for the exhaust gas by unfolding the vanes The flow rate is increased due to the expanded passage Increased turbine impeller s...

Page 222: ... Taxi patrol service or delivery service extended idling and excessive driving with low speed Unit Description Specification Oil pump Lubrication system Gear pump forced circulation Type Internal gear Capacity 74 L at 4 000 rpm 3 bar Relief pressure 6 3 bar 0 3 bar Oil filter Type Fulle flow Paper element Engine oil Specified oil Quality class Ssangyong genuine engine oil Total Quartz INEO ECS 5W ...

Page 223: ...ficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary 2 Replenishment If the level gets to the lower point open the filler cap on top of the cylinder block and add the genuine oil without exceeding the level of the upper mark Recheck the oil level after 5 minutes Regularly check the engine oil level and add Ssangyong genuine engine oil if ne...

Page 224: ... In other words it creates an oil film on each sliding surface to convert solid friction to liquid friction in order to minimize wear and prevent temperature increasing on the friction part For the D20DTF engine with no oil pressure switch the engine ECU receives the low engine oil level signal from the oil level sensor and communicates with the instrument cluster through the CAN communication to ...

Page 225: ...ng system and some mechanical devices as below System Components Supplementary devices Power steering pump HPS Alternator A C compressor Belt drive Belt tensioner Idle pulley Cooling Water pump Thermostat Cooler housing and Pipes Lubrication Oil filter Oil cooler except coolant pipes ...

Page 226: ...07 7 0000 00 1 Operation Flow 2 OPERATING PROCESS ...

Page 227: ...iston ring on the piston seals the cylinder The oil gets into the clearance in piston ring to secure the sealing for compression pressure and combustion gas 4 Anti corrosion The oil generates the thin film on the surface of components to prevent the material from contacting with air water and corrosive gas 5 Cleaning The oil transfers the residue of material due to friction oxidized substance and ...

Page 228: ...over 68 000kcal h Antifreeze Type Long life coolant Mixing ratio water antifreeze 50 50 Cooling fan module Type Electric Capacity 220W Ø360 150W Ø360 Control type Series low speed Parallel high speed Coolant reservoir Capacity over 2 2L Circulation Closed roof type Pressure cap Screw type 1 4bar Vacuum valve Screw type 1 4bar Thermostat Type Wax pallet type Opening temperature 90 Fully open temper...

Page 229: ...proper coolant mixture ratio Kinked coolant hose Add coolant Check the coolant concentration Anti freeze Repair or replace the hose Defective thermostat Defective water pump Defective radiator Defective auxiliary reservoir or tank cap Replace the thermostat Replace the water pump Replace the radiator Replace the auxiliary reservoir or tank cap Cracks on the cylinder block or cylinder head Clogged ...

Page 230: ... MAX and MIN mark on the coolant reservoir Check the coolant level If the level is below the MIN mark immediately add coolant 1 2 Scalding hot coolant and steam could be blown out under pressure which could cause serious injury Never remove the coolant reservoir cap when the engine and radiator are hot Avoid any direct contact of the coolant to the painted body of the vehicle MAX MIN ...

Page 231: ...n Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank Connect the tester to the tank filler and apply pressure 1 4 bar Check all the coolant hoses pipes and connections for leaks when the pressure of the tester drops and replace or tighten if necessary 2 3 4 3 Thermostat Immerse the thermostat into the water Heat the water and check the valve opening...

Page 232: ...se burns by hot steam or water To open the coolant reservoir cap wrap the cap with a wet towel or thick cloth after the engine is cooled down sufficiently If cool water is added to the heated engine the engine or radiator can be deformed The anti freeze in the coolant can damage the painted surface so avoid the contact of the coolant to the painted body The anti freeze and water should be mixed in...

Page 233: ...e coolant flow to the radiator to maintain the engine temperature 1 SYSTEM DESCRIPTION 1 Overview Coolant reservoir Long life coolant is used Water pump The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine Oil filter module Water pump pulley Impeller vane Sealing ...

Page 234: ...perature and sends the result to the engine ECU Electric fan Circulates the fresh air forcibly to exchange heat with the radiator core fin Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core ...

Page 235: ...08 10 3 System Layout ...

Page 236: ...08 11 0000 00 ...

Page 237: ...ICATION Specification HPS EPS Alternator Crankshaft pulley Alternator Pulley 1 2 94 Normal output idling 2200 rpm 70 120 A 70 140A Regulator voltage 14 6 V Brush Length 12 5 mm Wear limit 7 mm Battery Type MF Capacity 90AH ...

Page 238: ...gear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measur...

Page 239: ...ted battery Replace Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace Defective ground of alternator circuit Repair Charge warning lamp does not go off aft...

Page 240: ...09 6 3 Checking Battery ...

Page 241: ...ixing current load capacity and time and varying voltage Determine battery capacity based on the amount of voltage drop when discharging a fixed load capacity 120 A for 5 seconds Connect the tester to the battery and read the display while applying a load for 5 seconds How to read display Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a batte...

Page 242: ...towing hook 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle whi...

Page 243: ... key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the battery surface using a rubber glove and a clean cloth wetted with soapy water If the charge warning lamp on the instrument cluster comes on while driving there is a malfunction in the charge...

Page 244: ...the electrical energy 1 SYSTEM DESCRIPTION 1 Overview The charge system is designed to supply electrical energy to the vehicle while driving and supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according...

Page 245: ... battery charger to the cold battery the amount of current the battery can accept initially is very small As the battery gets warmer it can accept more current Charging capacity Charging a battery with a low capacity charger takes longer time than charging with a high capacity charger Charging status Charging a fully depleted battery takes twice or more as long as charging a half depleted battery ...

Page 246: ...09 12 2 CHARGING OPERATION 1 With Smart Key System ...

Page 247: ...09 13 0000 00 2 Without SMART Key System ...

Page 248: ...09 14 3 CIRCUIT DIAGRAM ...

Page 249: ...n Specification Glow plug Rated voltage 12 V Operating voltage 6 to 16 V Maximum temperature 1300 C Operating temperature 1100 C Glow plug control unit EMS operating voltage 6 to 16 V Operating temperature 40 C to 110 C Dark current Max 1 mA ...

Page 250: ...10 4 GCU Glow plug Control Unit 2 TIGHTENING TORQUE No Name Tightening torque 1 Glow plug 15 1 5 Nm 2 Glow plug control unit bolt 10 1 0 Nm Glow plug ...

Page 251: ...s used to heat the intake air This enables the diesel fuel to be ignited in low temperature condition The ECU receives the information such as engine rpm coolant temperature engine torque etc through CAN communication during pre heating process and the pre heating control unit controls the pre heating heating during cranking and post heating by the PWM control Glow plug Glow plug control unit GCU ...

Page 252: ...10 6 2 SYSTEM OPERATION 1 Input Output Diagram of Glow Plug Control Unit 2 System Diagram ...

Page 253: ......

Page 254: ...10 8 3 Circuit Diagram ...

Page 255: ...10 9 1413 00 ...

Page 256: ...MS voltage Battery voltage 1 2 3 1 Characteristics of temperature and current in AQGS AQGS unit increases the glow plug temperature very rapidly 1 000 C in 2 seconds FET similar to transistor for each cylinder in AQGS unit pre heats the glow plug If the glow plug temperature reaches to target temperature the temperature is controlled by duty ratio 1 2 3 AQGS PWM Control Actual voltage pattern AQGS...

Page 257: ...y the preheating request from the engine ECU before starting The time for pre heating is controlled by the ECU If the input voltage VB is 11 5 V or less GCU supplies the battery voltage for preheating time T1 If the input voltage VB is greater than 11 5 V GCU supplies the voltage of 11 5 V for preheating time T1 The preheating time may vary according to the conditions Input voltage VB V Pre heatin...

Page 258: ...30 seconds Step 1 Step 3 if no cranking signal is received after the step 1 During cranking The step 3 is started after the step 2 Post glow Step 4 The post heating is for reducing HC CO after the engine is started If the time for post heating exceeds 180 sec the GCU unit cuts off the power to each glow plug even if there is preheating request from the engine ECU Emergency glow If no CAN signal is...

Page 259: ...10 13 1413 00 Normal operating mode This shows the components of preheating system in the pre heating and the post heating steps ...

Page 260: ...10 14 When there is no engine cranking signal after turning the ignition key ON ...

Page 261: ...SPECIFICATION Capacity 12V 2 3kW Engagement Meshed type Rotating direction Clockwise Pinion gear manufacturing Cooled forging Solenoid operating voltage Max 8 V Weight 2 5 kg Bracket manufacturing Aluminum die casting ...

Page 262: ...switch or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replace Loose corroded or damaged battery cable Repair or replace Faulty starter Starter does not stop Faulty starter Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring gear Replace ...

Page 263: ...or starts the engine with rotational power by converting the electric energy to the mechanical energy When the engine is cranking the pinion gear meshes with the ring gear If the ring gear overruns the pinion gear clutch overruns to protect the pinion gear System Configuration ...

Page 264: ... engine immediately if it receives the engine cranking request 2 when pressing the Engine Start Stop button 1 2 3 4 5 6 Engine cranking request 1 when pressing the Engine Start Stop button shortly in normal conditions Engine cranking request 2 when pressing the Engine Start Stop button again after first press or when pressing the Engine Start Stp button for more than 3 seconds Engine start during ...

Page 265: ...11 7 1461 00 2 With SMART key system ...

Page 266: ...11 8 3 Without SMART key system ...

Page 267: ......

Page 268: ...11 10 2 Circuit Diagram 1 With SMART key system ...

Page 269: ...11 11 1461 00 ...

Page 270: ...11 12 2 Without SMART key system ...

Page 271: ...11 13 1461 00 ...

Page 272: ...ust be greater than 38 km h to engage the cruise control This feature is especially useful for motorway driving The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle to vehicle distance meets the legal requirement Auto cruise operated ECO cruise operated ...

Page 273: ...torways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Improper use of the cruise control could be dangerous Do not use on winding roadsyy Do not use in heavy traffic Do not use on slippery wet roads This could result in a loss of control collision and or personal injuries ...

Page 274: ...of cruise control system and monitors the braking performance vehicle speed road conditions and ESP system operation If the engine ECU determines that there are not any problem to drive in cruise control mode the vehicle can be operated by cruise switch signals decelerating accelerating cruising ...

Page 275: ...12 6 2 Components Test voltage VCC 5V FUNCTION KEY VOLUE REMARK MAIN 0 15 0 55V DECEL 0 7 1 1V ACCEL 1 6 2 0V RESUME 2 52 2 92V ECO 4 22 4 82V ...

Page 276: ...km h 150 km h higher than 3rd gear M T To set the desired speed push up ACCEL switch or push down DECEL switch of the cruise control lever when the vehicle speed is in the operating range 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 ...

Page 277: ...e ACCEL switch of the cruise control lever and hold it And then release the accelerator pedal slowly When the desired speed is reached release the lever 1 2 3 3 Tap up while the cruise control system is running To increase the vehicle speed in stages while the cruise control system is running follow the procedures below Push up the ACCEL switch of the cruise control lever less than 0 5 second per ...

Page 278: ...until the desired speed is reached while the vehicle speed is over 40 km h And then release the accelerator pedal slowly When the desired speed is reached release the lever But the cruise control system cannot maintain the cruise function at less than 38 km h 1 2 3 3 Tap down while the cruise control system is running To decrease the vehicle speed in stages while the cruise control system is runni...

Page 279: ...hicle speed is over 38 km h without an acceleration intervention But if you turn off the ignition switch the memorized set speed is cleared and you cannot recover the previous set speed But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle speed properly ...

Page 280: ...and deceleration to improve the fuel economy The ECO cruise system is ready when pushing down the cruise control lever At this moment the ECO indicator on the instrument cluster comes on The ECO cruise system operates when pulling up the cruise control lever To cancel the ECO cruise driving push doen the cruise control lever At this moment the ECO indicator on the instrument cluster goes off and t...

Page 281: ... the cruising speed is downed less than 38 km h When pushing the ON OFF switch of the cruise control lever When ESP is activated When applying the parking brake when driving When using the clutch in order to shift M T only And the cruise control system can be operated again in driving state 1 2 3 4 5 Keep the main cruise control switch in the neutral position when not using the cruise control ...

Page 282: ...rotect the vehicle system and for a safe driving Ensure that the safe distance is maintained and use the brake pedal if needed 1 2 3 4 1 Abnormal Cancellation of the Cruise Control Sharp acceleration or deceleration 50 km h faster than set speed 25 km h faster than set speed for one minute 70 km h slower than set speed 65 km h slower than set speed for 3 minutes When the cruise control lever is fa...

Page 283: ...Item E EGR valve Motor EGR response time 50 mS Driven by DC motor Valve EGR gas flow rate 120 Kg h Position sensor Sensing type Hall sensor Supply voltage 5V 10 Signal range 5 95 Max current consumption 15mA E EGR cooler Cooling capacity 8 3 kW or more Coolin fin type Wavy fin Coller type U shaped ...

Page 284: ...acity reduces the Nox and the bypass valve reduces the CO and HC due to EGR gas before warming up Also the engine ECU adjusts the E EGR opening by using the air mass signal through HFM sensor If the exhaust gas gets into the intake manifold when the EGR valve is open the amount of fresh air through HFM sensor should be decreased Benefits of E EGR valve Improved accuracy and response through electr...

Page 285: ...uxiliary map values EGR pipe Transports the exhaust gas from the EGR cooler and EGR bypass valve to the intake duct E EGR cooler and bypass valve The cooler lowers the high temperature of the exhaust gas and the bypass valve directly supplies the exhaust gas to the intake duct without passing through the EGR cooler to reduce the emission of exhaust gas before warming up the engine E EGR valve Rece...

Page 286: ...13 6 2 OPERATING PROCESS 1 Schematic Diagram ...

Page 287: ...ompensation by the intake air temperature The engine ECU calculates the EGR amount by adding main map value intake air volume and auxiliary map value and directly drives the solenoid valve in the E EGR to regulate the opening extent of the EGR valve and sends the feedback to the potentiometer 1 Operating conditions Intake air temperature between 10 and 50 Atmospheric pressure 0 92 bar or more Engi...

Page 288: ...ssion Regulation Euro V Front Area 182 41cm Size DOC 124 X 158 X 78L DPF 124 X 158 X 194L CDPF Canister Shell SUS430J1L X 1 5t End Cone SUS430J1L X 2 0t Single CDPF Catalyst Capacity 4 2L Material of Filter AT Aluminum Titanium Alloy ...

Page 289: ...turn off the engine while the vehicle is running Do not shift the gear selector lever to neutral when going downhill Do not use improper engine oil or fuel additives Do not drive for a long time when the warning lamp is illuminated Make sure no flammable material such as dry grass or tissue paper contacts with the catalyst filter while the vehicle is parked For the vehicles used in urban traffic d...

Page 290: ...ase the fuel injection volume and control the intake air volume by the throttle body in order to increase the temperature of the exhaust gas The driver may not feel any particular difference from the vehicle If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process the soot is continuously accumulated in the CDPF When this condit...

Page 291: ...sive amount of soot can be accumulated in the CDPF This case is much worse than the simple over load of the CDPF To inform this to the driver the engine warning lamp comes on and the engine power is decreased to protect the system To solve this problem blow soot between the engine and exhaust system several times and erase the related DTC Then check if the same DTC is regenerated again If so check...

Page 292: ...h the oxidation process of CO and HC And the DPF Diesel Particulate Filter collects PM Particle Matter and is regenerated to reduce the quantity of particulates HC and CO But there is a limitation in reducing the emission of exhaust gas for each system so the CDPF which combines these two system is applied ...

Page 293: ...M collected by reading the pressure difference between before and after the CDPF Electric throttle body Regulates the rate of air intake CDPF DOC DPF Front temperature sensor Protects the turbocharger Rear temperature sensor Measures the temperature of fuel combustion 2 COMPONENT Oxygen sensor ...

Page 294: ...emperature exceeds 600 the life of CDPF can be reduced So the amount of fuel post injection is decreased If the temperature drops under 600 the rate of regeneration can be decreased So the amount of fuel post injection is increased Differential pressure sensor This sensor checks the amount of PM collected by calculating the pressure difference between before and after the CDPF Electric throttle va...

Page 295: ...started for regeneration The amount of fuel post injection is controlled by the exhaust gas temperature measured by the rear temperature sensor If the temperature is less than 600 the amount of post injection is increased to increase the regeneration temperature Otherwise the fuel injection amount is decreased or the fuel is not injected When the engine is running with low load the intake air amou...

Page 296: ...lues of before and after the CDPF The pressure difference between before and after the CDPF is measured by the differential pressure sensor If PM is collected in the CDPF the pressure difference between before and after the CDPF exceeds the specified value Rear EGT sensor Measures the temperature of DPF The DPF burns the soot with hot exhaust gases regeneration at around 600 and the rear EGT senso...

Page 297: ...mperature and burns the collected PM at approx 600 C Oxidation DOC When the exhaust gas enters into the CDPF assembly its CO HC and PM are reduced by the redox reaction of the DOC The remaining PM is filtered and collected in CDPF and the temperature of the exhaust gas is increased to between 450 and 500 C 5 OPERATING PROCESS Configuration and principle of operation The exhaust gas passed through ...

Page 298: ...14 13 1114 00 6 OPERATING TEMPERATURE ...

Page 299: ...14 14 7 ELECTRIC CIRCUIT DIAGRAM ...

Page 300: ...ngines diesel and gasoline Problems when using non designated engine oil for CDPF 3 Decreases the life span of engine oil due to accumulated ash in DPF around 30 Decreases the fuel economy due to friction resistance exhaust gas resistance and frequent recycling process of DPF The fule containing high sulfur may cause the same problems 2 Do Not Use the Fuel Containing High Sulfur Producing white sm...

Page 301: ...angle TA 0 Full Open to 78 Close Engine torque Nm varies by engine conditions Injection time ms 3 to 5ms Battery voltage V 13 5 V to 14 1 V Accelerator pedal position 1 V 04 to 4 8V Accelerator pedal position 2 V 0 2 to 2 4 V Throttle position 1 V 0 3 to 4 6 V Throttle position 2 V 0 3 to 4 6 V Oxygen sensor mV 0 to 5 V A C compressor switch 1 ON 0 OFF Full load 1 ON 0 OFF Gear selection A T 1 ON ...

Page 302: ... temp sensor Electronic throttle body T MAP sensor Temp Pres Injector C3I 1 MAJOR COMPONENT Oxygen sensor Front exhaust gas temp sensor Camshaft position sensor Glow plug Variable swirl valve Knock sensor 2 Oil level sensor ...

Page 303: ...15 5 0000 00 HFM air mass temperature Fuel temp sensor GCU Glow plug control unit Differential pres sensor D20DTF ECU Coolant temp sensor IMV E EGR bypass valve E EGR valve Fuel rail pres sensor ...

Page 304: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU 1 ECU Block diagram ...

Page 305: ...sensor Oxygen sensor Exhaust gas temp sensor HFM sensor 2 Components for ECU Input Crankshaft posi sensor Accel pedal posi sensor Throttle posi sensor Knock sensor T MAP sensor Camshaft posi sensor CAN ABS ESP GCU Meter cluster TCU BCM Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal Oil level sensor ...

Page 306: ...EGR cooler bypass valve E VGT actuator IMV Throttle posi sensor Injector A C compressor Start motor Variable swirl valve 3 Components for ECU Input PTC heater CAN Glow plug unit ABS ESP unit BCM E coupling unit EPS GCU Meter cluster SKM TCU Self diagnosis ...

Page 307: ...ectives Operating temperature range of ECU is normally 40 to 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circu...

Page 308: ...ngine 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 according to injected fuel and coolant temperature b Fuel...

Page 309: ...ing 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 310: ...etermined by the ESP system the antagonistic torque engine brake transmitted to the drive wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking The system thus chooses the greater of these 2 values main flow pilot flow in order to prevent any loss of control of the vehicle during a sharp deceleration As soon as the injected fuel becomes high...

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

Page 312: ...d when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of the fault the system activat...

Page 313: ...f 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 difference between these two instantaneous speeds is then calculated Finall...

Page 314: ...er is detected The knock sensor detects the vibration from the engine after a small volume of fuel is injected And the time interval between the points of injection and vibration is measured so that MDP can be learned MDP learning is helpful to prevent engine vibration high emission and power reduction through performing calibration for the old injectors During MDP learning a little vibration and ...

Page 315: ...tablish the background noise level of the accelerometer signal for each cylinder This window must therefore be positioned at a moment when there cannot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection 1 2...

Page 316: ...naled is a percentage of the maximum possible value of the ratio Because of the severity of the recovery process engine shut down the etection must be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too much Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and ...

Page 317: ...erated because the air flow is slow To generate strong swirl there are two passages in intake manifold and one of them has the valve to open and close the passage When the valve closes the passage the air flow through the another passage will be faster and the strong swirl will be generated by the internal structure of the passage This swirl makes the better mixture of air and fuel eventually the ...

Page 318: ...15 20 b Input Output for variable swirl valve ...

Page 319: ...d creates the bowl type squish d Swirl control In DI type diesel engine the liquefied fuel is injected into the cylinder directly If the fuel is evenly distributed in short period the combustion efficiency could be improved To get this there should be good air flow in cylinder In general there are two intake ports swirl port and tangential port in each cylinder The swirl port generates the horizon...

Page 320: ...tion e Features Swirl and air intake efficiency To generate the swirl the intake port should be serpentine design This makes the resistance in air flow The resistance in air flow in engine high speed decreases the intake efficiency Eventually the engine power is also decreased Thus the swirl operation is deactivated in high speed range to increase the intake efficiency Relationship between swirl a...

Page 321: ...o high during strong swirl the injection angles might be overlapped Therefore the system may decreases the fuel injection pressure when the swirl is too strong Anti knock methods Shorten the ignition timing by pilot injection lessen the fuel injection volume during ignition delay period Increase engine speed Maintain intake sir temperature with intercooler or glow plug device Increase intake air p...

Page 322: ...RO 5 regulation The solenoid type actuator is used in the conventional model but in this new model the DC motor type actuator with improved response rate is adopted Also the hall sensor which provides a more stabilized signal than the potentiometer and the EGR bypass flap which improves engine warming up efficiency are also used The HFM sensor and the position sensor are used to feedback the amoun...

Page 323: ...15 25 0000 00 c Input Output of E EGR system ...

Page 324: ...e rpm Used as the signal for determining EGR operating range Coolant temperature When the coolant temperature is low NOx is decreased but PM could be increased So to reduce PM decrease EGR ratio when the coolant temperature is low Intake air mass and temperature HFM sensor measures the intake air mass to calculate the actual EGR volume If the air mass is larger than programmed value in map EGR rat...

Page 325: ...rdingly the concentration of NOx is decreased The point with highest NOx is immediately after TDC As EGR temperature goes up the concentration of NOx will be higher Thus it is necessary to cool down the exhaust gas However during engine cooled it may cause large amount of PM To prevent this the exhaust gas is bypassed the EGR cooler ...

Page 326: ... the passage in turbine housing The newly adopted DC motor actuator E actuator controls the E VGT system more precisely and faster To get the high operating power from turbine the ECU reduces the exhaust gas passage In low speed range and increases it in high speed range b Components E VGT actuator Coolant temperature Front EGT sensor T MAP sensor Crankshaft pos sensor HFM sensor intake air temp E...

Page 327: ...15 29 0000 00 c Input Output for E VGT system ...

Page 328: ...r operation and the boost temperature is used for calculating the precise density E VGT provides higher engine power with faster reaction speed compared to conventional VGT Operating wave Vane Control Low speed range In low speed range retract the vane to increase boost pressure The vane has low duty and the unison ring moves to retract the vane in weak PWM signal High speed range The unison ring ...

Page 329: ...rent from the one that used for gasoline engine The combustion in diesel engine is controlled by fuel injection volume Therefore the wide band oxygen sensor should be used in diesel engine This sensor measures the air fuel ratio in very wide range and is also called full range oxygen sensor The wide band oxygen sensor measures the oxygen density in exhaust gas and sends it to ECU to control the EG...

Page 330: ...15 32 c Input Output for oxygen sensor ...

Page 331: ...en ions when there is oxygen concentration difference between exhaust gas and atmosphere If a certain voltage is applied to the sensor the movement of oxygen ions occurs regardless of the oxygen density The current generated through this flow of ions is called pumping current IP and the oxygen sensor measures this value ...

Page 332: ...tat opens The coolant then goes back to the radiator where it cools The heat from automatic transaxle is also cooled down through the radiator by circulating the oil through the oil pump There are two cooling fans 200W 150W in D20DTF engine ECU controls the electric cooling fans with three cooling fan relays to improve the engine torque and air conditioning performance For details about A C compre...

Page 333: ...15 35 0000 00 c Input Output for cooling fan and A C compressor ...

Page 334: ...8 bar Refrigerant pressure HI 105 Coolant temp 115 HI 115 Coolant temp OFF cut A C compressor OFF conditions Coolant temperature below 20 or over 115 Approx 4 seconds after starting the engine Engine rpm below 650 rpm or over 4500 rpm When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 30 kg then ON below 21 4 kg The output voltage from refrigerant pressure ...

Page 335: ...lant temperature sensor and HFM sensor This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment Because PTC system is heated by electrical power high capacity alternator is required PTC does not operate during engine cranking while the battery voltage is lower than 11 V or during preheating process of glow plugs b Components PTC heater D20DTF...

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

Page 337: ...rature 10 Coolant temperature 15 65 to 60 intake air temperature 10 to 0 Coolant temperature 15 60 intake air temperature 0 to 5 PTC LO ON Stop A C blower switch OFF Defective ambient air temperature sensor including open or short circuit Engine cranking Low battery voltage below 11V During pre glow process glow indicator ON Operation diagram for PTC heater LO step 2 ...

Page 338: ...rized persons The transponder integrated in the key and the engine control unit have the same code When the ignition key with the integrated transponder is turned to the ON position the ECU Engine Control Unit checks the crypto code of the key and if correct allows the vehicle to start the engine For details refer to Chapter BCM b Components Basic components ignition key system Immobilizer key Sta...

Page 339: ...CU ECU communicate with the immobilizer key to check if it is valid crypto code If it is valid ECU start to control the engine when turning the ignition switch to START position The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again ...

Page 340: ...15 42 c Components for immobilizer with Smart key system Components For antenna refer to Chapter SKM Smart key slot Smart key Start motor Meter cluster BCM SKM D20DTF ECU ...

Page 341: ...ot to check if it has valid crypto code If it is valid ECU start to control the engine when pressing the Engine Start Stop button The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again Smart key approval When pressing the Engine Start Stop button or depressing the brake pedal without Smart key inserted into the k...

Page 342: ...er to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC Diesel Oxidation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxidation Catalyst and DPF Diesel Particulate Filter For details refer to Chapter CDPF b Components Rear temp sensor CDPF DOC DPF Throttle valve D20DTF ECU Differenti...

Page 343: ...15 45 0000 00 c Input Output for CDPF control ...

Page 344: ... pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is accumulated and the post injection is performed to raise the temperature of exhaust gas The amount of fuel injected is determined according to the temperature of exhaust gas detected by the rear temperature sensor If the temperature is below 600 C the amount o...

Page 345: ...cumulating Eventually this ashes will block the filter 3 Benefit for specified engine oil Minimized the sulfur content of engine oil which reduces the service life Improved fuel economy and emission level of CO2 with high performance and low viscosity Increased service life of engine oil with high resistance to temperature 4 Problems when using unspecified engine oil The service life of filter may...

Page 346: ...ccording to the communication speed Instrument cluster BCM and diagnostic connector use both types of communication And ECU ABS ESP TCU GCU E coupling and EPS unit use P CAN communication because it is faster than B CAN The terminal resistances are installed in ECU and BCM Abbreviation Function GCU Glow Control Unit EPS Electronic Power Steering Unit BCM Body Control Module ...

Page 347: ...ocation S101 Floor wiring LH Under fuse relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind meter cluster cowl cross member S202 Main wiring Behind meter cluster cowl cross member S205 Floor wiring LH Under driver s door scarf ...

Page 348: ...15 50 3 Input Output for CAN communication ...

Page 349: ... play Intake 0 1 0 35 mm Exhaust 0 1 0 35mm Valve timing Intake valve open BTDC 35 10 Intake valve close ABDC 14 62 Exhaust valve open BBDC 40 40 Exhaust valve close ATDC 12 12 Journal bearing Diameter 24mm Width 17 mm Oil clearance 0 037 0 074 mm Intake exhaust valve Lift of intake valve Max 9 0 mm Lift of exhaust valve Max 8 0 mm Length of intake valve 115 0mm Length of exhaust valve 114 0mm Con...

Page 350: ... Main gallery screw bolt 1 55 5 5 Nm Main bearing cap bolt 10 55 Nm 90 Cylinder head bolt M12X1 75X102 10 55 Nm 180 Cylinder head TGCC side bolt M8 X 1 25 X 30 4 25 2 5 Nm Cylinder head front cover bolt M6 X 1 0 X 25 8 10 1 0 Nm Cylinder head cover bolt M6 X 1 0 X 30 20 10 1 0 Nm Crankshaft center bolt M18 X 1 5 X 50 1 200 20 Nm 90 10 Flywheel bolt M10 X 1 0 X 22 8 45 5 Nm 90 10 Connecting rod bol...

Page 351: ...30 1 25 2 5 Nm Belt tensioner lower bolt M10 X 1 5 X55 1 82 5 Nm Water pump pulley bolt M6 X 1 0 X12 4 10 1 Nm Thermostat bolt M6 X 1 0 X22 3 10 1 Nm Coolant outlet port bolt M6 X 1 0 X22 3 10 1 Nm Coolant pipe mounting bolt M6 X 1 0 X14 3 10 1 Nm Bypass hose clamp M24 2 3 0 5 Nm EPS idler pulley 1 25 2 5 Nm Engine mountinf stud bolt 2 50 5 0 Nm Engine front mounting bolt M10 X 45 3 60 6 0 Nm Engi...

Page 352: ...e stand and engine crane 1 ton To prevent the engine from abruptly starting during service in engine compartment never allow anybody to stay in the vehicle Make sure to disconnect the negative cable from the battery to prevent any damage to electric systems Make sure to clean the working area and to prepare the necessary tools before service works Always place the ignition switch to OFF position i...

Page 353: ...F use the angle tightening as a final step 1 Clean the mating surfaces before tightening 2 Place the marks with paint to tighten by angle if the angle wrench is not available Exhaust system Wear the protective gloves before removing the exhaust pipe The exhaust pipe is very hot immediately after stopping th engine Check if the exhaust pipe is fully cooled down before servicing the exhaust system C...

Page 354: ...Used engine cotains the hazardous material that may cause the skin cancer Do not allow the used engine to make contact with your skin Make sure to wear the protection gloves and goggle when handling the engine oil If contact happens rinse affected areas immediately with plenty of water Do not wash it with gasoline or solvent If irritation persists consult a doctor Improperly disposed engine oil ca...

Page 355: ...elt Overview There are two types of belt system EPS Electric Power Steering and HPS Hydraulic Power Steering In the vehicle with ESP instead of power steering pulley the idle pulley is installed on the engine The belt system is a single belt drive system which uses single V belt with 6 grooves This design provides the long life span and minimizes the belt slip and noise Components With idle pulley...

Page 356: ...spring hydraulic damper lever arm and tension pulley To transfer the tension to the belt from the hydraulic tensioner in small working space in G20DF engine the belt system uses the longer lever arm Overview Location and Components Hydraulic tensioner assembly Components No Name 1 Tensioner pulley cap 2 Tensioner pulley mounting bolt 3 Tensioner pulley 4 Lever arm 5 Hydraulic tensioner bolt 6 Hydr...

Page 357: ...nsioner automatically adjusts the belt tension to provide the reliability and durability for the system And the belt tension is decreased to minimize the friction loss and improve the belt operating noise Overview Location Crankshaft pulley CRS Timing mark ...

Page 358: ...ounting Right mounting assembly Location Engine block side and body side member Location Right mounting Left mounting assembly Location Upper side of transaxle housing and body side member Location Left mounting Rear mounting assembly Location Rear side of transaxle housing and front side of sub frame Location Rear mounting ...

Page 359: ...Bracket Insulator Type Rubber type mounting Function support torque reaction Left mounting Bracket Insulator Type Rubber type mounting Function support power train rod support torque reaction Rear mounting Bracket Insulator and D damper Type Hydraulic type mounting Function support power train rod power train bounce vibration absorber support torque reaction ...

Page 360: ...inder block This contains the combustion chamber intake and exhaust ports valve running housing and oil gallery And this also contains the water jacket to dissipate the heat from the combustion chamber Location Top of cylinder head Bottom of cylinder head Intake side Exhaust side ...

Page 361: ...02 15 1211 01 Closed roof water jacket improving coolimg efficiency Intake side Exhaust side Cylinder head oil gallery ...

Page 362: ...02 16 Components Exhaust camshaft OCV Finger follower HLA Intake camshaft Intake camshaft CVVT gear Camshaft position sensor ...

Page 363: ...thing system with PCV valve for recirculation of blow by gas The blow by gas is induced into the intake manifold through the breather nipple and PCV Valve To improve the sealing performance new bolt pattern is introduced And to prevent the freezing the PCV valve is tilted with 9 to the below direction Location Breather nipple PCV valve ...

Page 364: ...tains the cam octagon cam OCV gallery cam position rotor The camshaft operates the intake and exhaust valves Location Exhaust camshaft Intake camshaft Timing marks Align the timing marks A on the camshaft flange and camshaft cap when installing the intake exhaust camshaft ...

Page 365: ...y introducing the roller type finger follower Valave installation angle 17 Decreased running amount by compact design increased valve following movement in high speed and improved fuel economy by decreased friction loss 2 Layout and components Intake camshaft assembly Exhaust camshaft assembly Valve stem seal Valve upper spring seat Valve guide Hydraulic lash adjuster Exhaust valve assembly Valve ...

Page 366: ...head gasket is installed between cylinder block and cylinder head to seal the combustion gas from the combustion chamber engine oil and coolant Overview Location Cylinder head gasket 3 Layer MLS Gasket Thickness 0 7 mm Compressed PFP Max 85 bar ...

Page 367: ...nd operated by hydraulic pressure and spring in tensioner Chain bush upper Chain type Single bush type Chains 146 ea Tensioner rail Installed between exjaust camshaft sprocket and crankshaft sprocket Crankshaft sprocket Teeth 21 ea Oil pump sprocket Teeth 28 ea Exhaust camshaft sprocket Teeth 42 ea Intake camshaft sprocket CVVT Teeth 42 ea OCV Controls the hydraulic circuit to control the intake c...

Page 368: ...tion Shielding the chain noise Timing gear case cover prevents the oil from leaking The crankshaft front seal and the engine mounting bracket are installed on the timing gear case cover Timing gear case cover Do not touch the inner lip of crankshaft front seal installed on the timing gear case cover ...

Page 369: ...chain tensioner In G20DF engine the hydraulic auto tensioner is used to keep the tension for chain drive system of engine The auto tensioner is operated by the spring in tensioner and the hydraulic pressure 2 Hydraulic Auto Tensioner Oil gallery ...

Page 370: ...02 24 3 Oil Pump Chain Tensioner Layout and Location Oil pump chain tensioner Operated by spring in tensioner Tensioner type Compensating and absorbing the impact Static and dynamic force spring ...

Page 371: ... A Timing chain B Oil pump chain 4 Timing Chain and Gear Timing chain Simple layout provides the optimized timing Decreased chain vibration and noise Single stage layout minimized chain load Teeth 146 ea Teeth 58 ea ...

Page 372: ...nd reduces the chain wear The chain rail is normally made of PA Polyamide nylon and PA66 and PA46 are used for the chain rails in G20DF engine For the tensioner rail PA46 is used to provide high anti wear function and high strength since the load to the rail is huge Ther is an open area for shoulder bolt hole in the clamping rail The chain rails are installed by shoulder bolts Tensioner rail Insta...

Page 373: ... the engine to the powertrain system Additionally DMF decreases the rattling noise in transaxle and the vehicle vibration by reducing the differences of torque and rotational speed due to the combustion in engine The drive plate initially drives the powertrain system by using the power from the start motor when starting the engine The drive plate is installed on the crankshaft and is engaged to th...

Page 374: ...ularity increases more less pulsation absorbing effect Transaxle protection function Reduces the torsional vibration to powertrain transaxle by reducing the irregularity of engine Compression stroke Combustion stroke Small changes from engine k Damper increases the torque changes to clutch Large changes from engine j Damper decreases the torque changes to transaxle by absorbing the impact Torque c...

Page 375: ...response by using 2 stage type spring Strengthens the torque response in all ranges low medium and high speed by applying respective spring constant at each range Stable revolution of the primary and secondary wheel by using planetary gear Works as auxiliary damper against spring changes Less heat generation due to no direct friction against spring surface Plastic material is covered on the spring...

Page 376: ...piston pin and snap ring The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy Overview Layout and Components Top Bottom Oil ring Piston ring No 1 ring Piston pin No 2 ring Snap ring Piston ...

Page 377: ...er 2 ring Scrapes the engine oil on the cylinder bore and prevents the leaked combustion gas from 1 ring from leaking into the crank chamber Oil ring Scrapes the engine oil on the cylinder bore B Piston pin Connects the piston the connecting rod and transfers the linear movement of piston to connecting rod to convert it to rotating energy Piston ring Piston ring end gap mm 1 end gap 0 170 0 320 2 ...

Page 378: ...stall the piston rings with the X mark on the ring facing upwards Position the end gap of 1 ring at 180 away from the end gap of 2 ring Position the end gap of oil ring at 180 away from the end gap of coil spring and position the end gap of oil ring at 90 away from the end gap of 2 ring 1 cylinder ...

Page 379: ...ement of crankshaft The big end is connected to connecting rod bearing and the crank pin journal and the small end is connected to the piston pin Components Connecting rod Piston pin bush Connecting rod Connecting rod upper bearing Connecting rod lower bearing Connecting rod cap Connecting rod cap bolt A B C D E F ...

Page 380: ...ection of connecting rod bearing Select the bearing shell combination according to the table below Conrod_UPR Grade Conrod_LWR Grade Clearance Red Blue 0 005 0 050 Yellow Yellow 0 005 0 050 Blue Red 0 005 0 050 ...

Page 381: ...02 35 1130 01 Overview Crankshaft is installed on the cylinder block The crankshaft converts the reciprocative movement of piston to the rotatinal movement Layout and Components Crankshaft ...

Page 382: ...별 베어링 선택 Pin punch mark Color Diameter of crankshaft main journal in cylinder block mm Blue 62 500 62 506 Yellow 62 506 62 513 Red 62 513 62 519 Mark Color Diameter of crankshaft main journal mm B Blue 57 960 57 965 Y Yellow 57 955 57 960 R Red 57 950 57 955 W White 57 945 57 950 V Violet 57 940 57 945 Engine name Main journal bearing 1 2 3 4 5 G 2 0 D F R R W W R ...

Page 383: ...is made of special cast iron and contains the major components such as cylinder head crankshaft and piston assembly There are oil and coolant galleries to lubricate and cool the engine Components Plug screw water jacket plug 70Nm Expansion plug intake 4 Spring pin A C mounting Oil gallery oil filter assembly Ctankshaft position sensor mounting Plug screw oil gallery plug Spring pin RR seal mountin...

Page 384: ...ngine oil Coolant Coolant and oil flows Cylinder head Cylinder block water jacket Coolant pump Coolant pipe Thermostat Supply line to cylinder head Oil pump Supply line to PCJ Main bearing Oil filter assembly ...

Page 385: ...ilter type Dry filter element Filtering area 0 225 m Service interval Clean every 7 500 km Change every 15 000 km Air cleaner assembly Weight 1 45 kg Operating temperature 25 Capacity 7L Shorten the service interval under severe conditions such as driving on a dusty road or offroad ...

Page 386: ...04 4 2 LAYOUT Intake Manifold Assy Bolt T MAP sensor Bolt Intake Manifold Brkt 1 2 3 4 5 Bolt Electric Throttle Body Bolt Acoustic Cover 6 7 8 9 ...

Page 387: ... Insulator Collar Spring Clamp Resonance Duct Resonance O Ring Air Cleaner MTG NO 1 Air Cleaner MTG Bolt 1 3 5 6 7 8 9 10 11 Snorkel Assy Water Portector Resonator Assy RR Fascia MTG Screw Rivet Bolt Nut Screw Air Cleaner to Engine Hose Assy 12 13 14 17 18 19 20 21 ...

Page 388: ...ld It provides the Long Runner in low speed and the Short Runner in high speed And to reduce the internal pulsation in the intake manifold the Runner 1 and 2 are located in symmetry position with Runner 3 and 4 To reduce the air resistance the throttle body is tilted by 15 2 COMPONENTS VIS solenoid valve Intake manifold assembly ...

Page 389: ...04 7 0000 00 Purge control solenoid valve Blow by hose PCV valve Electronic throttle body Air cleaner element ...

Page 390: ...04 8 When Long Runner is operating When Short Runner is operating 3 OPERATING PROCESS Intake air flows ...

Page 391: ...04 9 1740 01 4 INPUT OUTPUT DEVICES ...

Page 392: ...04 10 5 CIRCUIT DIAGRAM ...

Page 393: ...soline Fuel injection MPI Muilt Point Injecter type Fuel supply Returnless Fuel System Fuel tank Capacity 57 L Material Plastic Fuel sender Dual sender type Fuel filter Service interval Change every 100 000 km Fuel pump Pressure 3 8 bar Injector Color Black Capacity 187 2 g min ...

Page 394: ...sy Heat shield assy Sub sender assy Main fuel pump assy Fuel filler assy Fuel filler cap assy Feed tube assy Return tube assy 1 3 4 5 6 7 8 9 10 Suction tube assy Harness wiring assy Fuel pump plate cover O ring clamp Nut Nut Screw 11 12 13 14 20 21 22 23 ...

Page 395: ...03 5 2221 01 Fuel Filter Assy Bolt Fuel Return Pipe Fuel Supply pipe Fuel Vapor Pipe Assy Canister Compl Fuel line Holder Fuel line Holder 1 2 3 4 6 9 14 15 ...

Page 396: ... controls the fuel injection in each injector electronically According to the engine loads the engine ECU draws or cuts off the evaporated gas in canister into the combustion chamber The fuel system consists of fuel tank fuel lines fuel pump and fuel pressure regulator Fuel supply line to sub tank Fuel return line Fuel supply line Maintain 3 8 bar ...

Page 397: ......

Page 398: ...03 8 Fuel pump and fuel sender assembly 2 COMPONENTS Canister Fuel filter Fuel tank assembly Primary fuel sender Fuel tank assembly Fuel neck hose Canister Fuel filter ...

Page 399: ...03 9 2221 01 Engine ECU Engine compartment Injector Purge control solenoid valve Fuel rail Secondary fuel sender ...

Page 400: ...03 10 3 SCHEMATIC DIAGRAM OF FUEL FLOWS ...

Page 401: ...ates the accelerator pedal based on the input signals from various sensors and controls the overall operation of the vehicle The ECU receives the signals from various sensor through data line and performs effective airfuel ratio control based on these signals ...

Page 402: ...05 3 1745 01 1 TROUBLESHOOTING ...

Page 403: ...05 4 2 LAYOUT Exhaust Manifold Assy Exhaust Manifold Gasket Hex Flange Nut Heat Protector Assy Hex Bolt M6 X 1 X 25 Heat Protector Assy Hex Bolt M8 X 1 25 X 16 1 2 3 4 5 6 7 ...

Page 404: ...ssy UCC Compl Muffler Complete RR Exhaust FRT Heat Protector CTR Muffler Heat Protector RR Muffler Heat Protector Clamp Gasket 1 2 3 4 5 6 7 8 9 Hanger Hanger Hanger Nut Nut Bolt Gasket Ring Nut CTR Muffler Complete 10 11 12 13 14 15 16 19 20 ...

Page 405: ... components are positioned at regular intervals from all other parts of the under body Be careful not to damage the exhaust system when lifting the vehicle from its side All components and body parts of the engine exhaust system should be inspected for crack damage air hole part loss and incorrect mounting location Also check for any deformation which can result in exhaust gas drawn into the vehic...

Page 406: ...ondition For detailed description see the corresponding section The fuel evaporative gas is a gas evaporated to the atmosphere in the section between the fuel tank and fuel line and its main component is hydrocarbon HC The fuel evaporative gas is temporarily stored in the canister and it is drawn to the engine through the throttle body when the purge control solenoid valve is open according to the...

Page 407: ...05 8 PCV valve 2 COMPONENTS Engine ECU WCC Engine CHECK lamp Blow by hose Exhaust manifold ...

Page 408: ...05 9 2414 00 Rear oxygen sensor Exhaust No 2 Exhaust No 1 Exhaust No 3 main muffler UCC Front oxygen sensor ...

Page 409: ...05 10 3 WORK FLOW IN EXHAUST SYSTEM ...

Page 410: ...05 11 1745 01 4 INPUT OUTPUT DEVICES ...

Page 411: ... 7 kΩ Center electrode Iridium alloy Ground electrode Platinum alloy Electrode clearance 1 1 mm Change interval 160 000 km Ignition coil Primary operating current 7 0 5A Generated voltage primary secondary Max 400 V 5 20 kV Ignition type Independent ignition type Ignition sequence 1 3 4 2 ...

Page 412: ...06 4 2 LAYOUT Ignition Coil Bolt Spark Plug 1 2 3 ...

Page 413: ...ned by the signals from camshaft position sensor and crankshaft position sensor This ignition system controls the electronic ignition timing received from the engine ECU To control the ignition timing precisely the ECU use the information below Engine load Coolant temperature Intake air temperature Engine rpm Camshaft position sensor CPS Crankshaft position sensor CKS If the signal from the camsha...

Page 414: ...06 6 2 COMPONENTS Ignition coil Camshaft position sensor Knock sensor Injector Spark plug ...

Page 415: ...06 7 1443 01 Electric throttle valve T MAP sensor Accelerator pedal position sensor Coolant temperature sensor Engine ECU Crankshaft position sensor ...

Page 416: ...06 8 3 INPUT OUTPUT DEVICES ...

Page 417: ......

Page 418: ...06 10 4 CIRCUIT DIAGRAM ...

Page 419: ...06 11 1443 01 ...

Page 420: ...o check the engine oil level and shorten the cycle to replace the engine oil under severe driving conditions The engine oil filter element should be changed at the same time with the engine oil Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sand...

Page 421: ...ax Min Replenishment If the level gets to the lower point open the filler cap on top of the cylinder block and add the genuine oil without exceeding the level of the upper mark Recheck the oil level after 5 minutes Operating vehicle with insufficient amount of oil can damage the engine Make sure the engine oil level is correct and add oil if necessary Regularly check the engine oil level and add S...

Page 422: ...Pump Assy Seal Ring Oil Pan Bolt Drain Plug Bolt Oil Pump Chain Oil Pump Chain Tensioner Assy 1 6 8 10 11 21 22 24 Bolt Oil Dipstick Tube Assy Oil Dipstick Gauge Assy O Ring Bolt O Ring Sealant Dust Cover 25 31 32 33 34 37 44 45 ...

Page 423: ...07 6 Oil Filter Assy Oil Filter Cover Oil Filter Element Kit Drain Plug 1 2 9 10 O Ring Oil Filter Bypass Valve Assy Oil Filter Housing Gasket Bolt Oil pressure switch 11 26 30 31 35 ...

Page 424: ...uns frictional heat is generated on each lubrication section If this condition persists the bearing can be burned and stuck In other words it creates an oil film on each sliding surface to convert solid friction to liquid friction in order to minimize wear and prevent temperature increasing on the friction part 2 COMPONENTS Engine oil dipstick Oil jet Engine oil pan Oil pump Oil filter module ...

Page 425: ... 8 1 Operation Flow 3 OPERATING PROCESS CVVT Cam journal bearing Main oil gallery in cylinder block Oil pressure switch Oil filter assembly Oil supply Oil pump Main journal bearing Chain tensioner Oil jet ...

Page 426: ...TION Unit Description Specification Alternator Type HPS EPS Crankshaft pulley Alternator pulley 1 2 66 Normal output idle 2200rpm 70 140A Regulator voltage 12V Brush Length 12 5mm Wear limit 7 0mm Battery Type MF Capacity 90AH ...

Page 427: ...09 4 2 LAYOUT 1 Alternator Alternator assembly Bolt 1 2 ...

Page 428: ...able assembly Cable positive Cable assembly Battery ground Bolt Earth Cap Terminal Connector Battery 1 2 3 5 6 8 9 10 Nut Nut Cab Earth Box assembly Battery sub Fuse MID 80A Clamp Battery cable Grommet Ring terminal Grommet Ring terminal 17 18 20 21 22 23 24 25 ...

Page 429: ...ear selector lever to the neutral position Maintain the engine speed at 2 500 rpm with the vehicle unloaded Turn all the electrical switches off 1 2 Open circuit If the measured current is 5 A or higher Disconnect the negative cable from the battery Remove the B terminal and turn off the ignition switch Measure the resistance between the L and F terminals with an ohmmeter 1 2 3 Pass If the measure...

Page 430: ... Replace Defective ground Repair Charge warning lamp does not come on when turning on ignition switch with engine stopped Defective alternator voltage regulator Replace Open circuit in charge warning lamp fuse or wiring Replace or repair the charge warning lamp or fuse Defective ignition switch Replace Defective ground of alternator circuit Repair Charge warning lamp does not go off after starting...

Page 431: ...09 8 2 Battery Inspection ...

Page 432: ...t load capacity and time and varying voltage Determine battery capacity based on the amount of voltage drop when discharging a fixed load capacity 120 A for 5 seconds Connect the tester to the battery and read the display while applying a load for 5 seconds Red area overdischarge or faulty battery Yellow area Need to be charged using a vehicle alternator and a battery charger Green area Normal Red...

Page 433: ...ok 1 2 3 4 Starting Prepare a set of jumper cables Place another vehicle that has the same 12 V of power near to the discharged vehicle Switch off all electrical accessories for the discharged vehicle Apply the parking brake and shift the transaxle to the P position automatic transaxle or neutral N position manual transaxle Connect the jumper cables Try to start the discharged vehicle while accele...

Page 434: ...he terminals are corroded clean them with a wire brush or sandpapers Always disconnect the battery cables with the ignition key removed When disconnecting the battery cables with the ignition key turned to ON or ACC position several electric units can be damaged due to sudden voltage change Check the battery for crack damage or fluid leaks Replace it if necessary Wipe out the battery fluid on the ...

Page 435: ...constant direct current voltage by converting mechanical rotational movement to electrical energy The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change Body ground B wiring Alternator The alternator charges the battery and supplies power to each electric ...

Page 436: ...09 13 1452 01 2 CHARGING OPERATION 1 Vehicle without Smart key system ...

Page 437: ...09 14 2 Circuit Diagram ...

Page 438: ...11 3 1462 01 1 SPECIFICATION Unit Description Specification Start motor Capacity 12V 1 4kw Engagement Meshed type Rotating direction Clockwise Solenoid operating voltage Max 8V Weight 2 5kg ...

Page 439: ...11 4 2 LAYOUT Starter Bolt 1 2 ...

Page 440: ...h or blown fuse Repair or replace Poor engine ground Repair Engine cranks too slow Low battery voltage Charge or replace Loose corroded or damaged battery cable Repair or replace Faulty starter Starter does not stop Faulty starter Repair or replace Faulty ignition switch Replace Engine cranks normally but does not start Broken pinion gear or faulty starter Replace the starter Broken flywheel ring ...

Page 441: ...otor starts the engine with rotational power by converting the electric energy to the mechanical energy When the engine is cranking the pinion gear meshes with the ring gear If the ring gear overruns the pinion gear clutch overruns to protect the pinion gear ...

Page 442: ...11 7 1462 01 2 OPERATING PROCESS ...

Page 443: ...11 8 3 CIRCUIT DIAGRAM ...

Page 444: ...25kg h Throttle position angle TA 0 Full Open 78 Close Engine torque Nm varies according to engine conditions Injection time Ms Battery voltage V 13 5V 14 1V Accelerator pedal position 1 V 0 3 4 8 V Accelerator pedal position 2 V 0 3 2 4 V Oxygen sensor mV 0 5 V OCV Oil Control Valve 0 100 VIS solenoid valve 1 ON 0 OFF A C compressor switch 1 ON 0 OFF Full load 1 ON 0 OFF Knocking control 1 ON 0 O...

Page 445: ...15 4 Spark plug OCV Oil Control Valve Rear oxygen sensor MCC complete Knock sensor Injector Oil pressure switch Ignition coil 1 MAJOR COMPONENTS PVC valve ...

Page 446: ...urge control solenoid valve G20DF engine ECU Coolant Temp sensor Camshaft position sensor Crankshaft position sensor T MAP sensor VIS solenoid valve Electronic throttle body Magnetic trigger ring Front oxygen sensor ...

Page 447: ...15 6 2 SYSTEM OPERATION 1 Input Output of ECU ...

Page 448: ...osition sensor Crankshaft position sensor Front oxygen sensor Knock sensor G20DF Engine ECU Electronic throttle body Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal CAN ABS ESP Instrument cluster TCU Oil pressure switch Oil pressure warning lamp T MAP sensor ...

Page 449: ... Valve 3 Components for ECU Output Start motor Injector VIS solenoid valve Purge control solenoid valve G20DF Engine ECU Ignition coil CAN ABS ESP unit BCM E coupling unit EPS Instrument cluster SKM TCU Diagnostic tool Cooling fan module ...

Page 450: ...a among electrical systems automatic T M and brake system in the vehicle fluently And the diagnostic tool can be used to diagnose vehicle status and defectives Operating temperature range of ECU is normally 40 to 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks 2 Control Functions Controls by operating stages To make optimum combustion un...

Page 451: ...the emission gas ECU determines the injection volume and timing 2 Components Input Components Accelerator pedal position sensor Front oxygen sensor Coolant temperature sensor Crankshaft position sensor Camshaft position sensor Knock sensor T MAP sensor Electronic throttle body Output Components ...

Page 452: ...15 11 0000 00 3 Input Output for Injection Volume Control ...

Page 453: ...15 12 4 Basic Injection Volume Map ...

Page 454: ...ingle ignition system Each spark plug is operated independently by the ECU and one ignition coil and spark plug are provided for each cylinder 2 Components Input Components Crankshaft position sensor Accelerator pedal position sensor Knock sensor Camshaft position sensor Electronic throttle body Output Components ...

Page 455: ...15 14 3 Input Output for Ignition System ...

Page 456: ...ition timing control can be performed faster than the control through the throttle valve Fuel cut off in deceleration The ignition timing is retarded temporarily to prevent abrupt increase of the torque when the combustion is restarted Intake air temperature coolant temperature The ignition timing is retarded to prevent knocking if the intake air temperature or coolant temperature is high The igni...

Page 457: ...15 16 5 Warm Up of Catalytic Converter 1 Components Input Components T MAP sensor Coolant temperature sensor Crankshaft position sensor Output Components ...

Page 458: ...ioner compressor operation The air conditioner control unit sends the air conditioner operation signal to the ECU to increase the throttle valve opening amount in order to prevent reduction of the engine speed when the air conditioner compressor is in operation at idling 3 Warm up Control Operating Conditions To make the catalytic converter reach a operating temperature the ignition timing is reta...

Page 459: ...rating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools The heat from automatic transaxle is also cooled down through the radiator by circulating the oil through the oil pump There are two cooling fans 180W 120W in G20DF engine ECU controls the electric cooling fans with three cooling fan relays to improve the engine torque and air condit...

Page 460: ...15 19 0000 00 3 Input Output for Cooling Fan and A C Compressor ...

Page 461: ...frigerant pressure 18 bar ON HI 18 bar Refrigerant pressure HI 105 Coolant temp 115 HI 115 Coolant temp OFF cut A C compressor OFF conditions Coolant temperature over 118 Approx 4 seconds after starting the engine When abrupt acceleration Refrigerant pressure OFF below 2 0 kg then ON over 2 4 kg OFF over 32 kg then ON below 26 0 kg Output voltage according to refrigerant pressure The output voltag...

Page 462: ...r integrated in the key and the engine control unit have the same code When the ignition key with the integrated transponder is turned to the ON position the ECU Engine Control Unit checks the crypto code of the key and if correct allows the vehicle to start the engine For details refer to Chapter BCM 2 Components Conditions for cooling fan Immobilizer antenna Immobilizer key Start motor Instrumen...

Page 463: ...CU communicate with the immobilizer key to check if it is valid crypto code If it is valid ECU start to control the engine when turning the ignition switch to START position The system has 10 seconds of valid time out period If the engine does not start in this period the key approval process should be done again ...

Page 464: ...PS Electronic Power Steering Unit BCM Body Control Moudule SKM Smart Key Moudule CAN system communicates with the system units in vehicle It consists of P CAN and B CAN according to the communication speed P CAN B CAN SKM Instrument cluster BCM Disgnostic connector P CAN ECU ABS ESP TCU E coupling EPS unit Terminal resistance installed on ECU and BCM ...

Page 465: ...S101 Floor wiring LH Under fuse relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind instrument cluster cowl cross member S202 Main wiring Behind instrument cluster cowl cross member S205 Floor wiring LH Under driver s door scuff ...

Page 466: ...15 25 0000 00 3 Input Output for CAN communication ...

Page 467: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 SPECIFICATION 3 RECOMMENDED FLUIDS AND LUBRICANTS 4 SCHEDULED MAINTENANCE SERVICES 3 6 8 9 ...

Page 468: ......

Page 469: ...01 3 0000 00 Top view Side view Front side Rear view 1 SPECIFICATIONS 1 830 1 675 4 410 4 500 2 650 1 573 1 566 1 558 1 551 Unit mm option 1 Dimensions ...

Page 470: ...345 is stamped on the fire wall in engine compartment front passenger side 1 The engine number ex 671 950 0 0 999999 is stamped on the lower area of cylinder block in exhaust manifold side 3 The certification label is affixed on the bottom of driver side B pillar ...

Page 471: ...01 5 0000 00 VIN NO Engine NO ...

Page 472: ...740 1 785 2WD 1 580 1 595 Fuel Diesel Fuel tank capacity ℓ 57 Engine Engine D20DTF Number of cylinders Compression ratio 4 16 5 1 Total displacement cc 1 998 Camshaft arrangement DOHC Max power M T 149 ps 4 000 rpm Max torque 360 Nm 1 500 2 800 RPM Idle speed 750 20 rpm Cooling system Water cooled forced circulation Coolant capacity ℓ 8 5 Lubrication type Gear pump forced circulation Max oil capac...

Page 473: ...r capacity V KW 12 2 3 Alternator capacity V A 14V 140A EPS 14V 120A NPS option Description Diesel 2 0 Engine D20DTF Low CO2 Manual Transaxle Operating type Floor change type Gear ratio 1st 3 385 2nd 1 708 3rd 1 033 4th 0 786 5th 0 730 6th 0 595 Reverse 3 747 Transfer Case Model 4WD Type Electronic control type Clutch Operating type Hydraulic type Disc type Dry single diaphragm type Power Steering...

Page 474: ... 6ℓ Ssangyong genuine oil SAE 75W 85 API GL 4 Transfer Case Fluid 4WD 0 58ℓ Ssangyong genuine oil IDEMITSU LW 80W 90 Rear Axle Oil 4WD 0 7ℓ Ssangyong genuine oil SAE 80W 90 API GL 5 Brake Clutch Fluid As required Ssangyong genuine oil DOT4 Power Steering Fluid 1 0ℓ Ssangyong genuine oil ATF DEXRON II TOTAL FLUIDE DA Extreme cold condition only Use only Ssangyong genuine fluids Use of non recommend...

Page 475: ...01 9 0000 00 4 SCHEDULED MAINTENANCE SERVICES ...

Page 476: ...01 10 ...

Page 477: ...01 11 0000 00 ...

Page 478: ......

Page 479: ...MODIFIED ITEMS 1 MAJOR CHANGES 2 MAJOR CHANGES IN ENGINE 3 CHANGES IN CABIN 4 CHANGES IN CHASSIS 3 4 9 10 ...

Page 480: ......

Page 481: ...mbly Changed the layout T MAP boss added 1451 01 Alternator assembly Changed the diameter of pulley Changed the regulator and control logic 2412 01 CDPF assembly Changed the sampling location of differential pressure 1525 21 Coolant outlet port Changed the layout Turbocharger cooling system deleted 1914 01 Turbocharger assembly Changed the E actuator Deleted the cooling system Adopted metal gasket...

Page 482: ...ing bracket D20DTF D20DTF Low CO2 To improve the durability add the differential pressure sensor pipe mounting bracket 2330 01 Intercooler assembly D20DTF D20DTF Low CO2 To improve the intake capacity by increasing the heat radiation add the core fin and increase the intercooler volume 1127 01 Cylinder block D20DTF D20DTF Low CO2 The pipe screw has been changed to plug screw according to the delet...

Page 483: ...S Electronic Battery System 2313 01 Air cleaner assembly Increasing the volume 6 5 L 8 L to improve the fuel economy and to reduce the noise and NOx 1491 01 D20DTF ECU D20DTF Low CO2 Changed the software for D20DTF Low CO2 engine and added pin number for EBS system ...

Page 484: ...ntake manifold assembly D20DTF D20DTF Low CO2 Changed the layout T MAP boss added 1451 01 Alternator connector D20DTF D20DTF Low CO2 Changed the regulator and control logic 2 Engine Assembly 1451 02 Alternator pulley D20DTF D20DTF Low CO2 Changed the diameter of pulley D20DTF engine D20DTF Low CO2 engine ...

Page 485: ...hanged the number of pins in connector for new E actuator 1525 21 Coolant outlet port D20DTF D20DTF Low CO2 Changed the layout Turbocharger cooling system deleted 2412 01 CDPF assembly D20DTF D20DTF Low CO2 Changed the sampling location of differential pressure Front of DOC Front of DPF D20DTF engine D20DTF Low CO2 engine Pipe to coolant outlet port ...

Page 486: ... the intake efficiency changed the turbine wheel impeller to dual type from single type Turbocharger cooling line D20DTF D20DTF Low CO2 Deleted the coolant inlet and outlet lines from the turbocharger Maximum temperature of turbocharger 780 C 3 Turbocharger E VGT D20DTF D20DTF Low CO2 Adopted E actuator 1914 01 D20DTF 1914 01 D20DTF Low CO2 ...

Page 487: ...2 Changed the function and circuit for EBS system 8010 01 Meter cluster D20DTF High power The charge warning lamp uses hard wiring without EEM system D20DTF Low CO2 The charge warning lamp uses CAN communication line with EEM system EEM Energy Efficiency Management Charge warning lamp ...

Page 488: ...w CO2 Gear ratio 1st 3 539 2nd 1 909 3rd 1 179 4th 0 814 5th 0 737 6th 0 628 Reverse 3 909 4015 01 Rear sub frame D20DTF D20DTF Low CO2 Added brackets 2WD 3 4WD 7 for floor cover Gear ratio 1st 3 385 2nd 1 708 3rd 1 033 4th 0 786 5th 0 730 6th 0 595 Reverse 3 747 ...

Page 489: ...0000 00 0000 00 Floor cover D20DTF D20DTF Low CO2 Reduce the air resistance to improve the fuel economy New Floor cover RH Same for 2WD and 4WD Floor cover LH Different for 2WD and 4WD Under cover RR 2WD only ...

Page 490: ......

Page 491: ...s GEN Clean every 7 500 km change every 15 000 km But shorten the service interval under severe conditions Air cleaner assembly Weight 1 5kg Operating temperature 30 100 Capacity 8L Intercooler Core material Aluminum Size 510X122X67 WxHxT Tank material Plastic Molding Efficiency 80 Exhaust system Turbocharger assembly Max temperature of turbine housing 780 Diameter of turbine housing ø40 0 Diamete...

Page 492: ......

Page 493: ...02 5 0000 00 T MAP sensor Turbocharger CDPF 1 MAJOR COMPONENTS D20DTF Low CO2 ECU Intercooler assembly Air cleaner assembly ...

Page 494: ...02 6 2 COOLANT FLOWS IN COOLING SYSTEM ...

Page 495: ...02 7 0000 00 ...

Page 496: ...ine is equipped with a throttle body which includes a flap This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off The intake manifold contains the swirl control valve and dual port system to make the optimum turbulence The T MAP sensor is located on the left top of the intake manifold and the HFM sensor for precise co...

Page 497: ...r Mass Sensor HFM sensor version 6 Refer to Chapter Engine Control Air cleaner assembly Its volume is increased and air flowing efficiency is improved Intercooler assembly Its volume is increased and cooling efficiency is improved ...

Page 498: ...40A 6500rpm 25 13 5V Battery Capacity 90Ah 20hr Reserve capacity 180 minutes Starting current when engine cooed 710A Weight 23kg EBS Electronic Battery Sensor Resolving power 1mA Operating voltage 7 18V Operating temperature 40 105 Communication LIN 2 0 Unit Description Specification ...

Page 499: ...e D20DTF Battery capacity 12V 90Ah Alternator capacity Delphi 120A Delphi 140A Alternator Changed the diameter of belt pulley Front view Changed the regulator and control logic Rear view ECU Without EEM logic With EEM logic EBS None Monitoring the battery conditions voltage current temperature and SOC ...

Page 500: ...r dirt with a wire brush or sand paper and then wash out with lukewarm soapy water 2 Measuring the Voltage Drop Measuring at battery terminal Measure the voltage between battery terminal and wiring clamp Specified value below 0 3V If the terminals are corroded clean and retightening them If the specified tightening torque cannot be kept replace the clamp Terminal Terminal Terminal 4 5 Nm Terminal ...

Page 501: ...ting bolt for corrosion and looseness If there is a poor contact due to corrosion or paint wipe out the contact area and retighten it Wiring mounting bolt to body ground 17 Nm Measuring the battery voltage Stop the engine and wait for 20 minutes Measure the voltage between terminal and terminal with the ignition switch OFF and all electric devices OFF Specified value over 12V ...

Page 502: ...out of the specified value check the terminal and clamp for looseness Checking the charge warning lamp Turn off all electric devices and put the ignition switch ON Pre warning Check if the charge warning lamp goes out If the charge warning lamp does not go off inspect the electric circuit Start the engine and check if the charge warning lamp keeps off 1 2 3 ...

Page 503: ... INSPECTION CHARGING CURRENT Perform the basic inspection Setting up the testers Preparation Set up the ammeter and voltmeter as shown in the figure 1 Make sure to set up the tester while keeping its polarity ...

Page 504: ...0 rpm 1 Specified value 60 of rated current limit Turn the ignition OFF after inspection Disconnect the negative cable from the battery and remove the testers ammeter and voltmeter 2 3 Characteristic curve output from alternator The output current may not reach the limit value due to various parameters high temperature or electric load etc Thus do not perform the inspection with fully charged batt...

Page 505: ...n Turn the ignition ON and measure the voltage on the voltmeter 1 Start the engine and turn all electric devices OFF Increase the engine speed to 2 700 rpm and maintain the speed Measure the voltage when the output current from alternator decrease below 30A 2 3 Specified value over 12V Specified value 11 5 15 5V Make sure to set up the tester while keeping its polarity ...

Page 506: ... inspect the affected circuit 1 Specified value below 0 05A 6 INSPECTION DARK CURRENT Perform the basic inspection Setting up the tester Preparation Disconnect the negative cable from the battery Set up the ammeter as shown in the figure above 1 2 1 When Using Multi tester Connect the probe to ground wiring and probe to terminal of battery ...

Page 507: ... up the ammeter and MSM as shown in the figure above 1 2 2 When Using MSM Connect the negative cable to the battery 3 Make sure to set up the tester while keeping its polarity Measure the current while removing the fuses one by one If the current drops sharply when a certain fuse is removed inspect the affected circuit ...

Page 508: ... replacement required 7 INSPECTION BATTERY Perform the basic inspection all electric devices OFF Battery tester 1 Voltage Check without load Connect one measuring clamp to terminal of battery first then connect the other one to terminal Disconnect the clamps in the reverse order 1 Read the measurement 2 ...

Page 509: ...ection for less than 5 seconds 1 Read the measurement 2 Specified value 7 9V Red Over discharged or faulty 9 11V Yellow Charging required 11 13V Normal To identify the battery capacity with the voltage drop V value discharge the fixed load capacity 120A for a certain period 5 seconds ...

Page 510: ...warning lamp ON condition Turn the ignition ON Engine stopped Open or short circuit of L terminal wiring open or short internal circuit of alternator fixed control of 13 8V Open or short circuit of F terminal wiring no feedback output signal 1 2 3 ...

Page 511: ...14 16 1 LAYOUT D20DTF Low CO2 D20DTF ECU Battery sensor EBS Alternator ALT Meter cluster charge warning lamp ...

Page 512: ...SOC to engine ECU with LIN communication Engine ECU outputs the information from EBS and regulating control signal PWM according to the engine load conditions to L terminal on alternator Engine ECU controls the magnetic resistance between stator coil and rotor coil by controlling the current in rotor coil according to PWM duty value The alternating voltage induced to stator coil is converted to di...

Page 513: ...asic control logic according to the driving conditions Engine ECU determines the engine loads according to the fuel injection volume and engine speed It charges the battery by increasing the generating voltage during deceleration To improve the fuel economy by reducing the alternator load during acceleration engine ECU decreases the generating voltage and consumes the battery voltage ...

Page 514: ...p Overview Meter cluster charge warning lamp The meter cluster receives the charge warning lamp ON signal from ECU through CAN line Charge warning lamp ON conditions Pre warning When DTC related EEM set Open or short circuit in alternator Circuit diagram ...

Page 515: ...14 20 4 CIRCUIT DIAGRAM ...

Page 516: ...GENERAL INFORMATION 1 EXTERIOR LAMP SYSTEM LAYOUT 2 INTERIOR LAMP SYSTEM LAYOUT 3 SWITCH SYSTEM LAYOUT 4 SCHEMATIC DIAGRAM FOR WIRING AND ELECTRICAL DEVICES 5 CAN COMMUNICATION CONFIGURATION 3 6 8 10 14 ...

Page 517: ......

Page 518: ...e repeater lamp Puddle lamp 1 EXTERIOR LAMP SYSTEM LAYOUT Front fog lamp Position lamp Headlamp assembly Rear turn signal lamp High mounted stop lamp Tail stop lamp Reflector Backup lamp Rear fog light License plate lamp Front view Rear view ...

Page 519: ...01 4 Puddle approach lamp Front fog lamp Headlamp Side repeater lamp High beam low beam Turn signal lamp Position lamp ...

Page 520: ...01 5 0000 00 High mounted stop lamp Rear combination lamp Vehicle without spoiler Vehicle with spoiler License plate lamp Stop lamp and tail lamp Rear fog lamp Turn signal lamp Backup lamp ...

Page 521: ...01 6 Sun visor lamp Glove box lamp Front room lamp 2 INTERIOR LAMP SYSTEM LAYOUT ...

Page 522: ...01 7 0000 00 Center room lamp Luggage lamp Door courtesy lamp ...

Page 523: ...itch Passenger door switch Lower main panel switch Start stop switch Cruise control switch Hazard warning switch bezel assembly Multifunction switch FATC switch Drive door main switch Outside rearview mirror switch 3 SWITCH SYSTEM LAYOUT ...

Page 524: ...enter room lamp switch Front seat heated wire switch STD Rear door switch RH Overhead console switch Rear door switch LH Tailgate switch Front seat heated wire switch DLX Luggage lamp switch Driver power seat switch ...

Page 525: ...01 10 4 SCHEMATIC DIAGRAM FOR WIRING AND ELECTRICAL DEVICES 1 Wiring Harness Arrangement ...

Page 526: ...01 11 0000 00 2 Electrical Devices Mounting Locations ...

Page 527: ...01 12 3 Connector Ground And Splice Pack Connector ...

Page 528: ...01 13 0000 00 Ground Splice pack ...

Page 529: ...hrough both P CAN and B CAN at the same time and the SKM SMART Key Module communicates with the instrument cluster and BCM through B CAN 1 CAN Configurations P CAN B CAN Abbreviations Meaning Function GCU Glow Control Unit Glow control unit EPS Electronic Power Steering Unit Electrically driven power steering unit BCM Body Control Module Body control module SKM Smart Key Module Smart key module ...

Page 530: ...r wiring LH Under fuse and relay box in engine compartment S102 Floor wiring RH Inside of right fender S201 Main wiring Behind the instrument cluster cowl cross member S202 Main wiring Behind the instrument cluster cowl cross member S205 Floor wiring LH Bottom of driver seat front right ...

Page 531: ......

Page 532: ...e which has the correct amperage rating If you use a fuse with higher capacity than the specification the component can be damaged or catch fire Do not drop or appy excessive impact to sensors and relays 80 10 A 15 A Make sure to turn OFF the ignition switch and other lamp switches before disconnecting or connecting the negative battery cable Otherwise semiconductor parts can be damaged ...

Page 533: ...ity of the connector terminal with a circuit tester connect the tester probe to the terminal at the harness side For a sealed type connector connect the probe to the terminal through the hole in the rubber cap of the wiring Take care not to damage the insulation of the wires Insert the probe until it contacts the terminal completely When inspecting the airbag system make sure to use a diagnostic d...

Page 534: ...k that the grounding part has continuity with mounting bolts and vehicle body Check that wires are properly routed Make sure that wires are securely fixed to avoid contact with sharp body parts and high temperature parts such as the exhaust manifold and exhaust pipes The rotating parts such as fan pulley and fan belt perturbative parts and wiring should be secured tightly at regular intervals Secu...

Page 535: ...y boxes consist of three boxes Integrated Control Module ICM box in which the relays of rear wiper rear fog lamp mirror folding ACC IGN1 2 horn tailgate power outlet shift lock A T are integrated relay fuse box in engine compartment and interior fuse box 2 SYSTEM LAYOUT 1 OVERVIEW ...

Page 536: ...ngine compartment is located in the left side of the engine compartment The wiper relay horn relay fog lamp relay tail lamp relay and PTC relay are included in the PCB The B supply is provided through the ALT A line not by an extra fuse Capacity and name of engine compartment fuse and relay ...

Page 537: ...02 8 Engine compartment fuse and relay box I ...

Page 538: ...02 9 8410 00 ...

Page 539: ...02 10 Engine compartment fuse and relay box II ...

Page 540: ...02 11 8410 00 ...

Page 541: ...02 12 Engine compartment fuse and relay box IV ...

Page 542: ...02 13 8410 00 ...

Page 543: ...02 14 Engine compartment fuse and relay box V ...

Page 544: ...02 15 8410 00 ...

Page 545: ...02 16 2 Interior Fuse Box The interior fuse box is located in the left side of the instrument panel To remove this fuse box disconnect the main wiring first Capacity and name of interior fuse and relay ...

Page 546: ......

Page 547: ...02 18 Interior fuse and relay box I ...

Page 548: ...02 19 8410 00 ...

Page 549: ...02 20 Interior fuse and relay box II ...

Page 550: ...02 21 8410 00 ...

Page 551: ...02 22 Interior fuse and relay box III ...

Page 552: ...02 23 8410 00 ...

Page 553: ...02 24 Interior fuse and relay box IV ...

Page 554: ...02 25 8410 00 ...

Page 555: ...02 26 3 ICM Box The ICM box is installed on the back side of the instrument panel Arrangement of connectors and relays ...

Page 556: ...t CE box and fuse no 52 in the interior IP box This relay is controlled ON OFF by the relay operation signal which is connected to the no A11 of the BCM The rear fog lamp is turned on when the rear fog lamp switch is turned on with the headlamp turned on i e IGN2 switch ON Turning on the rear fog lamp switch again when the relay is activated turns off the fog lamp The rear fog lamps do not come ON...

Page 557: ... switch with IGN ON the mirrors are folded or unfolded according to the previous mirror position If the mirror is already folded then the mirror will be unfolded and vise versa This operation will be performed for T1 For models with SKM The power supplied through the AM1 fuse goes to the ACC relay no 1 and IGN1 relay no 1 The power supplied through the starter motor AM2 goes to the IGN2 relay no 1...

Page 558: ... Tailgate relay The power for the tailgate relay is supplied to the ICM terminals no C10 and no B5 through the battery SB1 and fuse no 42 in the interior fuse box The relay is operated i e ON OFF by the operation signal from the BCM terminal no D6 Deactivation condition Without SKM The tailgate open relay is turned OFF immediately after the driver s door is locked or the vehicle speed becomes 3 km...

Page 559: ...ed to the ICM terminal no C1 If the gear mode conditions are met the relay is operated by the signals from the terminal no 10 of the gear selector lever 8 Power outlet relay The power for the power outlet relay is supplied to the ICM terminal no B10 through the battery SB1 and fuse no 46 in the interior fuse box The relay is earthed through the fuse no 47 in the interior fuse box and then ICM term...

Page 560: ...z Operating temperature 40 to 85 C Max humidity 95 High resistant voltage 24 V Dark current BCM without SKM 7 0 mA or less BCM with SKM 4 0 mA or less All switches OFF key removed all doors LOCK and in sleep mode Voltage drop 1 0 V or less at pin B6 and all pins for IN OUT Frequency characteristics Pin No Specification Remark Receive frequency 433 920 0 015 MHz Bandwidth 15KHz 2KHz or less Modulat...

Page 561: ...en opening door O O 3 Tail lamp control Tail lamp ON warning O O External lamp warning display X O Tail lamp auto OFF O O 4 Door ajar warning Door status management X O Door ajar warning O O 5 Seat belt control Seat belt warning O O Seat belt reminder O O 6 Sunroof warning Sunroof warning control O O Sunroof warning display X O 7 Room lamp control Door coupled room lamp and dimming control O O Roo...

Page 562: ...itch O O Lock unlock control by REKES signal O X Lock unlock control by SKM REKES control X O Lock unlock control by SKM passive entry X O Auto door lock control O O Auto door unlock crash signal control O O 12 Panic alarm Panic alarm control by REKES signal O X Panic alarm control by SKM REKES FOB X O 13 Headlamp control escort Escort control by REKES signal O X Escort control by SKM REKES FOB X ...

Page 563: ...rd warning flasher control O O Emergency hazard warning flasher control coupled with ABS O O 19 DRL Daytime Running Light control DRL Daytime Running Light control X X 20 Fog lamp control Fog lamp control O O 21 Auto light control LIN Auto light control O O 22 Immobilizer function Key coding and synchronization O X Challenge O X CAN information O X 23 Mirror folding unfolding control Folding unfol...

Page 564: ...rmal operation after blinking 4 times second Deactivated when hazard warning flasher switch is pressed once during operation by emergency braking signal 1 2 Vehicle speed exceeds 50 km h when emergency braking signal is received activated at speed of 50km h or less Vehicle speed increases more than 10 km h above the speed when the signal is received during operation by emergency braking signal Tur...

Page 565: ...reminder is activated at speed of 10 km h or higher it will remain activated If the driver seat belt is not fastened with the ignition switch ON engine running and vehicle speed above 25 km h the seat belt reminder is activated In addition if the seat belt reminder is activated at the speed of 25 km h or higher and the speed reduces to below 25 km h within 5 minutes the interior buzzer sound stops...

Page 566: ...window control 4 Door ajar warning 17 System power sleep mode 5 Seat belt control 18 Flasher function 6 Sunroof warning 19 DRL daytime running lamp control 7 Room lamp control 20 Fog lamp control 8 Key hole illumination control 21 Auto light control LIN 9 Defogger control 22 Immobilizer function 10 Keyless entry function 23 Folding unfolding function 11 Door lock unlock control 24 Approach puddle ...

Page 567: ... wiper motor is in the parking position While the wiper operates at high speed when the mist switch signal is received it operates at low speed if the switch is returned to its starting position 1 2 Front washer coupled wiper When holding the front washer switch at ON position for more than 0 6 seconds with IGN ON the wiper relay is activated 0 5 seconds after The wiper stops after three more wipe...

Page 568: ...the washer motor stops and the front washer or automatic washer motor begins to operate 1 2 When holding the front washer switch at ON position for 0 1 to 0 59 seconds during the wiper operation by the intermittent automatic wiper switch the wiper will operate only once When holding the washer switch for more than 0 6 seconds the wiper relay is activated 0 5 seconds after The wiper stops after thr...

Page 569: ...d for 1 5 seconds and the wipers operate 3 times again The auto washer switch signal is overridden during speed sensitive intermittent wiper washer coupled wiper or auto washer coupled wiper operation When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent automatic wiping mode will be started The front and rear wa...

Page 570: ...03 13 8710 01 ...

Page 571: ...n AUTO position the wiper system operates according to the LIN data The data received from the rain sensor is recognized for 2 times consecutively Operation when recognizing data No data wiper low high relay OFF Low speed signal low relay ON ON for at least one cycle but high relay OFF High speed signal high relay ON ON for at least one cycle but low relay OFF The washer switch signal is overridde...

Page 572: ...rning the ignition switch to ON from OFF position When turning the intermittent automatic wiper switch to ON from OFF position with IGN ON the wipers operate once at low speed initially regardless of the communication with the rain sensor After that the wipers operate once at low speed only when the rain sensor detects the side fascia panel 1 2 ...

Page 573: ... activated when the data coupled with rain sensor indicates continuous wiper operation Even though the wiping system is in washer coupled wiper mode the operating data are sent to rain sensor 1 2 Sensitivity adjustment instant wiping When the wiping speed control switch is turned to FAST with IGN2 ON intermittent automatic wiper switch in ON position and wiper motor stop parking position the wiper...

Page 574: ...itch in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is shorted to power with IGN2 ON and intermittent wiper switch in ON position the wiper system sends the signal for current wiping status for 2 seconds After that it sends the current signal for parking status continuously The wiper motor runs only when the rain sensor requir...

Page 575: ...m 3 stage with IGN ON and intermittent automatic wiper switch in ON position the wiper motor operates one cycle at low speed 1 If the BCM is received the signal for communication error from the rain sensor unit when turning the wiping speed control switch to 3 from 4 stage with IGN ON and intermittent automatic wiper switch in ON position the wiper motor operates one cycle at low speed 2 ...

Page 576: ...tent wiper switch in ON position the wipers do not operate When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position the wipers operate one cycle The wiper s operation cycle depends on the vehicle speed CAN communication with instrument cluster and wiping speed the side fascia panel Operation cycle 3 0 5 sec FAST to 19 2 sec SLOW 1 2 3 ...

Page 577: ...ing wiper operation in low high mode even though the system does not receive P POS signal During intermittent automatic wiper operation the wiper relay should be deactivated after 5 seconds if there is no P POS signal for 3 seconds in order to inform the driver of faulty signal While the wiper operates at low high speed the front rear washer switch can be operated but the auto washer switch cannot...

Page 578: ...ile the ignition key is inserted into the key cylinder the buzzer sound for 10 seconds with the interval of 0 02 s ON and 1 38 s OFF When removing the ignition key or closing the driver door during the buzzer output within 10 seconds the buzzer stops its operation This function is not available when the ignition switch IGN1 is in ON position 1 2 3 ...

Page 579: ...ds and unlocked The door remain unlocked even when the door lock switch is received door lock signal within 0 5 seconds after opening and closing the door However the doors should not be unlocked when removing the ignition key during the locking process by door lock switch 1 2 3 1 Driver door lock switch or passenger door lock switch 2 Driver door switch or passenger door switch ...

Page 580: ...hen closing the door during unlock The system also performs operation as above while the key is removed or the ignition switch is turned to ON position The ignition key reminder function is activated while the ignition key is inserted into the key cylinder This function is not available when the vehicle speed is over 10 km h 1 2 3 4 1 Driver door lock switch or passenger door lock switch 2 Driver ...

Page 581: ... the driver door with the key removed without SKM with IGN OFF or ACC with SKM and tail lamp ON The buzzer stops its operation when turning off the tail lamp or closing the driver door during buzzer operation The buzzer stays ON when turning the tail lamp on again after turning it off during buzzer operation This function is not available when the ignition switch IGN1 is in ON position 1 2 3 ...

Page 582: ... the ignition key without SKM and turning on the ignition with SKM after tail lamp auto OFF The tail lamp should not go off when turning on the tail lamp switch with the ignition key removed without SKM and with power off or ACC ON with SKM 1 2 3 Tail lamp ON warning with SKM The tail lamp ON warning signal is sent via the BCAN communication when the tail lamp remains ON with the ignition key OFF ...

Page 583: ... door ajar warning lamp according to the signal from the BCM However the BCM controls the door ajar warning lamp with the electric wire together with the BCAN communication Also the instrument cluster controls the blinking function according to the vehicle speed However the BCM controls the door ajar warning lamp blinking with the electric wire together with the BCAN communication 1 2 1 Ajar Drive...

Page 584: ...cupied For the driver seat the seat belt reminder operates only when the seat belt is not fastened at the vehicle speed of 25 km h or higher The instrument cluster module controls the driver passenger seat belt warning lamps by receiving the driver passenger seat belt warning lamp signals When turning the ignition switch IGN1 to OFF position during the warning operation the buzzer stops and the wa...

Page 585: ...ds for 5 minutes If the seat belt reminder is operated due to unfastened passenger seat belt when the passenger seat belt reminder sensor detects that the passenger seat is occupied the instrument cluster sends the driver seat belt warning signal and the seat belt warning lamp stays on For this case the indicator shows each status of the driver and passenger seats but the indoor buzzer is common t...

Page 586: ...03 29 8710 01 ...

Page 587: ... closing the driver door or closing the sunroof during indoor buzzer operation the buzzer stops its operation immediately When closing the driver door or sunroof and opening again during warning operation the sunroof warning does not work If the condition is met after the ignition switch is turned to ON position again the indoor buzzer sounds for 10 seconds with the interval of 0 02s ON 1 58s OFF ...

Page 588: ...h IGN OFF key removed and door closed the room lamps come on for 30 seconds It operates depending on REKES unlock and manual unlock signals for BCM with SKM 4 When receiving the door unlock signal again in Step 4 the overhead room lamp and center room lamp stay on for 30 seconds additionally For BCM with SKM the extension depends on the REKES unlock signal When opening a door during the linked and...

Page 589: ...ition switch to ON position in Virgin condition the lamp comes on for 8 seconds with the interval of 0 5s ON 0 5s OFF 1 2 3 4 5 6 1 ON IGN ON OFF IGN OFF 2 Open driver or passenger door is open Close driver and passenger door are closed Room lamp OFF control The room lamps stop operating when the BCM enters into the theft deterrent or sleep mode This is to prevent battery discharge if the overhead...

Page 590: ...itch during the operation the defogger stops working If turning ON the defogger again within 10 minutes after completion of the first 12 minute operation the defogger additionally operates for 6 minutes one time only However this not applied if the defogger has been turned off by engine stop or defogger switch The defogger stops working when the ignition switch is turned to OFF position or engine ...

Page 591: ...ch during the operation the defogger stops working If turning ON the defogger again within 10 minutes after completion of the first 12 minute operation the defogger additionally operates for 6 minutes one time only However this not applied if the defogger has been turned off by engine stop or defogger switch The defogger stops working when the ignition switch is turned to OFF position or engine sp...

Page 592: ...ors and the tailgate and deactivates the theft deterrent mode When the theft deterrent mode is deactivated the emergency hazard lights blink once If the door tailgate or engine hood is not opened within 30 seconds after unlocking the door with the remote control key in theft deterrent mode the door is locked automatically hazard warning flasher blinks twice and buzzer sounds once entering into the...

Page 593: ...y from the ignition switch to avoid unintended operation If any of doors could not be locked when pressing the LOCK switch the system performs the unlock operation 1 2 3 4 5 Door lock escort button Locking door and tailgate briefly press If you press this button all doors and the tailgate are locked and the theft deterrent mode is activated When the theft deterrent mode is activated the hazard war...

Page 594: ... unlocked The REKES operation is not available when the ignition key is in the key switch Also it is not possible to use the switches on the remote control key for 1 second after removing the ignition key from the ignition switch to avoid unintended operation 1 2 3 4 Remote panic When pressing over 2 0 sec the PANIC switch on the transmitter the panic alarm is activated When receiving the panic me...

Page 595: ...ned within 30 seconds after unlocking the doors with remote control key in theft deterrent mode all doors will be automatically locked again change to theft deterrent mode If any door is not opened or the key is not detected within 30 seconds after receiving the unlock signal the lock signal is outputted and theft deterrent mode is activated When entering into the theft deterrent mode the turn sig...

Page 596: ... the door lock knob switch is not available when sending the LOCK UNLOCK signal by any other method such as remote control key When reconnecting the battery the door lock knob switch is not operational regardless of the door lock switch positions All doors stay unlocked when receiving the door lock signal in 0 5 seconds after closing the doors 1 2 3 4 5 The status for key cylinder switch and latch...

Page 597: ... is in theft deterrent mode When turning the ignition off all doors are automatically unlocked if any of the door lock knob switches is in LOCK position When pressing the central door lock switch with any door open the system unlocks the doors immediately after locking them 1 2 3 4 Door lock unlock control by REKES signal When receiving the door lock signal BCM sends the LOCK signal for 0 5 second...

Page 598: ... signal when pressing the door lock switch of the smart key s remote control with IGN OFF or ACC ON it sends door lock signal for 0 5 seconds If the BCM receives the UNLOCK command through the BCAN communication when pressing the door unlock switch of the smart key s remote control with IGN OFF or ACC ON it sends door unlock signal for 0 5 seconds 1 2 ...

Page 599: ...ut for 0 5 seconds when operating the outside door handle switch with IGN OFF ACC ON or IGN ON The BCM does not perform door lock if the driver door is unlocked when receiving the outside door handle switch signal with IGN ON The BCM activates door lock output for 0 5 seconds if the driver door is unlocked after receiving door lock unlock command BCAN signal outside door handle signal with IGN OFF...

Page 600: ...g Step 2 BCM sends the lock signal for the door up to 5 times The unlock output is activated automatically when door lock output conditions are met by this function or the IGN1 switch is turned to OFF from ON position even though the lock output is not activated if the vehicle speed is maintained above 30 km h under lock condition If the LOCK condition is established with the ignition switch ON th...

Page 601: ...F BCM sends the door unlock signal for 5 seconds after 0 04 seconds The unlock signal is sent for the remaining of the period even when turning OFF the ignition switch while receiving the unlock signal due to the crash The room lamps come ON when receiving the crash signal except when the front room lamp switch is in OFF position The turn signal lamps also blink when receiving the crash signal Thi...

Page 602: ... panic alarm stops other commands are overridden The theft deterrent functions are as below The theft deterrent alarm stops when receiving the panic alarm during its operation The panic alarm stops and then the theft deterrent alarm starts its operation when occurring the theft deterrent alarm conditions during panic alarm This function should be available regardless of the key status This functio...

Page 603: ...h Power OFF ACC and IGN ON The BCM stops the panic function and operates the function depending on the signal in the event of following commands during turn signal lamp and horn operation by the Panic command from smart key remote control The panic alarm stops and then the theft deterrent alarm starts its operation when occurring the theft deterrent alarm conditions during panic alarm All the func...

Page 604: ...e BCM activates the headlamp relay for 20 seconds Activating the escort function again during its operation will operate for another 20 seconds one time only for BCM with REKES The escort function stops as soon as the door lock is operated or igntion switch is turned to ON position during escort operation For BCM with REKES the function also stops when the key insertion is detected 1 2 ...

Page 605: ...ps go off when the ignition switch is turned to ON position during relay operation 1 2 3 Coming home lighting control The low beam keeps on for 30 seconds when the ignition switch is turned to ON from OFF position with the headlamp ON Coming home lighting OFF condition This function can be activated or deactivated with the diagnostic device default setting active 1 2 3 3 minutes after all doors an...

Page 606: ... turned ON for about 1 second The tailgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h during its operation When the tailgate switch on smart key is pressed in theft deterrent mode or with the smart key detected by the exterior antenna the SKM verifies the smart key and disarms the tailgate only When the tailgate is open and closed the...

Page 607: ...horn sound once When receiving the door lock signal with any door except tailgate and engine hood open the doors are unlocked immediately after locking them first When receiving the door lock signal with the tailgate or engine hood open the doors are closed if they are open but the theft deterrent mode is not activated However when closing the opened tailgate or engine hood the theft deterrent mod...

Page 608: ...ter completion of theft deterrent alarm for 30 seconds Horn and the turn signal lamps operate for 30 seconds with the interval of 0 5s ON 0 5s OFF Disarming conditions of theft deterrent mode 5 When pressing any switch lock unlock panic on the remote control key during the theft deterrent alarm the alarm stops its operation When turning the ignition switch to ON position during the theft deterrent...

Page 609: ...03 52 The theft deterrent alarm status is stored in the EEPROM and monitoring is followed by operation when connecting the battery ...

Page 610: ...l when the driver door is unlocked and any of doors is open The BCM locks all the doors and system does not enter into theft deterrent mode if all the doors are closed when the door lock signal is received from the smart key remote control with the tailgate and engine hood open However if the tailgate and engine hood is closed the turn signal lamps blink twice exterior buzzer sounds once and theft...

Page 611: ...s open The BCM locks all the doors and system does not enter into theft deterrent mode if all the doors are closed when the door lock signal is received from the outside door handle switch with the tailgate and engine hood open However if the tailgate and engine hood is closed the turn signal lamps blink twice exterior buzzer sounds once and theft deterrent mode is entered If all the doors tailgat...

Page 612: ...gate or engine hood is open in theft deterrent mode When unlocking the door lock switch in theft deterrent mode When opening a door after completion of theft deterrent alarm for 30 seconds Horn and the turn signal lamps operate for 30 seconds with the interval of 0 5s ON 0 5s OFF Warning cancellation requirements 6 The theft deterrent alarm is deactivated by the following BCAN signals during its o...

Page 613: ...eived the signal indicating that the verified smart key is not in the vehicle when the tailgate is closed again the system enters into the theft deterrent mode again in 1 second At this time the turn signal lamps blink twice and exterior buzzer sounds once by the BCM Operation when disarming 8 The horn and the turn signal lamps stop their operation ...

Page 614: ... system power down If any of conditions in Step 1 is not satisfied the System Wake up mode is activated When output such as room lamp key hole illumination tail lamps and power window is activating or all the doors keep closed for 30 seconds after door is unlocked for conditions in Step 1 the system is in normal mode Then if there is no change within 6 seconds with all output conditions and ready ...

Page 615: ...rior buzzer sounds with same interval Defective conditions by BCM Open below load of 3 0 A Short over load of 7 0 A load means lamp load here When turning ON the turn signal switch the lamp blinks 3 times by the BCM When turning OFF the switch during the operation the turn signal lamp blinks 3 times and goes off When turning OFF and then immediately ON the turn signal switch during auto blinking o...

Page 616: ...intervals of 300 ms ON 300 ms OFF for 100 min and the interior buzzer sounds with same interval Defective conditions by BCM Open below load of 3 0 A Short over load of 7 0 A load means lamp load here When turning ON the turn signal switch the lamp blinks 3 times by the BCM When turning OFF the switch during the operation the turn signal lamp blinks 3 times and goes off When turning OFF and then im...

Page 617: ...This function is available if the battery is connected B If the turn signal lamp is defective during its operation the left turn signal lamp blinks with the interval of 300 ms ON 300 ms OFF 100 min and the interior buzzer sounds with same interval The tolerance between left turn signal lamp and right turn signal lamp should be below 100 ms The hazard flasher has a priority over the turn signal lam...

Page 618: ...zard flasher is operated for more than 0 6 seconds the hazard flasher indicator blinks 10 times The hazard flasher has priority over the auto hazard flasher and both have the same flash frequency This function is only available when the ignition key is in the ON position When the ignition switch is turned to OFF position during its operation the auto hazard flasher stops the operation The hazard f...

Page 619: ... hazard flasher Emergency stop signal Emergency auto hazard flasher Auto hazard flasher If emergency stop signal is received through PCAN communication during hazard flasher operation the signal is overridden If the emergency hazard flasher signal is received during multi function automatic hazard flasher operation or multi function automatic hazard flasher is received during emergency hazard flas...

Page 620: ...peration by emergency braking signal the emergency hazard flasher stops operation When turning emergency hazard flasher switch OFF during operation by emergency braking signal it stops operation It is deactivated automatically 10 seconds after if items 2 and 3 above are not met during operation by emergency braking signal If multi function automatic hazard flasher signal is received during operati...

Page 621: ... available in the vehicle with DRL system If there is no DRL activation signal the light system operates in normal conditions 1 2 3 4 5 20 Fog Lamp Control When pressing the rear fog lamp switch with IGN2 ON headlamp ON condition the rear fog lamps are turned ON When pressing the rear fog lamp switch again during the operation the rear fog lamps are turned OFF The rear fog lamps do not come ON whe...

Page 622: ...Auto Light Control LIN The BCM communicates with the auto light sensor when turning the ignition switch to ON position and controls the tail lamps and the headlamps depending on the LIN data with the light switch AUTO 1 ...

Page 623: ...y the mirror folding operation is performed You can control the mirror position within the first 30 sec after turning the ignition OFF In other words this control must be available for 30 seconds time lag period after turning the ignition switch to OFF position Folding unfolding is completed when time lag of 30 seconds elapse during operation When receiving the folding unfolding signal during the ...

Page 624: ...ally The outside rearview mirror will be folded automatically if the auto folding function is set The factory setting is the enabling the auto folding function 4 5 23 Approach Puddle Lamp Control Without SKM Approach lamp ON 1 When receiving the UNLOCK signal in the theft deterrent mode the approach lamps come ON for 30 seconds When turning the ignition switch to OFF from ON position and opening t...

Page 625: ...eterrent mode the approach lamps come ON for 30 seconds When receiving the AUTO approach signal in the theft deterrent mode the approach lamps come ON for 30 seconds Approach lamp OFF 2 When receiving the door lock signal from the smart key remote control or outside door handle switch signal with the approach lamps ON the lamps go OFF reactivation of theft deterrent mode When turning the ignition ...

Page 626: ...cy and RF Radio frequency When the ignition switch is turned to ON position the BCM checks the verified transponder according to the immobilizer verification procedure if correct allows the vehicle to start the engine The immobilizer indicator comes on during the communication and if the verification is carried out successfully the indicator goes off If there is something wrong in the system the i...

Page 627: ...REKES key Immobilizer antenna ECU CAN line For the vehicle with the immobilizer there can be a problem in starting the vehicle or the system error When two or more immobilizer keys come into contact with each other s When the key is close to any device sending or receiving electromagnetic fields or waves other than Ssangyong products When the key is close to any electronic or electric devices such...

Page 628: ...side cover and main cover Replace transponder 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 please attend on the site In any cases the immobilizer system can not be removed from the vehicle If you attempt to remove it and damage the system starting will be impossible s...

Page 629: ...03 87 0000 00 1 REKES KEY Insert the ignition key into the key cylinder and turn it to ON position 1 Select vehicle type and system BCM on the diagnostic program and perform the diagnosis 2 ...

Page 630: ...03 88 Operate the PANIC button on the first REKES key for more than 2 seconds 4 Select REKES key coding menu and enter the password default value 0000 Press Next 3 ...

Page 631: ... from the vehicle and proceed second REKES key coding 5 REKES key coding should be carried out with IGN ON Therefore do not change the ignition key inserted into the key cylinder after finishing the coding for the first REKES key and use the PANIC button on the REKES key for coding from second time onwards ...

Page 632: ...03 90 Once the registration is completed press OK button REKES key can be registered up to 5 8 Listen for a beep from the vehicle 7 ...

Page 633: ...03 91 0000 00 2 TRANSPONDER BCM Insert the ignition key into the key cylinder and turn it to ON position 1 Select vehicle type and system BCM on the diagnostic program and perform the diagnosis 2 ...

Page 634: ...03 92 Press Next with the first key in the key box 4 Select Transponder registration menu and enter the password default value 0000 Press Next 3 ...

Page 635: ...ed insert another key into the key cylinder within 10 seconds and press Next for additional coding or press Done to exit the program 6 When first transponder coding is completed insert the second key into the key cylinder within 10 seconds and press Next 5 ...

Page 636: ...03 94 If the transponder registration fails press Previous and perform the procedures again 8 Once the registration is completed press OK button 7 ...

Page 637: ...03 95 0000 00 3 EMS REGISTRATION Insert the ignition key into the key cylinder and turn it to ON position 1 Select vehicle type and system BCM on the diagnostic program and perform the diagnosis 2 ...

Page 638: ...03 96 Select EMS registration menu and enter the password default value 0000 Press Next 3 ...

Page 639: ...03 97 0000 00 Once the EMS registration is completed turn the ignition off and press OK 5 Select EMS registration menu and enter the password default value 0000 Press Next 4 ...

Page 640: ...03 98 Once the EMS registration is completed press OK to exit the program 6 ...

Page 641: ... ignition on and select vehicle type and system BCM on the diagnostic program for diagnosis 1 When you select Variant coding menu and select Variant check the following confirmation window is displayed If there is no change press OK button 2 ...

Page 642: ...d successfully turn the ignition off and press OK button as instructed in the screen 4 If the variant coding needs to be corrected press Change variant at the home screen for variant coding Correct the variant coding and press Start button 3 ...

Page 643: ...03 101 0000 00 Turn the ignition on and press OK button 6 Wait for 15 seconds 5 ...

Page 644: ......

Page 645: ...2 V Operating voltage DC 9 V 16 V Operation temperature 30 C to 80 C Modulation method FSK Dark current 5 5 mA Auto A P 12 mA Maximum humidity 95 Range 10 m or more OPEN SITE Voltage drop 1 0 V or less Receive frequency 433 920 0 015 MHz Bandwidth 15 KHz 2 KHz or less ...

Page 646: ...he door after confirming the smart key information and the driver s door conditions when the driver carrying a smart key touches the door handle The passive START function starts the engine when the START switch is pressed by the driver sitting on the driver s seat The passive LOCK function locks the door when the door handle switch is pressed by the driver after exiting the vehicle Buzzer Start s...

Page 647: ...04 5 8712 03 Slot Rear bumper antenna Front interior antenna Rear interior antenna Smart key ...

Page 648: ...ch Passive UNLOCK by tailgate open switch Passive START by START switch Engine ECU and High speed CAN communication BCM Instrument cluster and Low speed CAN communication RF communication for REKES operation Smart key system warning function Smart key registration up to 3 keys 1 2 3 4 5 6 7 8 ...

Page 649: ...Coding for each unit 2 Operation with without smart key EMS registration Passive LOCK UNLOCK Ignition status change STARTING THE ENGINE New O 10 times Smart key registration O O EMS REGISTRATION Smart key EMS registration O O O 3 OPERATIONS ...

Page 650: ...e value from the EMS and no value is stored in the inactive memory area after the ignition status is changed to IGN ON the START signal is not sent Power control The coding is available only when the ignition status is IGN1 ON Engine start If the SKM is in Virgin condition the engine cranking can be performed up to 10 times No variant code in memory IGN ON Check variant code Operate START switch C...

Page 651: ...ation area Searching for a smart key signal from the outside the vehicle is prioritized in theft deterrent mode Searching for a smart key signal from the inside is prioritized when the theft deterrent mode is deactivated The smart key verification is performed only for the driver s or passenger s door which has received the input from the corresponding door handle switch If a verified smart key is...

Page 652: ...04 10 Passive start operation range Passive START actuation area Vehicle interior ...

Page 653: ...LOCK signal is received from the driver passenger door handle switch When the outside door handle switch is operated the SKM verifies if a smart key is outside the vehicle using the corresponding exterior antenna The SKM sends the signal for Passive LOCK command to the BCM through the BCAN if a smart key is identified as being outside the vehicle If no smart key is verified as being outside the ve...

Page 654: ...ing in the vehicle the smart key verification procedure is stopped If no verified smart key is identified as being in the vehicle the SKM sends the signal which identifies that there is no verified key inside the vehicle to the BCM and instrument cluster through the BCAN Smart key not identified warning Interruption of door LOCK Smart key function by outside door handle switch When the door LOCK s...

Page 655: ...e BCM through the BCAN if a smart key is identified as being outside the vehicle If no smart key is identified as being outside the vehicle this process is stopped and restarted when the next signal is received from the outside door handle switch When the driver s door is locked with the ignition status ACC ON or IGN ON the SKM sends the signal for Passive UNLOCK command to the BCM through the BCA...

Page 656: ...s is stopped and restarted when the next tailgate open request signal is received 1 2 Smart key search mode The system first identifies the last smart key used and then identifies all the other registered smart keys until a normal smart key is verified If the tailgate antenna identifies a normal smart key the system searches for a smart key in inside area of the tailgate and inside the vehicle The...

Page 657: ...operation signal If a smart key is found the SKM sends the 2nd operation signal 10 min timer terminated Re entering theft deterrent mode after deactivation Duration Function Time s 1st within 5 days Normal monitoring time 1 25 2nd within 5 to 14 days Increasing monitoring time 1 5 3rd 14 days or more Vehicle is stationary The SKM sends the signals for AUTO approach REKES UNLOCK and Passive UNLOCK ...

Page 658: ...l the smart keys inside the vehicle as function limited keys Silent Smart Key The function limited smart key provides the passive START ignition status change and REKES functions except the passive UNLOCK function Function limitation Function interruption How to deactivate function limited interrupted smart key Deactivate the theft deterrent mode If no smart key which outputs the door LOCK signal ...

Page 659: ...e UNLOCK button on the smart key it transmits this signal through the BCAN 1 REKES LOCK The SKM receives the signal for REKES LOCK 0 1 sec after the LOCK button on the smart key is turned ON and it transmits this signal through the BCAN When the REKES LOCK signal is received with the ACC ON the ACC is turned OFF and the signal for REKES LOCK is sent When the SKM receives the signal for REKES LOCK ...

Page 660: ... the signals for REKES panic and REKES escort by the panic button of the smart key to the BCM Panic siren mode by REKES panic control The SKM receives the REKES panic signal 1 sec after the panic button on the smart key is turned ON with the ignition status OFF ACC or IGN ON and it transmits this signal through the BCAN The SKM receives the REKES escort signal 1 5 sec after the LOCK button on the ...

Page 661: ...r ACC ON when brake is applied with B or ACC ON when START switch is operated with B when smart key is inserted into slot brake switch is operated or START switch is operated with B Once the vehicle interior verification is completed 30 sec pre verification timer is started when the ignition is turned OFF with IGN ON and engine running 30 sec pre verification timer is started without re verificati...

Page 662: ...m the TCU initialization and coding work Start button The SKM receives the signals from the START button and changes the ignition status or stars stops the engine Immobilizer holder antenna The SKM communicates with immobilizer antenna to verify the smart keys 1 2 Output ACC relay The SKM operates the ACC relay IGN1 relay The SKM operates the IGN1 relay IGN2 relay The SKM operates the IGN2 relay S...

Page 663: ...r inserts the smart key into the immobilizer slot in emergency mode the smart key verification is performed if the brake or START switch is pressed before the ignition status is changed ACC ON IGN ON Ignition status change during driving 1 2 3 4 5 6 7 When the engine START STOP switch is pressed for 3 sec or more at more than 3 km h the ignition status is changed from IGN to ACC If the engine STAR...

Page 664: ...rough the PCAN The SKM turns on the ACC IGN2 relays after the engine cranking and sends the signal for IGN after starting through BCAN When the START button is pressed and engine cranking request1 signal is sent the EMS cranks the engine after checking the engine warming up If the engine cranking request2 signal is sent the EMS cranks the engine without checking the engine warming up 1 2 3 4 5 6 E...

Page 665: ...changed from ACC to OFF When the START button is pressed and held with IGN ON the ignition status is changed to OFF When the START button is pressed briefly the ignition status is changed to ACC ON 3 5 ACC ON Power OFF The SKM changes the ignition status to OFF from ACC ON when the engine START STOP button is pressed with the brake pedal released after the ignition status is changed from IGN ON to...

Page 666: ...04 24 6 Power Relay Control integrated with ICM 1 OFF to engine starting 2 ACC to IGN ...

Page 667: ...04 25 8712 03 3 IGN to starting 4 IGN engine ON to ACC 5 IGN engine ON to OFF ...

Page 668: ...rs are closed with B the LED does not flash Start switch indicator control Door coupled function 1 When the driver s door is opened the switch indicator comes on the indicator remains on while the door is open 2 The indicator goes off immediately when the interior lamps are turned off 3 The indicator goes off after the driver s door is closed and 10 sec ON timer is activated 4 The indicator is res...

Page 669: ...smart key searching after transmission If a smart key is found no operation is performed Smart key not found warning deactivation conditions If below conditions are met the SKM sends the signal for Smart key not found warning to deactivate the warning ACC off OR IGN1 on OR Smart key in 1 2 3 Smart key not found warning with ACC ON Smart key not found warning with IGN ENGINE ON Initial condition IG...

Page 670: ...ors or the tailgate is closed with IGN OFF or ACC ON and a smart key is in the vehicle Smart key inside vehicle warning 2 If a smart key including immobilizer slot is identified as being in the vehicle after the outside door handle switch is pressed the SKM sends the signals for external buzzer and smart key detection warning to the BCM and instrument cluster through the BCAN to inform the driver ...

Page 671: ...sec If low smart key battery is detected during the verification process for ignition status change or engine start the SKM sends the signal for smart key battery low voltage warning to the BCM and instrument cluster through the BCAN for up to 10 sec until the warning condition is deactivated Smart key battery discharge confirmation and deactivation If the smart key battery low voltage is confirme...

Page 672: ...to 10 sec until the operating conditions are deactivated Transmission position warning deactivation When re attempting to start with IGN1 ON and transmission in P or N 7 SKM error alert The SKM sends the SKM error alert signal to the instrument cluster through the BCAN for up to 10 sec when an in ignition status related error or passive entry system error occurs SKM error transmission conditions W...

Page 673: ...10 min timer is terminated 10 Smart key slot detection alert The SKM sends the smart key slot detection alert signal for 10 sec when a smart key inserted into the slot is detected with IGN OFF and the driver s door open 11 SKM alert priority 1 Smart key out alert EXTERIOR 1 2 Smart key reminder alert EXTERIOR 3 Smart key verification fail alert INTERIOR 2 4 Transponder verification failure alarm I...

Page 674: ...to the immobilizer holder in the glove box and turn the ignition on 1 Start diagnosis of the system by selecting the vehicle model and system SKM in the diagnostic program 2 When the smart key is lost start coding after performing LIMPHOME IGN CONTROL ...

Page 675: ...04 69 8712 03 Select Smart key Transponder coding from the diagnosis menu and then enter the password The initial password is 0000 Press Next 3 ...

Page 676: ...04 70 When the smart key is registered to the system insert the next smart key into the immobilizer holder within 10 sec and click Next 4 ...

Page 677: ...eted press OK button 6 To register additional keys after completing the second registration insert another smart key into the immobilizer holder within 10 sec and click Next To finish registration click Done Smart key registration up to 3 keys 5 ...

Page 678: ...S REGISTRATION Insert the smart key into the immobilizer holder in the glove box and turn the ignition on 1 Start diagnosis of the system by selecting the vehicle model and system SKM in the diagnostic program 2 ...

Page 679: ...04 73 8712 03 Select EMS registration from the diagnosis menu and then enter the password The initial password is 0000 3 ...

Page 680: ...04 74 When the registration is completed turn the ignition off and then click OK button 4 Wait for about 30 sec 5 ...

Page 681: ...04 75 8712 03 When the registration is completed click OK button 6 ...

Page 682: ...04 76 3 LIMPHOME IGN CONTROL Start diagnosis of the system by selecting the vehicle model and system SKM in the diagnostic program 1 Click Next button 2 ...

Page 683: ...04 77 8712 03 When the LIMPHOME IGN CONTROL process is completed click OK button and then register the smart keys by following the procedure 3 ...

Page 684: ......

Page 685: ...operating voltage DC 7 V 18 V Inspection voltage DC 13 5 V Operating temperature 30 80 Storage temperature 40 85 Dark current IGN OFF 1 mA 12 V Measurement condition at 25 60 seconds after that ignition is turned off and stabilized data get IGN ON Max 2 A 12 V Measurement condition at 25 during DTC check mode ...

Page 686: ...es off when turning ignition on 1 Steering wheel heating indicator added 2 Pre warning indicator rearranged 3 Winter mode indicator added STD class Previous Current Winter mode indicator added one green LED SVC class Previous Current One indicator added since steering wheel heating function is equipped ...

Page 687: ...ds used on all models e g 4WD CHECK indicator symbol 4 Warning lamps according to ISO standards 5 Ambient temperature display SVC class This is displayed for 2 seconds when activating winter mode displayed for 2 seconds when deactivating winter mode and displayed for 4 seconds when starting engine and driving off DOT LCD message Automatic Automatic Manual SVC class SVC class STD class ...

Page 688: ...ine overheat removed Both SVC and STD class Previous Current Reset by user Reset by user and automatic reset when refilling 9 TDMS logic changed SVC class Current TDMS Tier Direction Management System is not displayed when EPS warning lamp comes on SVC class STD class Pre warning indicator for engine overheat is removed EPS warning lamp TDMS display LCD not displayed EPS warning lamp comes on LCD ...

Page 689: ...es in the instrument cluster used for KORANDO C SVC super vision and STD standard While the SVC type has three LCD screens DOT LCD GAGE SEG LCD and ODO SEG LCD the STD type has one LCD screen 2 LAYOUT SVC ODO SEG LCD GAGE SEG LCD GAGE SEG LCD ...

Page 690: ...05 8 Engine RPM gauge Speedometer STD LCD ...

Page 691: ...05 9 8010 01 1 SVC 3 Description of Warning Lamps Indicators ...

Page 692: ...05 10 2 STD ...

Page 693: ...il lamp is switched on This indicator comes on when the ignition switch is turned to the ON position and will go off when the glow plugs are sufficiently heated This indicator comes on when the water level in the fuel filter exceeds a certain level This lamp comes on when the headlamp high beam is operated This indicator comes on when the fog lamp switch is operated after the tail lamps comes on 3...

Page 694: ...nsor and cluster When the coolant temperature is 120 C or higher this lamp blinks at an interval of 1 second a message is displayed the warning sounds once through the speaker and the buzzer sounds at an interval of 0 5 seconds This lamp comes on when any door is open or not closed completely both STD and SVC class This lamp comes on when the ignition switch is pressed ON It keeps coming on if the...

Page 695: ...tive This lamp comes on when the start switch is ON or when the battery level is low For EEM warning lamp is controlled according to CAN signal This lamp comes on when the ignition switch is turned to ON position and then goes off if the engine oil level is normal If the engine oil level warning lamp comes on while driving check the engine oil level and oil leakage This indicator comes on when the...

Page 696: ... is operated This indicator comes on the immobilizer transponder is not certified This lamp comes on when the parking brake is applied or the brake fluid is insufficient If this lamp doesn t go off after the parking brake is released check the brake fluid level first and then fluid leakage This warning light comes on when the ignition switch is turned to ON and should go out if the system is norma...

Page 697: ...es off when the brake pedal is depressed auto cruise deactivated This warning lamp comes on when the 4WD LOCK switch is pressed This indicator goes off when pressing the switch again This warning lamp comes on when the 4WD system is defective This indicator comes on when the hazard warning flashers are switched on applies to STD class This indicator comes on when the ECO cruise system is activated...

Page 698: ...luster The winter mode is used to start off on a slippery road with the 2nd gear If the switch is pressed again the winter mode is deactivated and system returns to standard mode This indicator comes on when the ignition switch is turned to the ON position and goes off when the passenger s seat belt is fastened The left turn signal indicator blinks if the light switch is pushed down to the left an...

Page 699: ...n when the winter mode switch is switched on and goes off when the switch is off This comes on together with the winter mode display on the LCD screen applies to STD class This indicator comes on when the steering wheel heating switch is operated with the ignition switch turned on and the engine running applies to SVC class ...

Page 700: ...05 18 1 SVC 4 OPERATING PROCESS 2 STD ...

Page 701: ......

Page 702: ...05 20 SVC 3 Block Diagram ...

Page 703: ...05 21 8010 01 ...

Page 704: ...05 22 STD ...

Page 705: ...05 23 8010 01 ...

Page 706: ... TRIP A TRIP B DTE AFC IFC ILLUMINATION OUT TEMP Over 1 seconds Reset function Trip A B AFC Illumination 6 to 1 level unit of outside temperature Over 3 seconds Ready Mode change Illumination OUT TEMP ODO If the Trip Reset switch is not pressed within 3 seconds after getting into the illumination mode and the ambient air temperature mode the LCD changes to next mode The factory setting mode is DTE...

Page 707: ... is switched on All input signals can be input 4 seconds after the pre warning system check indicator starts illuminating Only the symbol and DOT LCD are illuminated initially if the SKM Smart Key Module or door B CAN signal is received while B power is supplied If the ignition is switched on with the LCD illuminated the DOT LCD and the symbol follow the side fascia panel When the step 1 2 and 3 a...

Page 708: ...ched off the message GOOD BYE is displayed for 2 seconds and disappears The other LCDs go off as soon as the ignition is switched off The dial and pointer dim down for 2 seconds and go off at the same time when the DOT LCD goes off 7 ...

Page 709: ...ht is illuminated right after the ignition is turned OFF or ON is ignored The LCD backlight and other lamps are illuminated 0 4 0 1 second after the ignition ON is detected The LCD display LCD backlight dial lamp and indicator lamp are turned on or off by the ignition switch ON OFF operation ...

Page 710: ...100 70 Operating power Illumination previous DOT LCD ODO GAGE LCD Dial pointer Day Night Day Night Day Night B B CAN Wake UP After Level 6 Level 6 OFF however level 6 for initial operation with B IGN1 ON After 1st time Maintains previous level Maintains previous level OFF however maintains previous level for initial operation with B IGN1 ON IGN1 Level 1 25 5 25 5 25 5 Level 2 40 12 40 12 40 12 Lev...

Page 711: ...05 29 8010 01 1 SVC Symbols in SVC 6 System Analysis ...

Page 712: ...05 30 Symbols in SVC via CAN ...

Page 713: ...osition IGN ON detecting time 40 80 ms after turning ignition switch to ON position The pre warning is performed for 4 seconds after turning the ignition switch to ON position BCM checks that the warning lamps ABS ESP ESP OFF 4WD CHECK 4WD LOCK are matched with CAN signals The pre warning is performed by the variant code ...

Page 714: ...05 32 2 STD Symbols in STD ...

Page 715: ...osition IGN ON detecting time 40 80 ms after turning ignition switch to ON position The pre warning is performed for 4 seconds after turning the ignition switch to ON position BCM checks that the warning lamps ABS ESP ESP OFF 4WD CHECK 4WD LOCK are matched with CAN signals The pre warning is performed by the variant code ...

Page 716: ...05 34 Symbols in STD via CAN ...

Page 717: ...05 35 8010 01 ...

Page 718: ...ulated by using the value of pulse per 1 km which is programmed in the EEPROM Applicable maximum driving speed is 300 km h If the vehicle speed goes over the limit ODO and Trip meter does not operate any more and the pointer indicates the maximum km h MPH The pulse count information is sent from the speed module according to the speed CAN data that matches the speed frequency ...

Page 719: ...e first time Press and hold mode switch for more than 1 sec Maximum Odo value If the signal indicating actual vehicle speed above 300 km h is received the data is not accumulated Function Signal Remark Input data Speed signal Display type 6 digits LCD Display range 0 999999 km mile Hold Resolution 1 km mile Maximum Odo value If the signal indicating actual vehicle speed above 300 km h is received ...

Page 720: ...m mile Display interval every 1 seconds 1 DTE Distance To Empty Mode The DTE distance to empty function is an estimation on how much further the vehicle can be driven with the fuel remaining in the tank based on the previous driving pattern fuel economy 8 Display Mode STD Class Odometer Display Data Storage STD SVC ...

Page 721: ...umption Mode The LCD display indicates average fuel consumption calculated based on total driving distance and total fuel consumption since B power supply or data reset 3 Instant Fuel Consumption Mode The LCD display indicates the instant fuel consumption for 2 seconds calculated based on driving distance and fuel consumption for last 2 seconds Function Signal Remark Display type 3 digits LCD Disp...

Page 722: ...nsumption is displayed at every 200 ms based on the fuel consumption and driving distance for 600 ms Function Signal Remark Display type DOT BAR TYPE 92DOT Display range 0 0 20 ℓ 100km km ℓ 0 0 50 MPG Resolution DOT 0 2174 ℓ 100km km ℓ per Bar 0 5435 MPG per Bar Display interval every 200ms 25 SVC ...

Page 723: ...splayed on the SEG LCD Function Signal Remark Display type 3 digits LCD Display range Resolution 1 1 TRIP RESET switch Press for less than 1 second change to next mode Press for more than 1 second Enter into illumination level mode Level changes by 1 step up and down when pressing the switch for more than 1 second on consecutively illumination mode e g Level 4 5 6 5 4 3 2 1 If the Trip Reset switc...

Page 724: ...nly Except Middle East Buzzer Priority ON_Time OFF_Time PAS O O 0 Over speed warning O X 500 ms 200 ms 1 ESP O O 100 ms 100 ms 2 Temperature warning O O 500 ms 500 ms 3 Fuel filter O O 500 ms 500 ms 4 Parking brake O O 2 8 s 1 5 s 5 Modulating frequency 1 96 kHz If the signal with higher priority is activated during the operation of signal with lower priority the current operation should be comple...

Page 725: ...n sensor or communication problem the information for the failed sensor is sent to the instrument cluster Fail condition However no obstacle should be within 30 cm 1 The signal wire is open 2 The power wire and is open Buzzer interval during self diagnosis 1 Sensor Operating Process The ultrasonic sensors transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it in th...

Page 726: ...d the PAS returns to undetected condition Process while re inputting After timeout the process is performed normally if the signal required for display is received from beginning to end not detectable if the signal is received in the midst of process 1 2 Exception error handling Buzzer interval when measuring distance ...

Page 727: ...tting mode Average fuel consumption indicates average fuel control Reset Press and hold the Trip switch for more than 1 second Instant fuel consumption indicates fuel consumption for a short periods TRIP switch Illumination brightness indicates tail lamp brightness control Brightness control Press and hold the Trip switch for more than 1 second Start up screen Displayed for 2 seconds right after i...

Page 728: ...hould be depressed and the ignition switch be pressed in order to start the engine if the ignition is switched to ACC mode for more than one time when the driver keeps pressing the ignition switch without depressing the brake pedal This message informs the driver that the clutch pedal should be depressed and the ignition switch be pressed in order to start the engine if the ignition is switched to...

Page 729: ...ny of the doors is open or closed While the door tailgate is displayed in 4 steps the hood displayed in 3 steps Parking aid system If any obstacle is detected in the rear of the vehicle when the shift lever is moved to R position with IGN ON each sensor shows its position and distance If any error is detected during initial diagnosis it is displayed as Other than that is operated in the same way a...

Page 730: ...is message comes on when the sunroof is open with the ignition in the OFF or ACC position For the vehicle without SKM this comes on when the sunroof is open with the ignition in the OFF position and the key removed Low fuel level This message comes on when the remaining fuel is insufficient ESP check This message comes on when the ESP system is faulty ABS check This message comes on when the ABS s...

Page 731: ...is message helps the driver to predict the driving direction since the tire alignment is displayed on the instrument cluster The images on the left show that the tires are aligned to the left When the tires are aligned to the right the image is symmetrical vertically Tire alignment is displayed between level 0 and level 5 depending on the alignment degree when the ignition switch is turned to ON p...

Page 732: ...gments are ON The spanner symbol goes off if CAN messages to the instrument cluster are OK If not it blinks The mode and illumination switch inputs are overridden 6 VARIANT CODING The instrument cluster enables all functions by receiving the vehicle s variant codes through CAN communication when turning the ignition switch to ON position The systems verified by variant code performs the pre warnin...

Page 733: ...ing circuit for the ambient temperature sensor added to the manual air conditioner controller for ambient temperature display on the instrument cluster Lower main panel switch Previous Current Changed layout due to addition of steering wheel heating switch Steering wheel heating switch ...

Page 734: ...06 4 Audio remote control switch Previous Current Bluetooth handsfree function added and button logo design changed ...

Page 735: ... 1 OVERVIEW Door panel switch driver Door panel switch passenger Door panel switch rear IP panel switch Steering wheel switch Front console switch Trunk switch Headlining switch 1 2 3 4 5 6 7 8 1 Mounting Locations ...

Page 736: ...control switch Passenger door switch Lower main panel switch Start stop switch Cruise control switch Hazard warning switch bezel assembly Multifunction switch FATC switch Drive door main switch outside mirror switch Switch layout ...

Page 737: ...enter room lamp switch Front seat heated wire switch STD Rear door switch RH Overhead console switch Rear door switch LH Tailgate switch Front seat heated wire switch DLX Luggage lamp switch Driver power seat switch ...

Page 738: ...itch 1 Driver Door Switches 2 SWITCH CLUSTER ON DOOR TRIM 1 Power window main switch Driver door window switch Rear LH window switch Window lock switch Passenger door window switch Rear RH window switch Door lock unlock switch ...

Page 739: ...itch The window is up and down while this switch is operated Rear RH window switch The window is up and down while this switch is operated Driver door window switch The driver s door window switch has Auto down Auto up function The window can be controlled within 30 seconds by activating the power window relay even after turning off the ignition switch However if any of front doors is opened or th...

Page 740: ...ower window relay is turned ON The power window relay keeps ON for 30 seconds even when stopping the engine However the power window relay is turned OFF when opening a front door When locking the door activation of theft deterrent mode the power window relay is immediately turned OFF 1 2 3 ...

Page 741: ... door locks The BCM controls the lock unlock switch using the door lock unlock relay This is a same control type with Auto door lock function that locks the doors when the vehicle speed exceeds 30 km h see circuit diagram Door lock unlock relay integrated in BCM Door lock unlock switch When the door lock unlock switch is pressed while all doors including the tailgate are locked all doors will be u...

Page 742: ...K from LOCK position BCM sends the UNLOCK signal for 0 5 seconds The LOCK UNLOCK operation by the door lock knob switch is not available when sending the LOCK UNLOCK signal by any other method such as remote control key When reconnecting the battery the door lock knob switch is not operational regardless of the door lock switch positions All doors stay unlocked when receiving the door lock signal ...

Page 743: ...n of driver door lock switch for 0 5 seconds The central door dock switch is not available when the system is in theft deterrent mode When turning the ignition off all doors are automatically unlocked if any of the door lock knob switches is in LOCK position When pressing the central door lock switch with any door open the system unlocks the doors immediately after locking them 1 2 3 4 ...

Page 744: ...ng switch Mirror selection switch The outside mirrors are folded unfolded whenever pressing this switch LH Driver side mirror RH Passenger side mirror Mirror aiming switch Adjust the selected mirror up down left or right by pressing the corresponding edges of the switch to get a desired view ...

Page 745: ...BCM without SKM When receiving the outside door handle switch signal or door lock signal from the smart key remote control the system operates in the sequence of Door lock Theft deterrent mode activation Mirror folding for BCM with SKM Auto unfolding sequence When receiving the UNLOCK signal from the REKES the system operates in the sequence of Door unlock Theft deterrent mode deactivation Mirror ...

Page 746: ...olding operation is performed You can control the mirror position within the first 30 sec after turning the ignition OFF In other words this control must be available for 30 seconds time lag period after turning the ignition switch to OFF position Folding unfolding is completed when time lag of 30 seconds elapse during operation When receiving the folding unfolding signal during the mirror folding...

Page 747: ...06 17 8510 00 2 Passenger Door Switches Passenger side door trim switch The window is up and down while this switch is operated manually Power window sub switch ...

Page 748: ...RH 3 Rear Door Switches Warmer switch Power window switch The window is up and down while this switch is pressed Press the switch to heat the seat and press again to stop the seat heating During heating the indicator light on the switch comes on ...

Page 749: ...06 19 8510 00 FATC switch 1 FATC Switches Air source mode switch Temperature dial Mode dial Fan speed dial A C switch In car temperature sensor 3 SWITCH CLUSTER ON INSTRUMENT PANEL ...

Page 750: ...rature The blower motor speed can also be controlled manually Mode dial You can choose a desired mode from the 5 modes by turning the mode as required The dial indicator for the selected mode comes on to inform the operator Air source mode switch When you press this switch recirculation indicator comes on and the system is changed into the recirculation mode However under defroster mode or defrost...

Page 751: ... flasher switch TRIP reset switch Digital clock Rear glass outside mirror heated wire switch Windshield heated wire The center fascia switch contains the hazard warning flasher switch windshield heated wire switch digital clock rear glass heated wire switch and trip switch ...

Page 752: ...on level Ambient air temperature for STD Trip A Trip B Distance to empty Average fuel consumption Instant fuel consumption Illumination level Ambient air temperature for SVC Press and hold this button to initialize reset Trip A Trip B and average fuel consumption adjust illumination level or change the unit of temperature Rear glass outside mirror heated wire switch Press this switch to turn on th...

Page 753: ... for about 12 minutes when the switch is pressed with the engine started Press the switch again to stop the operation 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 This function is available only when the engine is running Operation curve ...

Page 754: ... minutes when the switch is pressed with the engine started Press the switch again to stop the operation 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 This function is available only when the engine is running Operation curve ...

Page 755: ...age fuel consumption adjust illumination level or change the unit of temperature Description The factory setting is DTE mode Display Mode Switch Detecting time Function Briefly and hold Below 1 second 60 to 980 ms STD Mode change Odo Trip A Trip B DTE Average fuel consumption Instant fuel consumption Illumination level Ambient air temperature SVC Mode change Trip A Trip B DTE Average fuel consumpt...

Page 756: ...06 26 Lower main panel switch 3 Lower Main Panel Switch 4WD LOCK switch Steering wheel heating switch ESP OFF switch ...

Page 757: ...rease the torque to the rear wheels in AWD mode Steering wheel heating switch This switch is of push return type which is used to activate or deactivate the steering wheel heating function ESP OFF switch The ESP OFF switch is of push return type which is used to stop or resume the ESP function ...

Page 758: ...06 28 Power seat switch 1 Power seat switch Driver side 4 Power Seat Switch Assembly Seat sliding Seatback reclining Seat height adjustment Seat sliding Seatback reclining Seat height adjustment ...

Page 759: ...udio remote control switch RH Audio remote control switch LH 1 Audio Remote Control Switch 4 STEERING WHEEL SWITCH MUTE MODE switch Volume UP DOWN switch SEEK UP DOWN switch Handsfree switch Tip switch D Tip switch D ...

Page 760: ...tch Change down CD mode Select next previous track and FF REW Radio mode Change frequency UP or DOWN Press and hold to auto search MUTE MODE switch To eliminate the sound MUTE briefly press this switch To change the audio mode Radio CD USB AUX Radio press and hold this switch Handsfree switch To make receive end a call press and hold this switch ...

Page 761: ... washer switch The multifunction switch contains the auto washer and wiper switch front fog lamp switch and auto hazard warning flasher switch For the vehicle with air bag since the contact coil is fitted to the upper part of the multifunction switch and ESP steering wheel angle sensor is fitted to upper part of the contact coil pay attention to when removing and fitting or checking the wiring ...

Page 762: ...light analyzed by the automatic light sensor Lights OFF High beam ON To turn on the headlamp high beam push the lever towards the instrument cluster with the headlamp low beam on Right turn signal lamp blinks Passing Regardless of the position of the light switch when holding the lever toward the steering wheel the headlights are on high beam during the hold Front fog lamp switch To turn on the fo...

Page 763: ...ntrols automatically according to the vehicle speed or amount of rain rain sensing wiper Wiping speed gets faster when placing the pointer at the HI position Wiping speed gets slower when placing the pointer at the LO position MIST OFF AUTO LO HI Auto washer switch If pressing the switch when the wiper switch turns to the OFF position washer fluid is sprayed once and wiper operates 4 times After a...

Page 764: ...itch is released it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Page 765: ... The cruise control switch has a fivefold switch in it The engine ECU can determine the current driving condition since the resistance varies depending on the operation of the switch The cruise control system is operated at vehicle speed of between 38 km h and 150 km h The manual transmission is operated in the range of 3rd gear or higher This function can be used at the following traffic conditio...

Page 766: ...re is another horn installed at the bottom of the battery tray side in the engine compartment for theft alarm Operating the horn switch on the steering wheel applies the power to the horn relay to operate both horns Dual horn The theft deterrent horn is controlled by the BCM in armed mode regardless of the horn relay operation ...

Page 767: ...eat warmer switches are designed to control LO or HI the seat temperature Press the HI High temperature or LO Low temperature on the seat warmer switch to heat the seat and seatback When the temperature reaches 40 5 the thermistor integrated in seat connects and cuts the power to keep the temperature stable There is no separate seat warmer unit to control the heating temperature of the seat heated...

Page 768: ...eration switch ON When closing the driver or passenger door the front room lamp comes on for 2 seconds and then dims down for 3 seconds door coupled operation switch ON The front room lamp turns on off depending on the operation of the front room lamp ON OFF switch spot switch Front room lamp switch Door coupled operation switch Sunroof switch Front room lamp connector Sunroof connector ...

Page 769: ...matically opened Opening is carried out in 2 steps In first step the area 5 cm behind the sunroof is not opened Push up the switch once again in order to open the sunroof completely The sunroof operation stops if you operate the switch during its operation The sunroof is opened as long as pushing up the switch Pull down the switch briefly auto sliding close Pull down and hold the switch manual sli...

Page 770: ...ediately When receiving the door unlock signal with IGN OFF key removed and door closed the overhead console room lamp center room lamp come on for 30 seconds For specification with the SKM the lamps come on by the REKES unlock or passive unlock signal When receiving the door unlock signal again while the lamps stay on by the REKES or passive unlock signal the overhead console center room lamps st...

Page 771: ...and closing the driver door or closing the sunroof during indoor buzzer operation the buzzer stops its operation immediately When closing the driver door or sunroof and opening again during warning operation the sunroof warning does not work If the condition is met after the ignition switch is turned to ON position again the indoor buzzer sounds for 10 seconds with the interval of 0 02s ON 1 58s O...

Page 772: ...06 42 Tailgate open switch 7 TAILGATE SWITCH Tailgate open switch ...

Page 773: ...e tailgate open relay is turned OFF immediately after the driver door is locked or the vehicle speed goes over 3 km h during its operation When the tailgate switch on smart key is pressed in theft deterrent mode or with the smart key detected by the exterior antenna the SKM verifies the smart key and disarms the tailgate only When the tailgate is open and closed the system enters into the theft de...

Page 774: ...BULB 12V27W Korea P21W Other countries 2 EA High mounted stop lamp LED Without spoiler With spoiler 12 EA 24 EA License plate lamp BULB W5W 2 EA Side lamp Side repeater lamp LED 5 EA Puddle lamp LED 2 EA 2 Interior Lamps Item Type Amount Front room lamp BULB 10W FESTOON 2 EA Center room lamp BULB 10W FESTOON 1 EA Luggage lamp BULB 10W FESTOON 1 EA Sun visor lamp BULB 5W FESTOON 1 EA Glove box lamp...

Page 775: ...itting Diode or Luminescent Diode LED is a semiconductor diode that emits incoherent narrow spectrum light when electrically biased in the forward direction of the p n junction as in the common LED circuit In short it is an element that converts electric signals into light signals Yellow blue red and white LEDs are currently available The followings are the advantages of LED It is not glaring and ...

Page 776: ...07 4 Puddle approach lamp Front fog lamp Headlamp Side repeater lamp High beam low beam Turn signal lamp Position lamp 1 EXTERIOR LAMP 1 Layout ...

Page 777: ...07 5 8310 00 Rear combination lamp Vehicle without spoiler Vehicle with spoiler License plate lamp Stop lamp and tail lamp Rear fog lamp Turn signal lamp Backup lamp High mounted stop lamp ...

Page 778: ...vating the escort function again during its operation will operate for another 20 seconds one time only for BCM with REKES The escort function stops as soon as the door lock is operated or igntion switch is turned to ON position during escort operation For BCM with REKES the function also stops when the key insertion is detected Coming home lighting control 2 The headlamp is illuminated for 30 sec...

Page 779: ...d this lamp is turned on by the BCM when the rear fog lamp switch is operated after the headlamp is illuminated and it goes off when the rear fog lamp switch is operated again When the ignition switch or tail lamp switch is turned off the front fog lamp goes off When the ignition switch or headlamp switch is turned off the rear fog lamp goes off For Korean models stop lamps are installed instead o...

Page 780: ...r door during buzzer operation The buzzer stays ON when turning the tail lamp on again after turning it off during buzzer operation 1 2 Tail lamp auto turn off When opening and closing the driver door after turning off the ignition with the tail lamp ON the tail lamps go off automatically The tail lamps come on again when inserting the ignition key without SKM and turning on the ignition with SKM ...

Page 781: ...es per minute The BCM determines that there is an open circuit if the load is 3 0 A or less and there is a short circuit if the load is 7 0 A or more When turning ON the turn signal switch the lamp blinks 3 times by the BCM When turning OFF the switch during the operation the turn signal lamp blinks 3 times and goes off When turning OFF and then immediately ON the turn signal switch during auto bl...

Page 782: ...switch Automatic light sensor unit 6 Side repeater lamp Side repeater lamp The side repeater lamp is operated by the BCM when the BCM receives a signal from the multifunction switch The BCM cycles the side repeater lamp and buzzer ON OFF 75 times per minute The side repeater lamp operates only when IGN1 is ON If the side repeater lamp fails while it is illuminated the BCM cycles the lamp and buzze...

Page 783: ...l or outside door handle switch signal with the approach lamps ON the lamps go OFF reactivation of theft deterrent mode When turning the ignition switch to ON position with the approach lamps ON the lamps go OFF The approach lamps go OFF after 30 seconds Approach lamp ON 1 Lamp control for models without SKM When receiving the UNLOCK signal in the theft deterrent mode the approach lamps come ON fo...

Page 784: ...07 12 Sun visor lamp Glove box lamp Front room lamp 1 Layout 2 INTERIOR LAMPS ...

Page 785: ...07 13 8310 00 Center room lamp Luggage lamp Door courtesy lamp ...

Page 786: ...en fades out for 3 sec If the ignition is turned on the room lamp goes off immediately The front room lamp and center room lamp are illuminated for 30 sec when the door is unlocked by the REKES or passive door UNLOCK function with IGN OFF and the ignition key removed If the REKES or passive door UNLOCK signal is received again the room lamps are illuminated for another 30 sec The room lamp goes of...

Page 787: ...ch operated This lamp is not controlled by the BCM unlike the front center room lamp 3 Other interior lamps The glove box lamp comes on when the glove box is opened after the tail lamp is illuminated The sunvisor lamp comes on when the sunvisor vanity mirror cover is opened The door courtesy lamp comes on when the driver s door or passenger s door is opened ...

Page 788: ...wiper switch to the OFF position before any car wash to avoid unwanted operation of the wipers Wiper mist washer coupled wiper Auto washer coupled wiper Rain sensor coupled wiper operation LIN Speed sensitive intermittent wiper Wiper low high control Check if the sensor is off the position Check if the rain sensor cover is securely installed Check if the customer is familiar to how to control the ...

Page 789: ... wiper arm pressure Previous Current Wiper arm pressure Driver side 900 50 g Passenger side 600 50 g Wiper arm pressure Driver side 950 50 g Passenger side 650 50 g Wiper blade design changed blade size is the same Driver side 600 mm 24 in Passenger side 400 mm 16 in ...

Page 790: ...r the switch is turned ON and the wiper relay is turned ON for 4 cycles After that the washer motor is operated for about 2 seconds to spray the washer fluid again and the relay is turned ON for 3 cycles and then the relay is turned OFF 2 Rear Washer Fluid Supply System The front washer fluid reservoir supplies the rear washer fluid without additional washer fluid reservoir Operating part for rear...

Page 791: ...ance with a seamless contact condition between the mounting surface of the nozzle and the curved surface of the engine hood The inside of the nozzle is designed in a fan shape to change the spray direction continuously based on the time the fluid is sprayed Refer to the figure below The spray direction is changed by means of the whirlwind and back flow generated while the washer fluid is passing t...

Page 792: ...er switch AUTO and sensitivity control This sensor emits infrared rays through LED and then detects the amount of rain drops by receiving the rays reflected off the sensing section rain sensor mounting section on the windshield with photodiode AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay auto speed control A position that can control the sensitivity for the amount of rains...

Page 793: ... the operating request signal to the BCM which drives the wiper directly At this moment the BCM also sends the information on whether the wiper is in operation mode or whether the multifunction wiper switch is in AUTO position to the rain sensor BCM Underhood Fuse Box ...

Page 794: ......

Page 795: ... 10 Rain sensor unit 3 SYSTEM LAYOUT INCLUDING RAIN SENSOR Wiper Front wiper Rear wiper Rear washer hose and nozzle For vehicles with rear spoiler For vehicles without rear spoiler WIPER AND WASHER SWITCH ...

Page 796: ...08 11 7810 00 BCM Front nozzle assembly Washer fluid reservoir assembly Washer motor Reservoir tank Washer motor ...

Page 797: ...eed controlswitch When turning to FAST wiping speed gets faster and when turning to SLOW wiping speed gets slower Stop the operation Wiper speed controls automatically according to the vehicle speed or amount of rain rain sensing wiper Wiping speed gets faster when placing the pointer at the HI position Wiping speed gets slower when placing the pointer at the LO position MIST OFF AUTO LO HI ...

Page 798: ...e with the IGN1 ON the wiper relay is turned on after 0 1 sec has passed When the wiper returns to the park position the wiper relay is turned off When the MIST switch signal is input the wiper is operated at high speed When the switch is release from the MIST position the wiper is operated at low speed 1 2 ...

Page 799: ...g wiper operation The wiper relay should stay ON in low high wiper operation mode even if the parking signal for the wiper motor is not received In INT AUTO wiper operation mode the wiper relay should be turned OFF after 5 seconds if there is no parking signal for the wiper for 3 seconds and informs the driver of parking position signal abnormality While the wiper operates at low high speed the fr...

Page 800: ...he wiper stops after three more wipes since that the washer switch is turned to OFF position 1 2 Windshield Washer Control Function 1 Windshield washer coupled wiper Wiper and Washer Coupled Operation Pull the switch briefly for less than 0 6 sec One wiping cycle Pull and hold the switch for more than 0 6 sec Three wiping cycles with washer fluid spray ...

Page 801: ...e wiper operation by the intermittent automatic wiper switch the wiper will operate only once When holding the washer switch for more than 0 6 seconds the wiper relay is activated 0 5 seconds after The wiper stops after three more wipes since that the washer switch is turned to OFF position 2 ...

Page 802: ...er operation When turning the wiper switch to AUTO position during the operation of auto washer the auto washer stops its operation and the intermittent automatic wiping mode will be started The front and rear washer switch signal are overridden during the operation of auto washer The input from the switch during the AUTO washer coupled wiper operation also is ignored 1 2 3 4 5 2 AUTO washer coupl...

Page 803: ...d it will stop in the Rear Wiper Operation mode and only the wiper will keep operating Rear wiper operation Rear wiper stops When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer 3 Rear Wiper Control Function ...

Page 804: ...ch signal is received during the rear washer switch operation the washer motor stops and the front washer or automatic washer motor begins to operate 1 2 Rear washer motor control When the switch is fully turned washer fluid will be sprayed onto the rear window glass and the wiper will also operate When the switch is released it will return to the OFF position and turn off the wiper and washer ...

Page 805: ...5 Rain Sensor Coupled Wiper Control Function AUTO Wiper operates automatically by rain sensor FAST Auto delay auto speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly ...

Page 806: ...08 21 7810 00 System layout 1 Rain sensor coupled wiper operation LIN ...

Page 807: ...on When the INT AUTO wiper switch is turned on from off with the ignition switch ON the wiper is operated at low speed for the 1st cycle regardless of the rain sensor signals After that if the INT AUTO wiper switch is turned on from off the wiper cycles one time at low speed only when the rain sensor detects the presence of rain 1 2 2 Power up reminder wiper ...

Page 808: ...egardless of the communication with the rain sensor However if the washer switch signal is received the washer relay is activated and wiper relay remains activated when the data coupled with rain sensor indicates continuous wiper operation Even though the wiping system is in washer coupled wiper mode the operating data are sent to rain sensor 1 2 3 Washer coupled wiper operation during rain sensor...

Page 809: ...ch in ON position and wiper motor stop parking position the wiper motor operates one cycle at low speed only when the rain sensor detects raindrops If the wiping speed control switch is changed more than 2 stages within 2 seconds the wiper motor operates only one cycle 1 4 Sensitivity control instant wiping ...

Page 810: ...urrent signal for parking status continuously The wiper motor is operated only when there is a request from the rain sensor 2 The wiper system sends continuously the signal for current status when the wiper parking terminal is shorted to ground with IGN2 ON and intermittent wiper switch in ON position The wiper motor is operated only when there is a request from the rain sensor 1 5 For abnormal wi...

Page 811: ... communication error signal from the rain sensor unit with IGN ON and the INT AUTO switch ON 2 When the wiper speed control switch is turned to step 2 from step 3 the wiper motor cycles one time at low speed provided that the BCM receives a faulty sensor signal from the rain sensor unit with IGN ON and the INT AUTO switch ON 1 6 For faulty rain sensor ...

Page 812: ...sition the wipers do not operate When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position the wipers operate one cycle The wiper s operation cycle depends on the vehicle speed CAN communication with instrument cluster and wiping speed the side fascia panel Wiping cycle 3 0 5 sec FAST to 19 2 sec SLOW 1 2 3 7 Speed sensitive intermittent wiper ...

Page 813: ...08 28 Speed sensitive intermittent wiper interval ...

Page 814: ...ation if the foreign materials are removed the sensor operates normally Not defective but improperly working When the sensing portion is frozen operates normally after thawed When reversing on rough roads gravel roads hills or grass When receiving other ultrasonic signals metal sounds or air braking noises from heavy commercial vehicles When there is heavy rainfall or water drops When the sensor i...

Page 815: ...09 4 3 MAJOR CHANGES Parking aid unit Parking aid unit logic Changed sensor self diagnosis buzzer sound interval 65 ms 60 ms ...

Page 816: ......

Page 817: ...ny obstacle The PAS detects the returning signals reflected to the obstacles at regular intervals when the vehicle is parked to indicate the display and alarm for the distance between the obstacles by phase so as to allow the driver easy parking by securing safe distance 1 OVERVIEW Buzzer for PAS Buzzer sounds using instrument cluster buzzer Rearview camera Shift lever ...

Page 818: ...09 7 8790 00 2 CONFIGURATION Installation of PAS sensor Parking aid unit PAS sensor ...

Page 819: ...S receives R signal it starts to detect the obstacles behind vehicle after self diagnosis If the system detects the obstacle the buzzer sounds according to the distance If there is no obstacle starts to detect the obstacles after self diagnosis again ...

Page 820: ...h long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously Sensor detection range Within20 cm from the ground Objects may not be detected in this range Buzzer interval when measuring distance 2 Rear PAS Sensor ...

Page 821: ...09 10 Circuit diagram of ECU Internal circuit diagram of sensors ...

Page 822: ...09 11 8790 00 Sensor operating sequence The ultrasonic sensors transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it in the following order L C R ...

Page 823: ...d the PAS returns to undetected condition Process while re inputting After timeout the process is performed normally if the signal required for display is received from beginning to end not detectable if the signal is received in the midst of process 1 2 Exception error handling Self diagnosis is performed once when the ignition is switched on gear shift lever in R position If the system is defect...

Page 824: ...pe Astigma 3 beam Light source Semiconductor laser Wave length 780nm Frequency response 20Hz 20kHz 3dB Signal to noise ratio 50 dB Total harmonic distortion 1 1kHz Wow and flutter Below measurable limits Channel separation 35dB Radio Frequency range FM MW LW 87 5MHz 108MHz 522kHz 1 620kHz 144kHz 290kHz Usable sensitivity FM MW LW 18 dBu 35 dBu 35 dBu Signal to noise ratio FM MW LW 45dB 40dB 40dB S...

Page 825: ...c distortion 0 1 at 1kHz Dynamic Range 85dB at 1kHz Signal to noise ratio 60dB at 1kHz Channel separation 54dB at 1kHz Micro pole antenna Operating current up to 150 mA Operating voltage DC 10 5 16 0 V Operating temperature 30 C 60 C Storage temperature 40 C 80 C Input output impedance 75Ω FM ...

Page 826: ...t such as sports or music etc When tuned to an FM station which provides the RDS service the RDS indicator lights up the station frequency and then the station name if sent is displayed Not all FM stations provide RDS service nor do all RDS stations provide same services If in doubt check with local radio stations for details on RDS services in your area This machine can use the following RDS serv...

Page 827: ...10 6 Front door speaker Remote control switch on steering wheel 1 LAYOUT Audio CDP MP3 Radio USB AUX Bluetooth hands free Front door tweeter speaker ...

Page 828: ...10 7 8910 05 Hands free microphone Rear door speaker USB AUX Audio assembly CDP MP3 Bluetooth CDP MP3 RDS Bluetooth ...

Page 829: ...utton 1 6 and Audio function button 3 Bluetooth hands free CALL button 4 Bluetooth hands free END button 5 Previous and Next button 6 SCAN INFO button 7 BAND AS button 8 SETTING button 9 Display window LCD 10 USB AUX button 11 Disc Play button 12 Disc Eject button 13 Disc slot CDP MP3 Bluetooth ...

Page 830: ...F TA button 4 SEEK button 5 CALL button 6 Disc slot 7 CD AUX USB button 8 POWER button with VOLUME dial 9 Station memory button 1 6 10 BAND AST button 11 SCAN INFO button with dial 12 EQ SOUND button 13 END button 14 Disc Eject button CDP MP3 RDS Bluetooth ...

Page 831: ... go to the next previous preset station Press and hold to search the next previous radio station The radio seeks stations only with a strong signal that are in the selected band When playing a CD or USB Press to go to the next previous track Press and hold to fast forward backward through the tracks PHONE During the standby Press to make a call via voice activated dialing function Press and hold t...

Page 832: ...AYOUT 5 FRONT SUSPENSION COMPONENT LAYOUT 6 REAR SUSPENSION COMPONENT LAYOUT 7 BRAKE SYSTEM AND ESP SYSTEM LAYOUT 8 STEERING SYSTEM LAYOUT GENERAL INSTRUCTIONS 1 GUIDELINES FOR SERVICE WORKS 2 JACK UP POINTS 3 STANDARD BOLTS SPECIFICATIONS SPECIAL TOOLS AND EQUIPMENT 1 SPECIAL TOOLS 22 25 26 27 3 8 10 12 14 16 18 20 ...

Page 833: ......

Page 834: ...r and Cable Manual Transaxle Gear shift lever bracket Gear shift lever assembly Old New The gear shift lever bracket has been changed to adopt the premium console Gear shift cable assembly Old New The connection and socket to lever has been changed ...

Page 835: ... Steering Wheel Angle Sensor Old New The sensor has been changed due to newly adopted steering wheel heating system The location of sensor connector and the pin arrangement of connector have been changed 1 2 Sensor connector Sensor connector ...

Page 836: ...alled in the steering wheel assembly Lower main switch cluster Old New The steering wheel heating switch has been added on the lower main switch cluster Specifications Description Specification Power consumption Below 95W Rated voltage 12V Operating voltage 9V 16V Rated current 6 2 0A Steering wheel heating unit Steering wheel heating switch ...

Page 837: ...tomatic transaxle equipped vehicle Old New The parking brake lever bracket has been changed to adopt the premium console Parking brake lever assembly Manual transaxle equipped vehicle Old New The parking brake lever bracket has been changed to adopt the premium console ...

Page 838: ......

Page 839: ... of speed based on the information detected by the sensors and controls the pumping and boosting reducing keeping pressure by operating the valve and motor of HECU 2 MOUNTING LOCATIONS CHASSIS Moto HU Hydraulic Unit ECU Electronic Control Unit Moto HU Hydraulic Unit ECU Electronic Control Unit Motor angle 8P Motor power 3P Torque angle sensor 8P Battery 2P Connector to vehicle 8P Fuse for EPS Stee...

Page 840: ... receives and processes the following information from the inner sensors through CAN buses E coupling unit The E coupling unit is a control unit which determines the magnetic force by considering CAN signals wheel speed engine torque pedal opening ABS ESP CAN signals etc from other ECUs TGS Lever assembly The TGS communicates with TCU Transmission Control Unit ECU ESP HECU and instrument cluster t...

Page 841: ...nt wheel drive type 4WD vehicle Rear axle assembly The rear axle installed in this car is a removable axle called IRDA Independent Rear Differential Axle The rear differential carrier is installed directly on the sub frame and there is an independent suspension that allows each wheel on the same axle to move vertically independently of each other with the universal joint and the slip joint E coupl...

Page 842: ...t used in other vehicle so that it can be applied to FF Front engine Front wheel driving type vehicle and has an axle in one piece The engine torque and gear ratio of this transmission have been optimized to maximize driving performance It provides 6 speeds for forward travel and 1 reverse travel The 2WD vehicle with manual transmission is a front wheel drive type vehicle that doesn t have PTU pro...

Page 843: ...f the HPS type steering gear box 4 SUB FRAME AND STEERING GEAR BOX LAYOUT Front sub frame with EPS type steering gear box assembly This kind of front sub frame system has the same mounting structure with the frame with HPS But the EPS type steering gear box has no hydraulic pressure pipe since it is driven by the electric motor Rear side Front side HPS type steering gear box assembly Front sub fra...

Page 844: ...d also control the torque Rear side Front side Body mounting Rear sub frame assembly for 2WD The rear sub frame for 2WD vehicle functions in the same way as the one for 4WD vehicle but the structure is different from the one for 4WD It consists of 4 body bush mountings Body mounting Body mounting Body mounting Axle mounting Front side Body mounting Body mounting Rear side Body mounting Body mounti...

Page 845: ...this type of suspension the steering linkage tie rod is mounted on the knuckle The Macpherson Strut suspension is an independent suspension which has a spring on the strut with a built in shock absorber The lower arm is installed on sub frame and large strut damper is installed on the knuckle to support the tire Lower arm assembly The lower arm assembly connects the frame and knuckle It supports t...

Page 846: ...pe Its energy absorption rate per weight is higher than that of the leaf spring and it allows to absorb small vibration properly resulted in keeping the ride comforts Therefore it s difficult to make an effect on vibration damping because there is not any friction between coils Coil spring Shock absorber assembly ...

Page 847: ...sembly This vehicle uses the gas shock absorber This relieves the vertical vibrations of vehicle to provide ride comforts prevents the spring break enhances drivability and extends the life span of steering components Upper arm assembly Upper arm is installed between knuckle and sub frame and controls the lateral load and vehicle height Trailing arm assembly Trailing arm is installed between knuck...

Page 848: ... frame to minimize the tilting of the body Coil spring Coil spring is installed between the coil spring link and body frame It relieves the vibrations and impacts from wheels to vehicle body Lower arm assembly The lower arm is installed between knuckle and rear sub frame and relieves the load to coil spring from wheel In other word it controls the longitudinal load Stabilizer bar Bushing Clamp Lin...

Page 849: ... other D Front brake assembly The disc brake for 4WD vehicle is the same with the one for 2WD vehicle 7 BRAKE SYSTEM AND ESP SYSTEM LAYOUT B Master cylinder assembly Description for master cylinder in this chapter is based on ABS ESP equipped vehicle For CBS there is an extra pressure valve mounted to the master cylinder Caliper Disc Parking brake warning light ABS warning lamp ESP indicator ...

Page 850: ...brake for 4WD vehicle has the same structure with the one for 2WD vehicle but the appearance and knuckle shape is different from each other Caliper G Brake pedal Disc F Parking brake 4WD and 2WD Front side 2WD Rear side The wheel speed sensor for 4WD has the same structure and mounting location with the one for 2WD vehicle But the rear side wheel speed sensor for 2WD vehicle has different sensor a...

Page 851: ... Hydraulic Power Steering The hydraulic pump is a vane type pump and consists of the flow control valve and pressure relief valve The oil reservoir sends the oil to the power steering pump and receives the oil from the power steering gear There is a shock absorber which is folded in the axial direction when the vehicle is crashed and a ignition switch assembly on the column shaft The lower shaft m...

Page 852: ... to run the electric motor At this time the worm gear connected to the motor drives the helical gear mounted to the steering column to generate the assist torque for the steering column This allows the driver to operate the steering wheel easier ECU Tie rod end Tie rod end Gear box Steering cylinder Steering wheel assembly BLAC motor Lower shaft Column shaft Colum shaft assembly The column shaft a...

Page 853: ...his manual and follow the instructions carefully Signal words such as WARNING CAUTION and NOTE have special meanings indicates information to assist maintenance and instructions However above references and cautions cannot be inclusive measures so should have habits of paying attentions and cautions based on common senses indicates a potentially hazardous situation which if not avoided may result ...

Page 854: ...the disassembled parts as a set based on disassembly order and unit Pay particular attention not to miss or mix the fasteners If necessary especially for inspection clean the removed parts completely Apply the oil or grease on the running and sliding surfeces before installation Use the specified sealant and gasket to prevent leakage if necessary Tighten the fasteners to the specified tightening t...

Page 855: ...exhaust system including catalytic converter Inspect all the components and body frame near the exhaust system 4 Tires Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads may indicates the uneven tire inflation pressure or poor wheel balance 5 Steering and suspension system Inspect the front and rear suspension and the steering system for damage...

Page 856: ...ts and installation status front side Jack up points for 2 post lift Stand jack up points and installation status rear side Stand jack up points and installation status front side Jack up points for 2 post lift Installation status Installation status ...

Page 857: ...uring bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of ...

Page 858: ... Part number T99410010A Name Remover and installer fo rear knuckle bushing Use Installing and removing the rear knuckle bushing 1 1 2 3 When servicing the knuckle bushing on lower arm 2 1 2 4 When servicing the knuckle bushing on shock absorber A and upper arm B Part number T99420010A Name Installer for differential gear oil seal Use With a special tool for transmission installing the side gear oi...

Page 859: ...ission jack Use Heavy duty jack for removing the engine and transmission as a set Name Engine stand 1 ton or more Use Fixing the removed engine or engine and transmission transaxle Name Engine crane 1 ton or more Use Moving the engine module including transaxle to working area or on engine stand ...

Page 860: ...ool set is designated for manual transaxle WM6F1 and consists of 16 Part number T88310011A 1 Name Installer for gear Use With the bearing support T88310011A 9 installing the gear and hub on each output shaft Part number T88310011A 2 Name Installer for oil seal and taper roller bearing Use Installing the taper roller bearing 1 on input shaft and oil seal 2 on clutch housing ...

Page 861: ...uter race Use With the handle T88310011A 8 installing the bearing outer race on following shafts 1 Input shaft on transaxle housing 2 No 2 output shaft on transaxle housing 3 No 2 output shaft on clutch housing Part number T88310011A 4 Use With the handle T88310011A 8 installing the bearing outer race on differential assembly in transaxle housing ...

Page 862: ...ollowing shafts 1 No 1 output shaft on clutch housing 2 No 1 output shaft on transaxle housing Part number T88310011A 6 Name Installer for bearing outer race Use With the handle T88310011A 8 installing the front bearing outer race on differential assembly in clutch housing Part number T88310011A 7 Name Installer for bearing outer race Use With the handle T88310011A 8 installing the bearing outer r...

Page 863: ...ing the gear hub bearing or input shaft bearing Part number T88310011A 10 Name Installer for taper roller bearing Use With the bearing support T88310011A 9 installing the taper roller bearing on each output shaft Part number T88310011A 11 Name Installer for taper roller bearing on No 1 output shaft Use With the bearing support T88310011A 9 installing the taper roller bearing No 1 output shaft 1st ...

Page 864: ...embly Part number T88310011A 13 Name Installer for taper roller bearing Use With the bearing support T88310011A 9 installing the taper roller bearing on differential assembly Part number T88310011A 14 Name Installer for oil seal Use With the handle T88310011A 8 installing the oil seal on transaxle housing Part number T88310011A 15 Name Installer for oil seal Use With the handle T88310011A 8 instal...

Page 865: ...01 34 Name and Part Number Tool Use Part number T88310011A 16 Name Installer for oil seal Use Installing the oil seal on control shaft ...

Page 866: ...ee multi plate clutches One multi plate brake All hydraulic functions are directed by electronic solenoids to control Engagement feel Shift feel Shift scheduling Modulated torque converter clutch applications 1 2 3 4 Inhibitor switch Oil pan Torque converter TCU located under driver s seat TCU is located under the driver s seat and controls the transaxle operations TCU is activated and deactivated...

Page 867: ...witches on steering wheel Meter cluster This indicator shows the current position of the gear Gear selector lever Lever positions P Park R reverse N Neutral D Drive Mode switch W Winter mode pressed OUT S Standard mode pressed IN Toggle the mode between winter mode and standard mode by pressing this switch Tip switch manual shift switch The shiftable gear can be adjusted by moving this switch to f...

Page 868: ... 0 859 6th gear 0 676 Reverse gear 3 178 Oil Type Fuchs TITAN ATF 3292 Capacity approx 7 5 L Change interval EU Inspect every 20 000 km or 12 months But change every 60 000 km under severe condition General Inspect every 15 000 km or 12 months But change every 60 000 km under severe condition Resistance of oil temperature sensor 20 430 7 to 533 9 kΩ 0 146 8 to 175 7 kΩ 20 56 74 to 65 86 kΩ 100 3 2...

Page 869: ...02 6 2 Sectional Diagram Double planetary gear set Clutch pack Single planetary gear set Oil pump Torque converter Input shaft Intermediate shaft Differential assembly ...

Page 870: ...ew T30 mm X 25 16 0 Torque converter Mounting bolt 13 mm X 6 40 0 to 42 0 Cable Link nut switch side 13 mm X 1 13 7 to 19 6 Link nut cable side 12 mm X 1 14 7 to 22 5 Mounting nut floor side 12 mm X 1 17 6 to 21 6 Mounting nut dash panel side 12 mm X 2 17 6 to 21 6 TGS lever Mounting nut 12 mm X 4 17 6 to 21 6 TCU Mounting nut 8 mm X 2 5 0 to 6 0 Inhibitor switch Mounting nut 12 mm X 2 3 9 to 7 8 ...

Page 871: ...rols the oil pressure for various internal clutches and bands to select the gear It also controls the electronic elements shift pressure and torque converter slip If the system is defective TCU provides FMEC Failure Mode Effect Control to maintain the functionality of transaxle This keeps the basic function of transaxle gear selection even when there are failure in controls and power supply There ...

Page 872: ...er Park or Neutral are performed in less than 2 2 seconds There is no drive engagement prevention strategy implemented on the transaxle system as there is sufficient engine strategy to protect the system However reverse engagement is prevented until engine speed is less than 1 400 rpm and the accelerator pedal position is less than 12 and vehicle speed is less than 10 km h Converter Clutch Lock Up...

Page 873: ... Gear Change Transaxle 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 Coast down Coast down down shifts occur at 0 pedal when the vehicle is coasting down to a stop Torque Demand Torque demand down shifts occur automatically whe...

Page 874: ...thly on an icy and slippery road 3 MODES AND FUNCTIONS 1 Mode Switch 2 M Mode Manual Mode This allows the driver to define the highest possible gear by selecting or on the gear selector when the lever is in the M position When the lever is first moved to the manual M position the transaxle will select the lowest possible gear W Winter mode pressed OUT Use the standard mode in normal driving condit...

Page 875: ...2 and 3 1 automatic kick down shifts are available 3rd gear has engine braking available 4th Gear State The 4th gear state will display on the instrument cluster 4 3 and 4 2 automatic kick down shifts are available 4th gear has engine braking available 5th Gear State The 5th gear state will display on the instrument cluster 5 4 and 5 3 automatic kick down shift is available 5th gear has engine bra...

Page 876: ...gislation monitoring all components which may effect vehicle emissions 1 2 3 4 When the transaxle overheats Limp home mode may also be engaged if the battery charge falls below 8V If the transaxle overheats the shift patterns will automatically change to enable improved transaxle cooling During transaxle overheat the instrument cluster transaxle selector position display and the over temperature c...

Page 877: ...perates six variable bleed control solenoids and four on off solenoids to control transaxle operation 2 TCU Transmission Control Unit The transaxle control unit TCU is mounted under the driver s seat and controls the operation of the transaxle The TCU is activated and deactivated by the ignition power supply and is connected to the transaxle link harness by a 26 pin connector The TCU processes inf...

Page 878: ...d flow to control the fluid pressure within the three clutches and two bands Separate pressure regulators are used exclusively for torque converter clutch control and main transaxle line pressure The TCU monitors all TCU inputs and outputs to confirm correct system operation If a fault occurs the TCU is able to perform default action and inform the driver of the problem through the instrument clus...

Page 879: ...elected 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 Warm up Schedule Used typically when transaxle fluid temperature is below 20 C The torque converter will not lock up below 20 C to assist in transaxle warm up Hot Mode The hot mode is progr...

Page 880: ...als to be used by other vehicle systems via the CAN bus such as Selector lever position Selected gear state Manual mode activation Output torque Transaxle fluid temperature Engine torque reduction requests Schematic Diagram of Network Communication ...

Page 881: ...ear ratio Engagement element clutch band C1 C2 C3 B1 B2 1 2 OWC M1 4 156 ON ON 1st 4 156 ON ON 2nd 2 375 ON ON 3rd 1 522 ON ON 4th 1 144 ON ON 5th 0 859 ON ON 6th 0 676 ON ON Reverse 3 178 ON ON Gear ON OFF solenoid valve Variable bleed solenoid valve VBS S1 S2 S3 S4 S5 A S6 A S7 A S8 A S9 A S10 A M1 ON 1 0 1 1st ON 1 0 0 1 2nd ON ON 1 0 1 0 1 3rd ON ON 1 0 1 0 1 4th 0 0 0 1 5th ON 0 1 1 0 1 6th O...

Page 882: ... planetary gear Generates the gear ratio and transfers the power Engaged by hydraulic pressure and transfers the power to C1 clutch Transfers the power from torque converter to rear planetary gear Generates the gear ratio and transfers the power Engaged by hydraulic pressure and transfers the power to C1 clutch Transfers the power from input shaft to intermediate shaft Changes the rotating directi...

Page 883: ...G Planetary hear pinion PP Ring gear Internal 1 2 3 Rear planetary gear Forward sun gear FSG Reverse sun gear RSG Short pinion SPP Long oinion LPP Ring gear RG 4 5 6 7 8 Intermediate gear Drive gear Driven gear 9 10 Differential gear Pinion Differential 11 12 ...

Page 884: ......

Page 885: ...02 22 3 Hydraulic Circuit Diagram ...

Page 886: ...02 23 3680 01 ...

Page 887: ...02 24 4 Power Transfer in Each Gear 1 Manual position M 4 156 1 Power flow 2 Drive 1st Gear 1st Auto 4 156 1 Power flow ...

Page 888: ...02 25 3680 01 3 Drive 2nd 2nd Auto 2 375 1 Power flow 4 Drive 3rd 3rd Auto 1 522 1 Power flow ...

Page 889: ...02 26 5 Drive 4th 4th Auto 1 144 1 Power flow 6 Drive 5th 5th Auto 0 859 1 Power flow ...

Page 890: ...02 27 3680 01 7 Drive 6th 6th Auto 0 676 1 Power flow 8 Reverse 3 178 1 Power flow ...

Page 891: ...02 28 9 Neutral Park Power flow ...

Page 892: ... 957 3rd 1 179 1 033 1 207 4th 0 814 0 786 0 905 5th 0 734 0 730 0 842 6th 0 628 0 595 0 714 Reverse 3 910 3 747 3 747 Synchronizer ring type 1st T Triple cone 2nd T Triple cone 3rd T Triple cone 4th D Double cone 5th D Double cone 6th S Single cone Reverse T Triple cone Shifting Type Remote Cable type Gear selector lever position Reversing Reverse ring pull type Item Specification Remark D20DTF D...

Page 893: ...iving condition Fill for Life Severe driving condition Change every 120000 km GEN Inspect and replenish every 60000 km or 4 years Normal driving condition Fill for Life Severe driving condition Change every 120000 km Replacement interval DSL EU GEN GSL Inspect and replenish every 60000 km or 4 years Normal driving condition Fill for Life Severe driving condition Change every 120000 km ...

Page 894: ... 6 to 26 5 Nm 22 EA 4 Concentric slave cylinder mounting bolt 11 8 to 14 7 Nm 3 EA 5 Backup lamp switch 29 4 to 34 3 Nm 6 Neutral switch 29 4 to 34 3 Nm 7 Oil filler plug 58 8 to 78 4 Nm 8 Oil drain plug 58 8 to 78 4 Nm 9 Oil plug 58 8 to 78 4 Nm 10 Shift lever mounting nut 42 2 to 53 9 Nm 11 Selector lever mounting nut 42 2 to 53 9 Nm 12 Control shaft assembly mounting bolt 9 8 to 11 8 Nm 7 EA 13...

Page 895: ...ear Shift Lever and Cable Gear shift lever assembly Old New The gear shift lever bracket has been changed to adopt the premium console Gear shift cable assembly Old New The connection and socket to lever has been changed Gear shift lever bracket ...

Page 896: ...ERVIEW This vehicle is equipped with WM6F1 M T Manual Transmission This transmission is integrated with an axle and designed to maximize the driving performance by optimizing the gear ratio according to the engine torque WM6F1 M T assembly ...

Page 897: ...s used for Reverse gear shifting Features triple double single synchronization Clutch housing Transmission case Input shaft Concentric slave cylinder Shift lever Selector lever Wiring bracket Neutral switch Backup lamp switch Reverse idle shaft mounting bolt 1 2 3 4 5 6 7 8 9 10 Control guide bolt Oil filler plug for servicing Oil drain plug Oil filler plug for manufacturing Air breather Detent pi...

Page 898: ...03 9 3190 01 2 Internal Configuration ...

Page 899: ...o Input Output Input Output 1st 13 46 3 538 13 59 4 538 16 059 2nd 22 42 1 909 8 664 3rd 28 33 1 179 5 349 4th 43 35 0 814 3 694 5th 38 28 0 737 15 59 3 933 2 898 6th 43 27 0 628 2 47 Reverse 13 17 3 91 15 377 24 36 One input gear is used for 1st forward driving and back up driving One input gear is used for 4th and 6th forward driving ...

Page 900: ...03 11 3190 01 2 POWER FLOWS 1st speed gear 2nd speed gear 3rd speed gear Sectional view of WM6F1 M T ...

Page 901: ...03 12 Reverse gear 4th speed gear 5th speed gear 6th speed gear ...

Page 902: ...Selector lever 5th 6th speed gear shift lug Reverse gear shift fork 5th 6th speed gear shift fork 5th 6th speed gear Reverse shift rail 1st 2nd speed gear shift fork 3rd 4th speed gear shift fork 1st 2nd 3rd 4th speed gear shift rail 3rd 4th speed gear shift lug ...

Page 903: ...sverse 3 mm Clutch disc Type Dry type single diaphragm Rigid type Diameter of facing Outer 250 1 mm Inner 160 0 8 mm Thickness of disc Free 8 7 0 3 mm When loaded 8 0 0 2 at 7 800 N Numbers of disc 2 Weight 1 18 kg Flywheel type DMF Dual Mass Flywheel Setting load of clutch cover assembly At least 7 800 N Clutch master cylinder Operating travel 30 mm Inner diameter 17 46 mm Concentric slave cylind...

Page 904: ...lt Hexagon 5 mm 10 to 16 Nm 3 Concentric slave cylinder oil pipe nut 24 5 to 28 4 Nm Remove the nut if it is necessary Once removed apply the Loctite on the thread before installation Master cylinder nut 12 mm 7 8 to 17 6 Nm Master cylinder oil pipe nut 10 mm 14 7 to 17 6 Nm Master cylinder push rod lock nut 8 8 to 13 7 Nm Clutch oil chamber screw and bolt 10 mm 3 9 to 7 8 Nm Oil pipe nut 10 mm 14...

Page 905: ...Clutch pipe and hose Concentric slave cylinder Pressure plate Flywheel If a driver depress the clutch pedal the hydraulic pressure is generated in the master cylinder It is transmitted to the concentric slave cylinder through the pipe resulting in the cylinder being forced out At this time the clutch disc is forced against the cylinder by pushing the cover This in turn remove the flywheel from the...

Page 906: ...ctivates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out Unlike SAT type SATIC type does not need SST for clutch cover removal Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear Disc wear Free play Diaphragm spring 1 Adjusting eq...

Page 907: ... cylinder pipe mounted inside of transmission Driving elements The driving elements consist of two flat surfaces machined to a smooth finish One of these is the rear face of the engine flywheel and the other is the clutch pressure plate The clutch pressure plate is fitted into a clutch steel cover which is bolted to the flywheel Driven elements The driven element is the clutch disc with a splined ...

Page 908: ...04 8 3 Layout Clutch disc Clutch cover assembly Concentric slave cylinder Dual mass flywheel DMF Clutch setting jig ...

Page 909: ...mission The divided dual masses are connected to the coil spring and damping system internally The DMF has the following benefits Reducing fuel consumption by lowering engine speed Reducing rattling noise and vehicle vibration in all driving ranges Reducing synchronization wear Facilitating gear change Protecting power train parts by preventing excessive load from being delivered Primary flywheel ...

Page 910: ...ngth x Dia No 1 shaft TM to spider 1 069 x Ø60 mm No 2 shaft spider to axle 847 5 x Ø60 mm Runout of tube after installation 0 3 mm Unbalance 80g mm 3 000rpm second measurement 120 g mm U joint Starting torque 0 3 to 0 7 Nm Minimum starting angle 18 Amount of grease in CV joint 210 10g 2 TIGHTENING TORQUE Fastener Tightening torque Bolt nut for rubber coupling rear axle side 39 2 to 49 0 Nm Bolt n...

Page 911: ...he E coupling side to accommodate the height and length changes which occur as the shaft rotates at high speed And the rubber bushing for center bearing in the center of the propeller shaft keeps the balance of the shaft and absorbs its vibration Function of propeller shaft Transmits driving torque Accommodates the angle change universal joint CV joint Accommodates the axial length change splines ...

Page 912: ...haft 7 Boot 24 Fork yoke 8 Clamp small 25 Rubber coupling 9 Stub shaft 26 Alignment support 10 Bending absorber 27 Bolt 11 Paper damper 28 Washer 12 Tube yoke 29 Lock nut 13 Oil seal 30 Balance weight 14 Spider 31 Protecter 15 Bearing cap 32 Tube 16 Intermediate yoke 33 Tube 17 Bolt 34 Bending absorber Do not remove the rubber coupling since the vibration balance could be improper once removed it ...

Page 913: ...tside Ball joint Max allowed angle Inside 23 Outside 23 Rear differential carrier Type Independent Rear Drive Axle IRDA Reduction gear type Hypoid gear Gear reduction ratio 2 93 Diameter of gear Ø152 mm Oil type Hypoid gear oil SAE 75W 90 Final drive gear backlash 0 10 to 0 15 mm Differential gear backlash 0 to 0 076 mm Propeller shaft Joint type PTU side CV joint Rear axle side Rubber coupling Sl...

Page 914: ...For 2WD vehicle Front drive shaft LH Front drive shaft RH Intermediate shaft Power transfer unit PTU 4WD Propeller shaft 4WD 1 2 3 4 5 E coupling 4WD Rear differential carrier 4WD Rear drive shaft LH 4WD Rear drive shaft RH 4WD 6 7 8 9 ...

Page 915: ...ent this the intermediate shaft called Intermediate shaft is employed on each side so that the bending angle and the length are kept constant A gyroscope is a device for measuring or maintaining orientation based on the principles of angular momentum In essence a mechanical gyroscope is a spinning wheel or disk whose axle is free to take any orientation Although this orientation does not remain fi...

Page 916: ...IRDA Independent Rear Differential Axle The rear differential carrier is installed directly on the sub frame and there is an independent suspension that allows each wheel on the same axle to move vertically and independently of each other with the universal joint and the slip joint ...

Page 917: ...ypoid gear 23 38 Oil IDEMITSU LW 80W 90 Oil capacity 0 58 L Operating temperature 40 to 150 C E coupling Maximum torque 1 000 Nm Operating temperature 40 to 120 C Numbers of main clutch Outer 11 Inner 11 Numbers of pilot clutch Outer 4 Inner 3 Coil windings 240 turns Weight 8 kg Oil ECF107 ATF based EMCD special oil Oil capacity 0 145 L 145 ml ...

Page 918: ...essing 4WD LOCK switch This mode provides the highest traction Use this mode when driving on unpaved rugged steep sandy wet or slippery roads In 4WD LOCK mode if the rear wheel speed exceeds 40 km h 4WD LOCK mode is canceled and 4WD AUTO mode is activated Indicator OFF If the speed is decreased below 35 km h 4WD LOCK mode is resumed Indicator ON again Mode table 4WD LOCK switch Vehicle speed Drivi...

Page 919: ...onic Coupling E Coupling transfer the engine torque from PTU to rear axle and controls to distribute it between front wheels and rear wheels 3 E Coupling Control Unit ECU E Coupling controls the current clutch engagement force of EMCD in E Coupling according to CAN signals wheel speed engine torque pedal position ABS ESP signals EMCD Electro Magnetic Control Device PTU assembly E coupling control ...

Page 920: ...le of engine torque to 90 by combination between helical gear and hypoid gear and transfer it to E coupling to distribute the torque to rear wheels 1 Component Input shaft Helical gear Dust seal Helical gear 1 2 3 4 Hypoid gear Hypoid gear Output shaft Companion flange 5 6 7 8 ...

Page 921: ...Gear Combination PTU Gear ratio 2 929 22 39 helical gear x 23 38 hypoid gear 0 341 PTU gear ratio 1 0 341 2 929 3 Engagement of Input Shaft PTU is engaged with the ring gear on transaxle and always runs to rotate the propeller shaft ...

Page 922: ...07 8 1 Component E coupling assembly E coupling Bearing race assembly Front cover Dust seal 1 2 3 4 5 Companion flange assembly Drive pinion nut Wiring harness assembly Bolt 6 7 8 38 ...

Page 923: ...ft 9 10 11 12 13 14 15 16 The housing is engaged with propeller shaft through companion flange and rubber coupling and turns with propeller shaft The outer main clutch and the outer pilot clutch are connected to housing and the inner main clutch is connected to hub The inner pilot clutch is connected to hub through cap ball and pressure plate E Coupling is filled with oil The hub is connected to r...

Page 924: ... transferred to housing through propeller shaft rubber coupling and companion flange But if the current is not supplied to the magnet the pilot clutch is not engaged and the cam thrust cannot be generates Thus the main clutch is not engaged and the torque cannot be transferred to the companion flange ...

Page 925: ...The magnetic induction moves the armature and engage the pilot clutch If there is a speed difference between front axle and rear axle This also makes the speed difference between cam and pressure plate This difference rotates and slides the ball on the ramp According to this the cam is separated from the pressure plate Therefore the pressure plate with cam thrust pushes the main clutch to engage b...

Page 926: ... wheel speed engine torque pedal position ABS ESP signals 1 Operating mode 4WD AUTO LOCK mode Smart controlling according to steering angle and wheel speed In 4WD LOCK mode if the rear wheel speed exceeds 40 km h 4WD LOCK mode is canceled and 4WD AUTO mode is activated Indicator OFF If the speed is decreased below 35 km h 4WD LOCK mode is resumed Indicator ON again ...

Page 927: ...07 13 3280 17 2 Circuit Diagram ...

Page 928: ...07 14 3 Block Diagram of Input Output ...

Page 929: ...heat protection function When E Coupling is overheated E Coupling control unit reduces the torque to rear wheels In this mode E Coupling operates as if it is in 2WD mode The oil temperature sensor for E Coupling is not applicable E Coupling control unit recognizes the overheat condition by temperature characteristics of clutch and coil current E Coupling control unit monitors the system for 30 min...

Page 930: ...ameter B 163 1 mm Free length C 356 1 mm Installed length D 276 0 mm Coil windings 5 32 turns Winding direction Right direction Rear suspension Driving type AWD 2WD Suspension type trailing upper lower track rod Multi link type Spring type Coil spring Stabilizer type Torsion bar type Shock absorber Type Cylindrical reciprocation type Max length extended 551 mm Min length compressed 361 mm Coil spr...

Page 931: ...e 433 mm Camber maintenance free 0 15 0 5 Caster maintenance free 4 8 0 5 Total toe in 0 0 0 1 adjust by tie rod King pin angle 12 85 Rear Ground clearance A 63 3 5 mm Trim height wheel center Wheel house 437 mm Camber maintenance free 0 5 0 5 adjust by cam bolt on upper arm Total toe in 0 0 0 1 adjust by cam bolt on track rod ...

Page 932: ...08 5 0000 00 2 TIGHTENING TORQUE Front suspension assembly ...

Page 933: ...08 6 Rear suspension assembly ...

Page 934: ...and vehicle It absorbs the vibrations and impacts from road surface which enhances the comforts driving force braking force and drivability Underview of vehicle with 2WD 6M T Underview of vehicle with 4WD 6A T Front suspension Rear suspension Front suspension Rear suspension ...

Page 935: ...mper is installed on the knuckle to support the tire This type of suspension is normally applied to the vehicle with monocoque body especially on the front wheel drive type The upper part with spring is mounted at body mount and the strut with shock absorber is linked on the steering knuckle Advantages Compact and simple design Stable wheel alignment Good load distribution and easy installation Le...

Page 936: ...endent suspension It provides good ride comfort and drivability by reducing the coil spring weight Also it increases the space for passenger compartment by lowering the floor This type of suspension consists of multiple links such as trailing arm upper arm lower arm and track rod Layout ...

Page 937: ...08 10 1 SYSTEM LAYOUT 1 Front Suspension Damper strut assembly Lower arm Stabilizer bar link Stabilizer bar assembly ...

Page 938: ...08 11 0000 00 2 Rear Suspension Shock absorber Stabilizer bar assembly Coil spring and link Trailing upper arm track rod Stabilizer bar link Coil spring Coil spring link Trailing arm Track rod Upper arm ...

Page 939: ...ht is higher than that of the leaf spring and it allows to absorb small vibration properly resulted in keeping the ride comforts Therefore it s difficult to make an effect on vibration damping because there is not any friction between coils The lower arm relieves the load to knuckle This enables to absorb the various impacts according to the load shapes and to ensure the drivability The stabilizer...

Page 940: ...er drivability even though the structure is complicated This vehicle uses the gas shock absorber This vehicle uses the strut type shock absorber This shock absorber is connected to the piston rod in the strut This relieves the vertical vibrations of vehicle to provide ride comforts prevents the spring break enhances drivability and extends the life span of steering components Coil spring Shock abs...

Page 941: ...pring is installed between the coil spring link and body frame It relieves the vibrations and impacts from wheels to vehicle body Symmetry design Lower arm is installed between knuckle and rear sub frame and relieves the load to coil spring from wheel In other word it controls the longitudinal load Frame side Knuckle side Frame side Knuckle side B Coil spring C Lower arm D Track rod F Trailing arm...

Page 942: ...f torsion bar Its both ends are connected to the control arm and the its center area is mounted to the body frame It is not activated when both wheels are moving up or down simultaneously However it minimizes the vehicle s slope when each wheel moves up or down independently F Trailing arm Trailing arm is installed between knuckle and vehicle body and controls the front and rear load G Shock absor...

Page 943: ...y Program ABD Automatic Braking Differential ASR Acceleration Slip Regulation AYC Active Yaw Control Understeer and Oversteer Control HBA Hydraulic Brake Assistant ARP Active Rollover Protection HSA Hill Start Assistant 2 Functions Function Vehicle with CBS Vehicle with ABS EBD Vehicle with ESP ABS Not applied Applied Applied EBD Applied ABD Not applied ASR AYC HBA ARP HSA ...

Page 944: ...d Applied Applied Front wheel speed sensor Rear wheel speed sensor ABS warning lamp EBD indicator Longitudinal G sensor 2WD N A 4WD Applied Not applied Sensor cluster Yaw rate sensor lateral longitudinal G sensor Not applied Applied ESP indicator ESP OFF switch and warning lamp Steering wheel angle sensor ...

Page 945: ... Assembly Parking brake lever assembly A T Old New The parking brake lever bracket has been changed to adopt the premium console Parking brake lever assembly M T Old New The parking brake lever bracket has been changed to adopt the premium console ...

Page 946: ...D H Parking brake A Meter cluster ABS EBD ESP indicator warning lamp B Master cylinder and booster C HECU G Brake pedal 5 Component ABS warning lamp ESP indicator D Front brake assembly E Rear brake assembly Disc Disc Parking brake warning lamp Caliper Caliper ...

Page 947: ... disc 10 mm wear limit 8 4 mm Thickness of brake pad 10 mm wear limit 2 mm Pad wear indicator Mechanical type Brake booster Type Vacuum assist type Size 8 9 Tandem Master cylinder Type Tandem level sensor installed Inner diameter of cylinder Ø25 4 mm Brake pedal Maximum operating stroke 140 3 mm Pedal ratio 3 8 1 Free play 3 to 10 mm Parking brake Type Mechanically expanded rear lining Operating t...

Page 948: ...er cylinder booster pedal and supply lines pipes and hoses Hydraulic brake Brake pedal This system uses the leverage effect and Pascal s principle When depressing the brake pedal the pedal pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure The hydraulic pressure generated by the master cylinder is delivered to the brake caliper through the brake pip...

Page 949: ...12 8Nm Air breather screw 8 8 10 8Nm Caliper mounting bolt 19mm x 2EA 83 3 102 9Nm Brake hose bolt 12 mm 19 6 29 4Nm Wheel disc Brake caliper Brake hub Brake disc Knuckle Drive shaft Brake hose Brake pad Shock absorber Brake disc Back plate Knuckle 2 SECTIONAL DIAGRAM Front disc brake ...

Page 950: ... hub Brake disc Fastener Tightening torque Remark Brake pad guide bolt 25 5 30 4Nm 14 mm x 2EA Brake caliper mounting bolt 52 9 63 7Nm 17 mm x 2EA Brake hose bolt 19 6 29 4Nm 12mm Brake hose bracket mounting bolt 9 8 12 8Nm 12mm Air breather screw 8 8 10 8Nm 1 Tightening torque ...

Page 951: ...09 11 4850 00 3 SYSTEM LAYOUT Hydraulic line Brake booster Brake reservoir and master cylinder Front disc brake and caliper 1 2 3 HECU Hydraulic Electric Control Unit Rear disc brake and caliper 4 5 ...

Page 952: ...09 12 4 CIRCUIT DIAGRAM OF STOP LAMP ...

Page 953: ...09 13 4850 00 ...

Page 954: ...Wheel speed sensor ABS ESP CBS Operating temperature 40 C to 150 C 40 C to 150 C 40 C to 115 C 40 C to 115 C Operating frequency 1 to 2 500 Hz 1 to 8 000 Hz Operating voltage 4 5 to 16 V 3 3 to 18 V G sensor ABS CBS ESP Operating voltage 4 75 to 5 25 V N A Operating temperature 30 C to 85 C Operating range 1 5 to 1 5 g Output voltage 0 5 to 4 5 V ...

Page 955: ...10 4 ABS ESP CBS Circuit diagram of wheel speed sensor ...

Page 956: ...t safety beyond its physical limit ABS in this vehicle contains EBD function In normal driving conditions the brake system operates without ABS function 2 What is EBD Electronic Brake force Distribution EBD is an automobile brake technology that automatically varies the amount of force applied to each of a vehicle s brakes based on road conditions speed loading etc Always coupled with anti lock br...

Page 957: ...ppearance is different from that for 4WD 4 Wheel speed sensor for 4WD Located on knuckle The appearance of front sensor is same with rear sensor 2 ABS warning lamp EBD warning lamp ABS warning lamp Brake warning lamp 1 ABS hydraulic device and control unit Located under the power steering fluid reservoir and contains the pressure sensor 2 COMPONENT ...

Page 958: ...operation This unit controls the hydraulic pressure to each wheel If the system needs ABS operation the valves in the unit operate to control HOLD RISE and DUMP according to ECU control logic Motor 3 The motor is operated when ABS is activated The cam shaped output shaft of the motor enables the brake system to receive and supply the brake fluid during the motor operation Wheel speed sensor Wheel ...

Page 959: ...ion and actual wheel speed reduction in the event of braking since the driving wheels are in the front So the ABS HECU can control the vehicle based on a calculation value But on the 4WD vehicle if a speed reduction occurs in the front or rear of the vehicle it affects the other side wheel In other words braking the rear wheels induces also a large speed reduction in the front wheels The longitudi...

Page 960: ...nsing the speed information from 4 wheel speed sensors when the vehicle is being driven For example when the comparison of the reference speed with front right wheel speed shows a slip the control signal is determined according to whether it s deceleration or acceleration If the control conditions are met the brake for the front right wheel will be got under control ...

Page 961: ... the system is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected the warning lamp comes on ABS is not available during lamp ON In this condition Only normal brake system without ABS function is available When the communication between warning lamp CAN module in meter cluster the warning lamp comes on 1 2 3 4 ...

Page 962: ...s OK initialization mode When applying the parking brake the brake warning lamp comes on When the brake fluid is not sufficient the brake warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected the warning lamp comes on When the system is defective ABS warning lamp and the brake warning lamp come on simultaneously 1 2 3 4 5 6 Wh...

Page 963: ...10 12 5 SYSTEM OPERATION 1 Block Diagram of ABS HECU ...

Page 964: ...rawn at the start of braking 2 Brake force on a wheel The maximum possible brake force on a wheel depends on the wheel load and the adhesion coefficient between tire and carriageway With a low adhesion coefficient the brake force which can be obtained is very low You are bound to know the result already from driving on winter roads With a high adhesion coefficient on a dry road the brake force whi...

Page 965: ...freshly fallen snow for this curve increases at 100 slip In a vehicle without ABS the wheel locks on braking and therefore pushes a wedge before it This wedge of loose surface or freshly fallen snow means and increased resistance and as a result the stopping distance is shorter This reduction in stopping distance is not possible with a vehicle with ABS as the wheel does not lock On these surfaces ...

Page 966: ...in the circle the vehicle is stable to drive If a force exceeds the circle the vehicle leaves the road Brake force When depressing the brake pedal the brake force increases to the maximum then the brake force decreases until the wheel locks Cornering force The cornering force is a maximum when the wheel is turning freely with zero slip When braking the cornering force falls to zero if the wheel lo...

Page 967: ...s the mean I e average speed of all wheel speeds determined by simple approximation Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previous...

Page 968: ...omparing the reference speed with each wheel speed Firstly it is determined whether the vehicle is in the deceleration or acceleration state using the wheel speed change ratio Then a signal is transmitted to the valve Finally the brake pressure is adjusted via the signal ...

Page 969: ... distribution between the front and rear axles This is called Electronic Brake Distribution In an unloading car condition the brake efficiency is comparable to the conventional system but for a fully loaded vehicle the efficiency of the EBD system is higher due to the better use of rear axle braking capability Advantages Elimination of conventional proportioning valve EBD utilizes the existing rea...

Page 970: ...in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve At this moment the normally closed outlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Open OFF Outlet valve Normal close NC valve Close ...

Page 971: ...rder to prevent the hydraulic pressure from increasing the inlet valve will be closed the outlet valve will be opened and the oil will flow into the low pressure chamber In addition the ABS HECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises Solenoid valve Valve Open Close Pump mot...

Page 972: ... valve modulator operates the inlet valve control solenoid to stop increasing the hydraulic pressure by closing the inlet valve At this moment the outlet valve is closed This procedure helps the wheel to maintain a constant hydraulic pressure Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Close OFF Outlet valve Normal close NC valve Close ...

Page 973: ...ydraulic pressure to the wheel increases the wheel speed will reduce This operation continues repetitively until there are no signs that the ABS HECU tends to lock the wheels Since the ABS hydraulic pressure control process takes place repeatedly for a short time there may be some vibration and noises at the brake pedal Solenoid valve Valve Open Close Pump motor Inlet valve Normal open NO valve Op...

Page 974: ...10 23 4890 00 7 CIRCUIT DIAGRAM ...

Page 975: ...ure 40 150 Operating frequency 1 2 500 Hz Unit Description ABS ESP HECU Clock frequency 32 MHz Clock frequency 50 MHz Memory 128 KB Memory 512 KB Switch orifice Switch orifice Wheel speed sensor Active type Active type Steering wheel angle sensor None Max detection angle speed 1500 Sec Operating voltage 9 to 12 V Sensor cluster None Yaw rate sensor lateral G sensor longitudinal G sensor 4WD Longit...

Page 976: ...mperature 30 to 75 Supplying voltage 9 to 16 V battery voltage Output voltage HI approx 3 50 V 3 0 to 4 1 V Output voltage LO approx 1 50 V 1 3 to 2 0 V Pulses rev 45 pulses rev 3 Specification of Sensor Cluster Description Specification Supplying voltage approx 12 V 8 to 16 V Current consumption below 250 mA Operating range Yaw rate sensor 75 Sec Lateral longitudinal sensor 14 7m Sec ...

Page 977: ... Sensor SWAS Steering Wheel Angle Sensor Old New The sensor has been changed due to newly adopted steering wheel heating system The location of sensor connector and the pin arrangement of connector have been changed 1 2 Sensor connector Sensor connector ...

Page 978: ...ering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer understeer or cornering The ESP ECU controls against oversteer or understeer during cornering by controlling the vehicle stability using input values from these sensors and applying the braking force to the corresponding wheels independently The system also controls the engine power right before...

Page 979: ...Located under the power steering fluid reservoir and contains the pressure sensor 2 COMPONENTS 4 Sensor cluster Located on the floor under front passenger seat 5 Wheel speed sensor 4WD 2WD front Located on knuckle the appearance of front sensor is same with rear sensor 6 Rear wheel speed sensor 2WD Located on knuckle The appearance is different from that for 4WD ...

Page 980: ...d and when the brakes are not applied on a curve If the ESP system operates when the brake is applied the brake pressure will be increased on the corresponding wheel which already has braking pressure for the ESP controls ARP Operation During the ARP operation vehicle safety rollover prevention takes the first priority and thus stronger engine control is in effect Consequently the vehicle speed de...

Page 981: ... system is defective the warning lamp comes on When the self diagnosis is performing the warning lamp comes on When the HECU connector is disconnected the warning lamp comes on ABS is not available during lamp ON In this condition Only normal brake system without ABS function is available When the communication between warning lamp CAN module in meter cluster the warning lamp comes on 1 2 3 4 5 6 ...

Page 982: ...S HECU is defective When the voltage is abnormal When valve relay is defective a b c d e When the communication between warning lamp CAN module in meter cluster the warning lamp comes on 7 3 ESP OFF Indicator ESP OFF indicator ON When turning the ignition switch to ON position ESP warning lamp comes on for 3 seconds for self diagnosis and goes off if the system is OK initialization mode When the E...

Page 983: ...11 11 0000 00 5 SYSTEM DESCRIPTION 1 Block Diagram of ESP HECU ...

Page 984: ...esponding wheels independently The system also controls the engine power right before the wheel spin synchronized with the ASR function to decelerate the vehicle automatically in order to maintain the vehicle stable during cornering 1 Under steering What is understeering Understeer is a term for a condition in which the steering wheel is steered to a certain angle during driving and the front tire...

Page 985: ... steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction Compared to understeering vehicles it is hard to control the vehicle during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases ESP controls during oversteer The ESP system recognizes the directional angle with the st...

Page 986: ... pedal is depressed or not depressed during cornering when the ABS is operating and when braking without the ABS It also includes the vehicle conditions when the TCS a part of the ESP system is operating Condition Understeer control Oversteer control Only ESP in operation No braking by driver ESP Normal braking no ABS operation ESP ABS brake ESP ASR ...

Page 987: ...ce during initial braking according to pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels 2 Operation T...

Page 988: ...n the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sharp turns Lateral sensor In sensor cluster Vehicle speed Brake force Radius The vehicle driving condition is controlled by the internally programmed logic according to the input sig...

Page 989: ...6 HSA Hill Start Assist The HSA Hill Start Assist prevents the vehicle from rolling backward by supplying the hydraulic pressure to the wheels by the HECU after the brake pedal is released when starting off on uphill ...

Page 990: ...e vehicles behind 3 Operating process When receiving the emergency stop signal through PCAN communication it blinks with the interval of 4 Hz and when receiving the emergency stop OFF signal through PCAN communication it blinks with the interval of 1 25 Hz normal operating speed However the manual operation of the switch has a priority over this function Priority Manual operation Emergency stop si...

Page 991: ...n vehicle speed increases more than 10 km h above the speed when the signal is received during operation by emergency braking signal the emergency hazard flasher stops operation When turning emergency hazard flasher switch OFF during operation by emergency braking signal it stops operation It is deactivated automatically 10 seconds after if items 2 and 3 above are not met during operation by emerg...

Page 992: ...11 20 6 HYDRAULIC CIRCUIT OF ESP MCP Master Cylinder Primary MSP Master Cylinder Secondary ESV Electric Shuttle Valve NO Normal Open NC Normal Close LPA Low Pressure Accumulator ...

Page 993: ...not control the vehicle over the physical limit Do not solely rely on the system but be advised to drive the vehicle safely Drive feeling during ESP operation When the ESP system activates the driving feeling can be different depending on vehicle driving conditions For example it will feel different when the ESP system is activated while the ABS is operated by depressing the brake pedal and when t...

Page 994: ...e separation valve and the inlet valve are open normal open the electrically operated shuttle valve and the outlet valve are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve ...

Page 995: ...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 pump operates to allow fast oil drainage The shuttle valve and the separation valve do not operate while decompression ...

Page 996: ...be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens ...

Page 997: ...ve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Page 998: ...essure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the wheel starts to lock the HBA...

Page 999: ...11 27 0000 00 7 CIRCUIT DIAGRAM Wheel speed sensor Stop lamp switch Self diagnostic connector Warning lamp ABS ESP ...

Page 1000: ... Outer 31 24 Wheel alignment Toe in 2 2 mm Oil pump Type Vane removable pump and reservoir Maximum pressure 100 3 bar Displacement 6 0 to 9 75 ℓ min Pulley diameter Φ 115 mm Steering column Tilting angle Up 2 0 Down 30 Lower shaft Type Ball slip Steering oil Oil type ATF Dexron Ⅱ or Ⅲ Oil reservoir capacity 1 ℓ Change interval EU Diesel Check and add at every 20 000 km GEN Diesel Gasoline Check an...

Page 1001: ...pipe bracket mounting nut 6 8 to 10 8 Nm 10 mm 5 Tie rod end lock nut 44 1 to 53 9 Nm 17 mm 6 Tie rod nut 63 7 to 78 4 Nm 22 mm 7 Lower shaft Lower mounting bolt gear box side 17 6 to 24 5 Nm 12 mm Upper mounting bolt column side 17 6 to 24 5 Nm 12 mm 8 Column shaft Lower mounting bolt 19 6 to 24 5 Nm 12 mm Upper mounting nut 19 6 to 24 5 Nm 12 mm 9 Steering wheel nut 39 2 to 58 8 Nm 22 mm 10 Loos...

Page 1002: ... 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 No 1 idle pulley 9 No 2 idle pulley 10 Power steering pump HPS Hydraulic Power Steering EPS Electric Power Steering ...

Page 1003: ...e installed in the steering wheel assembly Lower switch cluster Old New The steering wheel heating switch has been added on the lower switch cluster Specifications Description Specification Power consumption Below 95W Rated voltage 12V Operating voltage 9V 16V Rated current 6 2 0A Steering wheel heating unit Steering wheel heating switch ...

Page 1004: ...essure relief valve in the pump controls the discharging pressure The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie rod end and the steering knuckle Even though the hydra...

Page 1005: ...llation of power steering pump and pipe 2 SYSTEM LAYOUT The steering pump is driven by the engine power through a belt This pump circulates the power steering oil from the reservoir steering pump oil supply pipe steering gear box oil return pipe reservoir to perform steering operations Return pipe Supply pipe ...

Page 1006: ...to 16 V C EPS ECU 8 to 16 V Full Performance 10 to 16 V Motor Type 3 Phase BLAC Brushless AC Rated current voltage 85 A 12 V at idle 0 5 A Position sensor type Hall sensor type Torque angle sensor Type Non contact type Steering column Operating type Manual tilting telescoping Lower shaft Type Sliding Ball slip type Steering gear Gear ratio 46 94 mm rev Rack stroke 146 mm Maximum steering angle Inn...

Page 1007: ...13 4 2 TIGHTENING TORQUE ...

Page 1008: ... 1 Crankshaft pulley DDU 2 Auto tensioner 3 Tensioner pulley 4 Vacuum pump 5 A C compressor pulley 6 Alternator pulley 7 Water pump pulley 8 No 1 idle pulley 9 No 2 idle pulley 10 Power steering pump HPS Hydraulic Power Steering EPS Electric Power Steering ...

Page 1009: ...motor s operation based on the input signals from the sensors such as torque sensor and angle sensor In turn the EPS receives the torque signal by the driver s movements of the steering wheel as well as the vehicle speed and uses the motor to determine the assist torque The EPS controls the motor for this Another features of EPS are fail safe function diagnosis function communication function betw...

Page 1010: ...ystem detect the rotation of the steering column to run the electric motor At this time the worm gear connected to the motor drives the helical gear mounted to the steering column to generate the assist torque for the steering column This allows the driver to operate the steering wheel easier Output torque 1 Steering force manual torque 2 Assist torque ...

Page 1011: ...mark Tire 16 inch 215 65R 16 Standard 17 inch 225 60R 17 Optional 18 inch 225 55R 18 Optional Tire inflation pressure 32psi Wheel 16 inch 6 5 J X 16 Standard 17 inch 6 5 J X 17 Optional 18 inch 6 5 J X 18 Optional Balance weight Inner Clip on type Outer Adhesive type Tightening torquse of wheel bolt 127 4 156 8 Nm 17mm X 5 Length 56 5 mm ...

Page 1012: ...according to the driver s driving habit improper servicing low tire inflation pressure changed tire location etc 1 Structure of Tire Tread This thick layer of rubber provides the interface between the tire and the road Wear resistant rubber is used to protect the carcass and belt against fractures and impacts and to deliver a long driving life Shoulder Located between the tread and sidewall the sh...

Page 1013: ...es the tread layer completely Thus the driving force and the braking force are optimized and the tire is worn out evenly resulting in increased life The contact area between the ground and tire is not enough so the tire is worn out unevenly and the tire is vulnerability to outside influence The contact area between the ground and tire is excessive so a lot of heat is generated and the tire is worn...

Page 1014: ...be blown out in a short period of time If the standing wave symptom occurs on the tire rubber on the tread comes off and eventually the tire can be blown out which is very dangerous When driving at high speed the inflation pressure should be increased to decrease heat generation due to extension and contraction motion to decrease hydroplaning and to prevent standing wave To prevent this symptom it...

Page 1015: ...t with the road surface but rotate floating on a thin film of water It causes brake failure lower traction force and losing the steering performance To prevent this increase the tire inflation pressure use tires with leaf shape tread which is not worn However it is a best measure to drive slowly 2 Hydro Planing ...

Page 1016: ...lance weight of a weight corresponding to unbalanced weight from B to A to maintain the static balance If the static balance is not maintained tramping up and down vibration of the wheels occurs 2 Dynamic Balance The static unbalance of the wheel creates the vibration in the vertical direction but the dynamic unbalance creates the vibration in the lateral direction As shown in the figure 2 a if tw...

Page 1017: ...ame 2WD Body mounting 4 points bush Transaxle mounting 2 points bush Weight 22 37 kg 1 2 3 Body mounting 4 points bush Axle mounting 4 points bush Weight 16 61 kg 1 2 3 Body mounting 40 points direct mounting Spring link Direct mounting without bracket on rear cross member Weight 12 74 kg 1 2 3 ...

Page 1018: ...ransaxle mounting Front 2 TIGHTENING TORQUE Bolt 17 mm Nut 17 mm 68 6 to 88 2 Nm Bolt 17 mm 88 2 to 107 8 Nm Bolt 17 mm 88 2 to 107 8 Nm 2 Bracket mounting bolts 17 mm 88 2 to 107 8 Nm Bolt 14 mm Nut 14 mm 68 6 to 88 2 Nm 3 Bolts 14 mm 29 4 to 49 0 Nm Front sub frame based on 4WD ...

Page 1019: ...nting LH RH Bolt 17 mm 88 2 to 107 8 Nm 6 Rear mounting LH RH Bolt 17 mm 88 2 to 107 8 Nm Rear mounting bolt 14 mm 68 6 to 88 2 Nm Upper arm bolt 17 mm Nut 19 mm 98 0 to 117 6 Nm Lower arm nut Bolt 19 mm 98 0 to 117 6 Nm Rear sub frame based on 4WD Rear mounting bolt 17 mm 107 8 to 127 4 Nm ...

Page 1020: ...nt Sub Frame Mounting nut 29 4 to 39 2 Nm Bolt 9 4 to 39 2 Nm Installation Sectional diagram 1 Front 2 Rear Mounting bracket Mounting bolt 3 Transaxle mounting Front For manual transaxle For automatic transaxle diesel 4 Transaxle mounting Rear ...

Page 1021: ...15 7 4012 00 2 Sectional Diagram and Bolts for Rear Sub Frame Installation Sectional structure 1 Front 4WD 2WD 2 Rear 4WD 2WD 3 Rear axle Front 4WD 4 Rear axle rear 4WD ...

Page 1022: ...de and transmission side mountings are rubber mountings with brackets and insulators while the body mounting is a rubber bush mounting which is fitted to the frame Installation of front sub frame 4WD The installation of the front sub frame is the same for both automatic transmission and manual transmission For 4WD the PTU and the propeller shaft are installed Installation of front sub frame 2WD Th...

Page 1023: ...ar sub frame 2WD The installation of the rear sub frame is the same for both automatic transmission and manual transmission The rear sub frame system consists of body bush mountings and direct mountings which reduce the vibration transmitted from the powertrain and road to the vehicle body For 4WD it consists of 4 body mountings bush mountings and 2 axle mountings bush mountings and for 2WD it con...

Page 1024: ...0 Capacity kcal h 4 700 Blower Supply power W 240 10 Max at 12 V Fan speed rpm 2900 200 Max Rec Mode 420 h PTC Supply power 1 kW Condenser Core size 588 x 455 x 16 2 625 Capacity kcal h 12 000 Capacity of receiver drier 250 cc compressor Capacity 170 cc rev Diameter of pulley Ø120 Max continuous speed 8 000 rpm voltage DC 12 V Power consumption 2 2 A ...

Page 1025: ... the heater and evaporator module Ambient temperature sensor signal wiring added to vehicle wiring connecting connector 2 circuits manual A C Blower max signal wiring added to vehicle wiring connecting connector 1 circuit manual A C FATC Manual A C Wiring pin added to controller assembly connector FATC Wiring pin added to existing connector of controller assembly ...

Page 1026: ...iving circuit for the ambient temperature sensor is added to the manual air conditioner controller for ambient temperature display on the instrument cluster Connector added Pin No Function B1 B2 B3 B4 Water temp signal B5 B6 B7 B8 B9 B10 Sun load sensor signal B11 Ambient temp sensor signal B12 ...

Page 1027: ...01 6 1 SYSTEM LAYOUT Line port A C compressor Electric fan A C condenser receiver drier Integrated receiver drier High pressure hose Low pressure hose ...

Page 1028: ...01 7 6810 00 FATC Incar sensor Refrigerant pressure sensor Ambient temperature sensor Sun load sensor Engine ECU ...

Page 1029: ... and the system is changed into the recirculation mode However under defroster mode or defroster floor mode it stays in the fresh air mode 1 Full Automatic A C Control 2 HEATER AND A C CONTROL To adjust the temperature turn this dial as required Turning the dial to HI increases the temperature and LO decreases the temperature Temperature dial Temperature dial ...

Page 1030: ...side glasses the air conditioner operates automatically and fresh air comes in The air flow direction can be controlled by turning the dial Airflow is changed automatically according to the setting temperature Fan speed dial Manual control Fan speed is manually controlled by this dial The increment is 1 Auto control Fan speed is automatically controlled by temperature setting The blower motor oper...

Page 1031: ...be adjusted by rotating the switch To stop the operation turn the dial to the OFF position The level is adjustable in 7 steps A C switch When pressing the switch with the engine running the A C compressor operates and the indicator comes on Pressing the switch again deactivates the compressor and turns off the indicator Fan speed dial ...

Page 1032: ... Mode dial Recirculation switch When pressing this switch the air is recirculated in the vehicle and the indicator on the switch comes on When pressing it again the indicator goes off and the fresh air comes in When it s rainy or humid set this switch to fresh air mode with the defroster mode selected to clear the fogged windshield Foot Defrost level Foot defrost mode Temperature dial Rotate this ...

Page 1033: ...e heat from the air around the evaporator Condition Liquid Liquefied gas Function Performs adiabatic expansion and flow control for easier evaporation Condition Gas Liquid Function Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure Condition Gas Function Circulates the refrigerant and increases the pressure and temperature for easier evaporation 2 Functions ...

Page 1034: ...or is called Adiabatic Expansion During adiabatic expansion the expansion valve lowers the pressure of the refrigerant and determines the correct amount of refrigerant going into the air conditioning evaporator That is the amount of heat which is needed to stop the evaporation is determined according to the cooling load The expansion valve detects this and regulates the amount of the refrigerant e...

Page 1035: ...01 14 4 A C COOLING CIRCUIT ...

Page 1036: ......

Page 1037: ...01 16 5 CIRCUIT DIAGRAM ...

Page 1038: ...01 17 6810 00 ...

Page 1039: ...0 90 Ignition temperature 30 85 Overvoltage protection 24 V 2 MAJOR REPLACEMENT PARTS AFTER AIR BAG DEPLOYMENT A In Case Of Front Air Bag Deployment Air bag unit and its wirings including connectors seat belt pretensioner and its wirings including connectors all front air bags instrument panel front impact sensor and other damaged components B In Case Of Curtain Air Bag Deployment Deployed curtain...

Page 1040: ...ct from the road surface impact against the curb at a very high speed or dropping impact onto the road surface with a large angle occurs Seldom oeprate A collision to diagonal direction not a front collision occurs or the vehicle tips over A weak collision which the sensor cannot detect occurs under the activation requirements A collision against narrow objects such as a telegraph pole or a tree o...

Page 1041: ...ear outboard occupants in a side collision Curtain air bag The curtain air bags are installed on the left side driver side and the right side passenger side of the front seat Side air bag The front air bag system and the side air bags system function independently of each other according to the impact area and the severity of the impact Driver s Passenger s ...

Page 1042: ...o not attempt to modify any air bag component including the steering wheel air bag mountings and related wirings Do not subject any air bag component such as the steering wheel air bag mountings wirings to impacts You might get severely injured by sudden deployment of the air bag As the air bag seat belt pretensioner parts are very hot after being deployed Allow them to cool down sufficiently befo...

Page 1043: ...evere side collision Do not put any object such as an umbrella or bags between the door and side air bag mounting Do not slam the front door to close it The side air bag may deploy unexpectedly Do not move your seat too close to the steering wheel or dashboard Being too close to the steering wheel or instrument panel during the air bag deployment could cause serious injury including death Move bac...

Page 1044: ...ld be packed in an air tight container to prevent any damage Do not connect a tester probe to the air bag connector or air bag body to measure the supply voltage or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag related components disconnect the negative battery cable 1 2 3 4 When turning on the ignition switch the ...

Page 1045: ......

Page 1046: ...02 10 Driver side air bag Seat Belt Pretensioner SDM unit assembly BCM Driver air bag module Passenger air bag module 1 SYSTEM CONFIGURATION ...

Page 1047: ...02 11 8810 00 Inflatable curtain air bag module Side air bag sensor assembly Front impact sensor assembly Air bag warning lamp IP Height adjuster ...

Page 1048: ...gnite Side air bag module Passenger side Not ignite IGN Inflatable curtain air bag module Driver side IGN Not ignite Inflatable curtain air bag module Passenger side Not ignite IGN Impact to Front side Driver air bag IGN Passenger air bag IGN Seat belt pretensioner Driver side IGN Seat belt pretensioner Passenger side IGN Once the ignition starts the SDM starts to diagnose the air bag system durin...

Page 1049: ...ate that each collision G sensor reads the air bag unit sends out about 2 4 or higher Amp current This current generates some heat which fires the detonator in the inflator The table shows the basic inner resistance of the air bag related module and the basic instant current necessary for firing 1 Air Bag System Deployment Firing Loop Do not connect a tester probe to the air bag connector or air b...

Page 1050: ...al is sent the second crash out will be delayed until the current 200 ms crash out is completed The tolerance at the time of signaling is 5 The signal repeats increasing for 390 msec and decreasing for 10 msec before crash At the time of crash the switch is closed and the signal is kept low condition for 200 msec At the time of crash the crash out signal is changed to the low condition for 200 ms ...

Page 1051: ...pecifications of the electrical interface The load resistance of the SDM is 590 ohms or higher It may not be possible to operate the collision occurrence circuit normally if the resistance value is not as specified Pin No Minimum Average Maximum Remark Driving current current value when the transistor is turned on 12 31 mA 19 6 mA 30 mA Depending on the battery voltage Leakage current current valu...

Page 1052: ...ecks the FIS condition and sends the result as OK or NOK and also sends the severity of the crash Same as FIS Voltage The FIS hardware reset was performed under 5 V communication voltage low Same as FIS Fault The fault is found in the current ignition cycle but the fault is deactivated in the next ignition cycle Multiple faults can be found and deactivated in the same ignition cycle The FIS moves ...

Page 1053: ...M is running without any active fault right after starting the ignition cycle When there is no active fault and past faults occurred less than 10 times The warning lamp is operated as shown below every time the vehicle is started if the SDM is running without any active fault in the entire time and past faults in the previous ignition cycle occurred within 10 times Battery voltage too low is not i...

Page 1054: ...except battery voltage too low Internal fault Impact record Pretensioner deployed only If the connector is not connected properly or SDM battery voltage is out of the specified range internally battery voltage for warning lamp the warning lamp is kept ON Warning lamp condition change during operation The warning lamp comes on or off according to the actual fault condition during SDM operation If t...

Page 1055: ...02 19 8810 00 5 CIRCUIT DIAGRAM 8810 01 Air bag Curtain air bag Side air bag ...

Page 1056: ...support 2 steps standard Seat warmer cushion seatback ON high low OFF ON high low OFF ON OFF Head restraint Convent ional Up Down 90 mm 15 mm x 6 90 mm 15 mm x 6 45 mm 15 mm x 3 Sliding 24 mm 8 mm x 3 24 mm 8 mm x 3 Electronic active type Optional tilting 15 Optional tilting 15 Seat belt 3 point type ELR PT L L 3 point type ELR PT L L LH RH Center 3 point type ELR Seatback pocket Net type Leather ...

Page 1057: ...tes against the heat such as a blanket or cushion Make sure that the head restraints are in place and secured properly Never drive the vehicle with the head restraint removed To minimize the injuries in a collision or an abrupt stop make sure the seatback is in the upright position before driving If the seatback is reclined too much the occupant could slide under the seat belt in a collision or an...

Page 1058: ...ous Current 2 point type 3 point type 4 MAJOR CHANGES 1 Rear Center Seat Belt 2 Front Seat Back Board Front seat back board Previous Current Hook Installed Pocket Net type Hook Not installed Pocket Fabric seat Net type Leather seat Band type ...

Page 1059: ...03 6 3 Front Buckle Front buckle Previous Current Pad is attached to buckle No pad is attached to buckle Front buckle Driver s ...

Page 1060: ...s Do not use any similar tool Take care not to drop the sunroof assembly when removing it and do not keep it right up 1 2 3 4 5 Operating voltage 9 to 16 V Operating current open close Max 6 A At no load Approx 3 A Leakage current Max 1 mA or less Roof motor operating speed at opening and closing 1 4 0 5 sec 100 mm Motor overload stop conditions Current for 25 A or higher and torque load for 7 5 N...

Page 1061: ...04 4 Sunroof switch 1 SYSTEM LAYOUT Sunroof assembly TILT OPEN Sunroof motor control unit ...

Page 1062: ... glass can be open in two steps and can be tilted by the switch operation The sunroof switches are included in the overhead console switches and consists of the TILT CLOSE and OPEN switches TILT CLOSE OPEN Sun shade panel Sunroof glass Sunroof switch Opens only rear section of the sunroof Closes the sunroof Opens the sunroof Sunroof glass Sun shade panel ...

Page 1063: ...lling down the switch Pull down the switch Push up the switch Open 2 step open Push up the switch briefly 2 step auto sliding open When pushing up the switch briefly the sunroof is automatically opened Opening is carried out in 2 steps In first step the area 5 cm behind the sunroof is not opened Push up the switch once again in order to open the sunroof completely The sunroof operation stops if yo...

Page 1064: ...roof is completely closed The sunroof may look closed but it might be tilted up Tilt Down Tilt Up The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof closed The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted up Pull down the switch Push up the switch ...

Page 1065: ... influx in air through the window or sunroof and its resonance effect If this happens adjust by opening the window or sunroof The anti pinch function is deactivated just before the sunroof closes The sunroof safety function is just a safety supplementary system which cannot replace driver s care and caution Moreover it may not be able to operate due to electric part or other conditions To prevent ...

Page 1066: ... in malfunction Especially in winter never operate the sunroof if operation areas are iced Wait until melted Make sure that the sunroof is completely closed when leaving the vehicle Leaving the vehicle with the sunroof open result in a theft In addition rain or snow can get into the vehicle through the open sunroof When the sunroof is fully open wind buffeting symptom can be worse In this case try...

Page 1067: ... Reset of Sunroof Zero Point Initialization The sunroof does not completely close or open by operating the switch once The sunroof slides back to close But the operation does not stop even after a complete close and tilts up the sunroof The opening gap remarkably decreases for the sliding open or tilt up Operation of the sunroof switch does not do anything or work properly The operating process is...

Page 1068: ...04 11 7340 00 5 CIRCUIT DIAGRAM ...

Page 1069: ...05 3 5110 01 Front view Previous Current Latch type Band type 1 MAJOR CHANGES 1 Luggage Lid Rear view Previous Current No anchor system for keeping lid open Retaining hook ...

Page 1070: ...06 3 5110 00 1 MAJOR CHANGES 1 Radiator Grille Radiator grille Previous Current The radiator grille mesh type is changed to chrome plated grille Grille mesh Grille mesh ...

Page 1071: ...MAJOR DIMENSION 2 JACK POINTS 3 SEALING APPLICATION POINTS 4 DEADENER APPLICATION POINTS 5 UNDER COATING 6 MAJOR WELDING POINTS 7 MAJOR BODY DIMENSIONS 8 GAP CHART 3 4 6 11 12 13 23 31 GENERAL INFORMATION ...

Page 1072: ......

Page 1073: ...07 3 5110 01 Top view Side view Front side Rear view 1 MAJOR DIMENSION ...

Page 1074: ...07 4 2 JACK POINTS 1 2WD ...

Page 1075: ...07 5 5110 01 2 4WD ...

Page 1076: ...07 6 3 SEALING APPLICATION POINTS 1 Dash Panel Engine Tunnel Floor Etc ...

Page 1077: ...07 7 5110 01 2 White Body ...

Page 1078: ...07 8 ...

Page 1079: ...07 9 5110 01 3 Front Rear Door Panel ...

Page 1080: ...07 10 4 Engine Hood Panel ...

Page 1081: ...07 11 5110 01 4 DEADENER APPLICATION POINTS ...

Page 1082: ...07 12 5 UNDER COATING ...

Page 1083: ...07 13 5110 01 6 MAJOR WELDING POINTS 1 Cross Sectional View of Major Panels ...

Page 1084: ...07 14 2 Side Panel ...

Page 1085: ...07 15 5110 01 3 Front Panel ...

Page 1086: ...07 16 4 Apron Panel ...

Page 1087: ...07 17 5110 01 5 Dash Cowl Panels ...

Page 1088: ...07 18 6 Front H Frame Panel ...

Page 1089: ...07 19 5110 01 7 Front Floor Panel ...

Page 1090: ...07 20 8 Rear Floor Panel ...

Page 1091: ...07 21 5110 01 9 Rear End Panel ...

Page 1092: ...07 22 10 Roof Panel ...

Page 1093: ...07 23 5110 01 7 MAJOR BODY DIMENSIONS 1 Under Body Unit mm ...

Page 1094: ...07 24 2 Vehicle Structure Unit mm ...

Page 1095: ...07 25 5110 01 3 Side Structure Unit mm ...

Page 1096: ...07 26 4 Windshield Glass Area Unit mm ...

Page 1097: ...07 27 5110 01 5 Tail Gate Area Unit mm ...

Page 1098: ...07 28 6 Front End Unit mm ...

Page 1099: ...07 29 5110 01 7 Engine Compartment Unit mm ...

Page 1100: ...07 30 8 Back Panel Unit mm ...

Page 1101: ...07 31 5110 01 8 GAP CHART 1 Side Body Unit mm ...

Page 1102: ...07 32 2 Front Unit mm ...

Page 1103: ...07 33 5110 01 3 Rear Unit mm ...

Page 1104: ......