SSANGYONG Korando Manual
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SSANGYONG Korando Manual

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Summary of Contents for SSANGYONG Korando

  • Page 96 MODIFIED ITEMS 1. EXTERIOR..........2. INTERIOR..........3. CHASSIS..........
  • Page 97 01-2 1. EXTERIOR Front view Rear view 7910-01 Radiator grille 7840-20 Rear glass Chrome plated Deleted the solar glass option...
  • Page 98 01-3 0000-00 Side view 7810-01 Wiper arm blade Arm pressure: driver’s - 900±50g Front passenger’s - 600±50g Arm pressure: driver’s - 950±50g Front passenger’s - 650±50g Changed the blade design and arm pressure (size is same with old version)
  • Page 99 01-4 2. INTERIOR 6810-20 Manual type A/C control 4610-01 Steering wheel heating system Steering wheel heating unit Added the connector Added the connector for ambient temperature Added the heated wire and heating unit in the sensor. steering wheel. 3030-01 Instrument cluster Smart key Standard type: Added the winter mode indicator and ambient...
  • Page 100 01-5 0000-00 8710-01 7410-01 Front seat Hook Leather seat Fabric seat Changed the seatback pocket design and deleted Changed the ESS (Emergency the hook on seatback board. Stop Signal) logic. - Leather seat: Band type seatback pocket Changed the SBR (Seat Belt - Fabric seat: Net type seatback pocket Reminder) logic.
  • Page 101 01-6 3. CHASSIS 8910-02 Gear shift cable assembly 3710-01 Gear shift lever (M/T) (M/T) Gear shift lever bracket Changed the connection and socket to the gear Changed the gear shift lever bracket. shift lever. 8530-09 SWAS: Steering Wheel Angle 8810-00 Contact coil Sensor Changed the sensor design, connector...

  • Page 102: Table Of Contents

    GENERAL INFORMATION 1. LAYOUT..........2. MAJOR COMPONENTS......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........

  • Page 104: Layout

    01-3 0000-00 1. LAYOUT Front view Rear view Right side view Left side view...

  • Page 105: Major Components

    01-4 2. MAJOR COMPONENTS ▶ Front View Vacuum pump Oil filter assembly Camshaft position sensor Power steering pump 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...
  • Page 106 01-5 0000-00 ▶ Right side View Wide band oxygen sensor Pre-CDPF pressure port Front exhaust gas temperature sensor Rear exhaust gas temperature sensor CDPF assembly Post-CDPF pressure port Oil drain plug E-VGT turbocharger ▶ Left side View Thermostat assembly Knock sensor 1 connector Oil cooler assembly Variable swirl valve assembly E-EGR valve...

  • Page 107: Guidelines For Service Works

    2) Equipment Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are integrated into a module. Therefore, 2-post lift and general equipment are necessary when working on the engine and transmission.
  • Page 108 0000-00 Remove the engine and transaxle as a set. Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are integrated into a module. Therefore, 2-post lift and general equipment are necessary when working on the engine and transmission.
  • Page 109 Check the oil level when the engine is still warm and add the specified engine oil if necessary. (7) Coolant Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material), and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed. (8) Engine drive belt Check all drive belts on the engine for wear, crack and looseness.
  • Page 110 01-9 0000-00 5) Guidelines on Engine Service To prevent the personal injuries and vehicle damages that can be caused by mistakes during service and to provide the optimized performance and safety after service works, the service technicials must keep the basic cautions and service guidelines below. These could be easily forgotten during service works.
  • Page 111 01-10 (4) Fuel and lubrication system When working with the fuel or oil systems in enclosed area, always keep the working area well-ventilated and never allow anybody to smoke. Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and nuts should be tightened as specified.

  • Page 112: Jack-Up Points

    01-11 0000-00 2. JACK-UP POINTS ▶ Stand jack-up points and installation status (front side) Jack-up points and setup (front side) Supporting Jack-up points Jack-up points for 2-post lift for 2-post lift Jack-up points and setup (rear side) Supporting...

  • Page 113: Standard Bolts Specifications

    01-12 3. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.

  • Page 114: Coding And Setup

    01-13 0000-00 4. CODING AND SETUP 1) Engine Variant Coding...

  • Page 115: Special Service Tools

    01-14 1. SPECIAL SERVICE TOOLS Name & Part number Tool How to use (on vehicle) Part number: 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...
  • Page 116 01-15 0000-00 Name and Part Number Special tool Part number: T99180010A Name: EURO-V injector remover ▶ Components of Injector Remover Name Quantity Component Injector remover set Main bar Cross bar Main bolt holder Ball bearing...
  • Page 117 01-16 Name Quantity Component Main nut - A Main bolt - A Injector holder - A Injector holder - B Injector holder cover Bar holder assembly Support mounting bolt Main support...
  • Page 118 01-17 0000-00 ▶ How to assemble the injector remover (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.
  • Page 119 01-18 ▶ How to set up the injector remover (injector holder and main bolt) to the vehicle Set up the injector holder assembly on the injector to be removed. Install the injector holder A. Tighten the main bolt. Install the injector holder B. Pay particular attention not to damage the injector return nozzle and thread of injector during setting up the injector holder.
  • Page 120 01-19 0000-00 ▶ How to remove the injector for Euro-V Set up the injector remover assembly on four cylinder head bolts. 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.
  • Page 121 01-20 Install the ball bearing on the main bolt. Tighten the main nut. Slowly release the injector by turning it counterclockwise with a torque wrench and socket (32 mm). To avoid any damage to cylinder head and head cover, keep the specified tightening torque.
  • Page 122 01-21 0000-00 Name & Part number Tool How to use 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. Part number: Y9922 082B, W9911 0230A, Y9922 018 Name: Valve spring complete Use: Used to compress the...
  • Page 123 01-22 Name & Part number Tool How to use Part number: Y9922 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...

  • Page 124: Normal Equipments

    Tool Name: Engine and transmission jack Use: High load jack dedicated for Chairman W, but can be used for Korando C to support module when lowering engine and transmission mounted to sub frame at the same time (replacing manual transmission).
  • Page 125 01-24 Name and Part Number Tool Name: Engine holder for C200 Use: Used to hold engine to prevent 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.
  • Page 126 01-25 0000-00 Name & 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 Disconnect the negatice cable from the battery. Unscrew three screw rivets on each fender cover and remove both fender covers. * Disconnect the negative cable from the battery.
  • Page 128 01-27 0000-00 Place the engine support hanger on the fender. Secure the hanger legs by turning the lever to arrow direction.
  • Page 129 01-28 Release the nut (A, B) on the legs and level the hanger. Chain up the rear engine hanger bracket. Rear hanger bracket Align the hook of support hanger with the hanger bracket by adjusting the top of the Front hanger bracket engine hanger support.
  • Page 130 01-29 0000-00 Make the chain tight by turning the hook level adjusting lever to arrow direction. Remove the engine support hanger in the reverse order of installation.
  • Page 132 02-3 0000-00 1. SPECIFICATION Unit Unit Description Description Specification Remark Cylinder head Height Height 131.9 to 132.1mm Flatness Flatness below 0.1mm Valve protrusion Intake Valve Intake Valve 0.1~0.7mm Cylinder head Valve protrusion Exhaust Valve Exhaust Valve 0.1~0.7mm Flatness on Intake manifold Intake manifold 0.08mm 0.08mm...
  • Page 133 02-4 2. TIGHTENING TORQUE Remark Tightening torque Component Size Quantity (Total torque) (Nm) 55 ± 5Nm, M12×82 Main bearing cap Not re-usable 180˚ 40 ± 5Nm, M9×52 Connecting rod cap 50~80Nm 90˚ ± 10˚ Crankshaft rear cover M6×20 10 ± 1Nm M8×35 25 ±...
  • Page 134 02-5 0000-00 Remark Tightening torque Component Size Quantity (Total torque) (Nm) M6×12 10 ± 1Nm Hot water inlet pipe M10×90 25 ± 2.5Nm Lower Alternator M10×116 46 ± 4.6Nm Upper M8×85 25 ± 2.5Nm A/C compressor M6×25 10 ± 1Nm A/C bracket M8×35 25 ±...
  • Page 135 02-6 Remark Tightening torque Component Size Quantity (Total torque) (Nm) Idle pulley/Tensioner 45 ± 4.5Nm pulley 20 ± 2Nm Glow plug 볼트 비고 품명 규격 규정토오크(Nm) M8×25 10 ± 1Nm 수량 (총 토오크) Vacuum pump M6×40 10 ± 1Nm Timing gear case cover M6×45 10 ±...
  • Page 136 02-7 0000-00...
  • Page 137 02-8...
  • Page 138 02-9 0000-00...
  • Page 139 02-10...
  • Page 140 02-11 0000-00 3. CHECK AND INSPECTION 1) Cylinder (1) Compression pressure test ▶ Specified value Compression ratio 16.5 : 1 at normal operating temperature (80˚C) Test condition Standard 32 bar Compression pressure 18 bar Minimum Maximum 3 bar Differential limit between cylinders The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket).
  • Page 141 02-12 (3) Piston protrusion check Position the piston at TDC and measure the piston protrusion from crank case mating surface. Specified value 0.475 to 0.745mm Measure it at both ends of crankshaft.
  • Page 142 02-13 0000-00 2) Cylinder Head (1) Cylinder head mating surface check ▶ Specified value 131.9 to 132.1 mm Total height "A" Minimum height after machining 131.9mm 0.1 / 150 Longitudinal direction Flatness Transverse direction 0.15 below 0.1 mm Parallel deviation of cylinder head Rmax7 Peak-to valley of surface Rz6.3...
  • Page 143 02-14 4. GUIDELINES ON ENGINE SERVICE To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 144 02-15 0000-00 ▶ Fuel and lubrication system 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.
  • Page 145 02-16 1. BELT SYSTEM The belt system is a single belt drive system which uses single belt and has components on the oil filter housing as FEAD (Front End Accessories Drive) type. ▶ Components with HPS (hydraulic power steering) with EPS (electric power steering) Crankshaft pulley (DDU) Auto tensioner Tensioner pulley...
  • Page 146 02-17 0000-00 2. VACUUM PUMP Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole in hollow shaft. ▶...
  • Page 147 02-18 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 reaction. Additionally, left mounting is hydraulic type and supports the engine vibration.
  • Page 148 02-19 0000-00 4. INTAKE/EXHAUST SYSTEM 1) Intake Manifold Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas.
  • Page 149 02-20 5. CYLINDER 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 PCV valve Oil separator...
  • Page 150 02-21 0000-00 6. CYLINDER HEAD Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install in vertical direction. This enables the compact layout in cylinder head assembly.
  • Page 151 02-22 ▶ Components Finger follower & HLA Intake/exhaust Camshafts Camshaft sprocket Cylinder head Camshaft position sensor HP pump drive gear Vacuum pump drive Cylinder head gasket...
  • Page 152 02-23 0000-00 7. CHAIN AND GEAR DRIVE SYSTEM D20DTF engine uses single stage chain drive system. Timing chain drives the exhaust side and gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil pump to lubricate the engine.
  • Page 153 02-24 ▶ Components Intake/exhaust Camshaft assembly Exhaust HP pump drive gear Connected to Camshaft vacuum pump Intake Camshaft...
  • Page 154 02-25 0000-00 Timing gear cover case (TGCC) TGCC Oil seal Screw plug...
  • Page 155 02-26 Mass Balance Unit (MBU) Crankshaft MBU drive gear Fuel HP pump HP pump drive gear HP pump gear...
  • Page 156 02-27 0000-00 8. OIL PAN The oil pan in D20DTF engine improves the noise and vibration. Especially, the oil drainage is very easier than before. The oil level sensor 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.
  • Page 157 02-28 9. MASS BALANCE 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 02-29 0000-00 10. FLYWHEEL AND DRIVE PLATE 1) DMF (Dual Mass Flywheel) The dual mass flywheel, or DMF, eliminates excessive transmission gear rattle, reduces gear change/shift effort, and increases fuel economy. There is a friction ring located between the inner and outer flywheel that allows the inner and outer flywheel to slip.
  • Page 159 02-30 11. PISTON/CRANKSHAFT/CYLINDER BLOCK 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 03-3 0000-00 1. SPECIFICATION Description Specification Fuel Diesel Fuel heater + priming pump + water Type separator integrated type Filter type Changeable filter element type Fuel filter every 40,000 km Change interval every 45,000 km Water accumulating capacity 200 cc Heater capacity 250W 13.5V Injector...
  • Page 161 03-4 2. MAINTENANCE AND INSPECTION 1) Maintenance Procedures for DI Engine Fuel System Always keep the workshop and lift clean (especially, from dust). Always keep the tools clean (from oil or foreign materials). Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
  • Page 162 03-5 0000-00 Follow the job procedures. If you find a defective component, replace it with new one. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques during installation.
  • Page 163 03-6 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.
  • Page 164 03-7 0000-00 2) Diagnostic Test for Engine Fuel System (1) Overview If a DTC is displayed on the diagnostic device, 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.
  • Page 165 03-8 (3) Excessive backleak of injector ▶ Excessive injector backleak Occurs when the injector control valve is not sealed due to the entry of the foreign materials. ▶ Example: Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector...
  • Page 166 03-9 0000-00 (4) Loss of pump pressure/flow ▶ Loss of HP pump 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 (>...
  • Page 167 03-10 3) Pressure Test for Fuel System in DI Engine (1) Test device (Tool kit) Tool kit for 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 03-11 0000-00 (3) DTC Check If several DTCs are output simultaneously, check the electric wiring for open or short circuit. Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry out the high pressure fuel system check.
  • Page 169 03-12 (4) Fuel System Check Procedure...
  • Page 170 03-13 0000-00 (5) High Pressure System Pressure Test ▶ Fuel rail pressure test Disconnect the fuel rail pressure sensor connector and then IMV connector. Connect the pressure tester to the fuel rail pressure sensor connector. Crank the engine 2 times for 5 seconds. Read the highest pressure value displayed on the tester display.
  • Page 171 03-14 ▶ How To Use Pressure Tester Press the "TEST" button 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. The fuel rail pressure value can be checked using a diagnostic device.
  • Page 172 03-15 0000-00 (6) Low Pressure System Pressure Test ▶ Inspection procedure All wirings/connectors and fuel lines should be connected and the engine should work properly. Prepare a special tool for low pressure test and clean it thoroughly to prevent foreign materials from entering.
  • Page 173 03-16 ▶ Static test for backleak of injector Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool). Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 174 03-17 0000-00 ▶ Dynamic test for backleak of injector Warm up the engine so that the engine coolant temperature be over 80℃ and star the engine again. Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool). Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 175 03-18 ▶ Pressure leak test in fuel system with scan tool When the dynamic test for injector backleak is performed, this test should be done together with it. However, you can check the pressure leak from the fuel system only with this test. To do this test, the coolant temperature should be over 60˚C.
  • Page 176 03-19 0000-00 ▶ HP pump pressure test Prepare a special tool for high pressure test and clean it thoroughly to prevent foreign materials from entering. Disconnect the high pressure fuel supply pipe on the HP pump and install the close rail in the tool kit.
  • Page 177 03-20 3. CAUTIONS FOR DI ENGINE 1) Cautions for DI Engine This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine, warning lights, symptoms when engine malfunctioning, causes and actions. DI Engine Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high power and reduces less emission.
  • Page 178 03-21 0000-00 2) Cleanness (1) Cleanness of DI engine fuel system ▶ Cleanness of DI engine fuel system and service procedures The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1,600 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.
  • Page 179 03-22 (2) Di engine and its expected problems and remedies can be caused by water in fuel ▶ System supplement against paraffin separation In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally.
  • Page 180 03-23 0000-00 1. OVERVIEW The components in the fuel system supply fuel and generate high pressure to inject fuel to each injector. They are controlled by the engine ECU. The common rail fuel injection system consists of fuel tank, fuel line, low pressure line which 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...
  • Page 181 03-24 2. SYSTEM LAYOUT AND OPERATION 1) Layout For sensor and actuator control logic, refer to Chapter "ENGINE CONTROL". Fuel supply line Fuel tank Fuel return line Fuel metering by dual sender. Supply the fuel in main fuel tank and sub fuel tank through fuel inlet tube Injector (C3I) Pre-injection, main injection, after-injection...
  • Page 182 03-25 0000-00 High pressure pump Accelerator pedal position Fuel filter assembly sensor Plunger type HP pump (1,800 bar) Vane type transfer pump (6bar) Supply clean fuel/fuel heating/water separation by Generates the high pressurized Detects driver's intention priming pump fuel and supply it. for speed up/down Engine ECU (D20DTF) Engine control by various...
  • Page 183 03-26 2) Fuel System Flow Diagram The fuel from the fuel tank is supplied to the fuel heater of fuel filter/priming pump and then low pressure generated by the low pressure pump (built into HP pump) is transmitted to the HP pump. The fuel pressure at the HP pump is controlled by the IMV valve, and the maximum allowed pressure is 1,800 bar.
  • Page 184 03-27 0000-00 3) Input/Output devices...
  • Page 185 03-28 The engine ECU calculates 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 air-fuel ratio control based on these signals. The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position) sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal depressed (driver's will) by receiving the electrical signals from the accelerator...
  • Page 186 03-29 0000-00 4) Flow Diagram of Fuel Supply System...
  • Page 187 03-30 5) Circuit Diagram...
  • Page 188 04-3 0000-00 1. SPECIFICATION Component Item Specification Filter type Dry, filter element 0.208 m² Filter area EU: Change every 20,000 km (But, shorten the Air cleaner element service interval under severe conditions) Service interval GEN: Change every 15,000 km (But, shorten the service interval under severe conditions) Weight 1.13 kg...
  • Page 189 04-4 2. INSPECTION 1) Troubleshooting ▶ When Abnormal Noises are Heard from the Engine Room For the vehicle equipped with DI engine, if a learning noise occurs in each range or other noises occur, the major cause of it is a faulty turbocharger assembly. But an interference issue, poor tightness or loose in the intake and exhaust system also can cause those noises.
  • Page 190 04-5 0000-00 3) Troubleshooting Sequence The basic checks for intake system are as follows: ▶ Basic Checks for Intake System Make sure to replace or clean the air cleaner element periodically. Otherwise, engine will be derated or work abnormally because of low intake air volume. Unlike the fuel system, which is a closed circuit, the intake system is an open circuit system.
  • Page 191 04-6 1. OVERVIEW The intake system for D20DTF engine is equipped with an electric throttle body which includes a flap. This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off. To be sure to get the optimized swirl in intake manifold, the swirl valve and dual type port have been adopted.
  • 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 04-10 1) Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Squish: Squish is the air flows due to the piston head.
  • Page 196 04-11 0000-00 Load Engine speed Swirl Amount of Remarks valve swirl Low speed, Increased EGR ratio, better air-fuel below 3,000 rpm Closed Heavy Low load mixture (reduce exhaust gas) High speed, Increase charge efficiency, higher over 3,000 rpm Open Light High load engine power The variable swirl valve actuator operates...
  • Page 197 04-12 5. CIRCUIT DIAGRAM...
  • Page 198 05-3 0000-00 1. TROUBLESHOOTING 1) Work Flow...
  • Page 199 05-4 2. CAUTIONS Do not park the vehicle on flammable materials, such as grass, leaves and carpet. Do not touch the catalyst or the exhaust gas ignition system when the engine is running. If a misfire occurs in the combustion chamber or the emission of pollutant exceeds the specified level, the catalyst can be damaged.
  • Page 200 05-5 0000-00 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 Exhaust manifold CDPF assembly 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 06-3 0000-00 1. SPECIFICATION Component Item Specification Max. expansion coefficient Max. turbine speed 215,000 rpm Turbocharger 800 ℃ Max. temperature of turbine housing Weight 7.2 kg E-Actuator Operation duty cycle 300 Hz...
  • Page 203 06-4 2. INSPECTION 1) Cautions During Driving The following lists cautions to take during test drive and on the turbocharger vehicle, which must be considered during the operation. It's important not to drastically increase the engine rpm starting the engine. It could make rotation at excessive speed even before the journal bearing is lubricated and when the turbocharger rotates in poor oil supply condition, it could cause damage of bearing seizure within few seconds.
  • Page 204 06-5 0000-00 2) Inspection of Turbocharger 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. On-board Inspection Check the bolts and nuts foe looseness or missing Check the intake and exhaust manifold for looseness or damage Check the oil supply pipe and drain pipe for damages Check the housing for crack and deterioration...
  • Page 205 06-6 3) Inspection of Turbine Thoroughly check the followings. Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it could damage the turbocharger or be hazardous during inspection. Interference: In case where is trace of interference or smallest damage on the compressor wheel means, most of times, that abrasion has occurred on the journal bearing.
  • Page 206 06-7 0000-00 4) Possible Causes of Defect The following tries to understand 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.
  • Page 207 06-8 Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil line.
  • Page 208 06-9 0000-00 Turbine Side: Inflow of foreign materials from engine Compressor Side: such as air filter, muffler and nut...
  • Page 209 06-10 Defects caused by reasons other than that of the turbocharger.
  • Page 210 06-11 0000-00 3. TROUBLESHOOTING The followings are cautions to take in handling defects of turbocharger, which must be fully aware 1) Cautions After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting condition of vacuum port and modulator, which is connected to the actuator.
  • 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 06-17 0000-00 1. SYSTEM DESCRIPTION OF E-VGT (Electric-Variable Geometry Turbine) A turbocharger is a centrifugal compressor powered by a high speed turbine that is driven by an engine's exhaust gases. Its benefit lies with the compressor increasing the mass of air entering the engine (forced induction), thereby resulting in greater performance (for either, or both, power and efficiency).
  • Page 217 06-18 1) Features (1) Performance (for EURO V) Enhanced emission control: By temperature control with CDPF system Target temperature and airflow control (2) E-Actuator (Electric-Actuator, Rotary type) Optimizes the exhaust gas flow rate by controlling the vanes inside the turbine housing with the E-Actuator.
  • Page 218 06-19 0000-00 2. COMPONENTS For more information about control logic, refer to Chapter "Engine Control". E-VGT turbocharger Engine ECU (D20DTF) Accelerator pedal position sensor Atmospheric pressure, RPM signal Transfers accelerating demand to ECU Improves engine power E-VGT duty control T-MAP sensor HFM sensor Coolant temperature sensor Operates the VGT according...
  • Page 219 06-20 3. INPUT/OUTPUT DEVICES...
  • Page 220 06-21 0000-00 4. OPERATING PRINCIPLES The E-VGT is designed to get more improved engine power in all ranges 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.
  • Page 221 06-22 2) How it Works at High Speed In a high speed zone, the amount of exhaust gas increases and it is accompanied with a great force. Therefore, if the inner diameter of venturi is more widened, the turbine in the turbocharger by the releasing force of abundant exhaust gas can deliver a more increased energy to the compressor.
  • Page 222 Type Fulle flow/Paper element Engine oil Specified oil Quality class: Ssangyong genuine engine oil (Total Quartz INEO ECS 5W 30, SK ZIC SY 5W 30 or oil Approved by MB 229. 51) SAE 5W30 Capacity Min.: 4.5 L / Max.: 6.0 L...
  • Page 223 Recheck the oil level after 5 minutes. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
  • Page 224 07-5 0000-00 1. SYSTEM DESCRIPTION 1) Overview The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove heat from the friction part. As the engine runs, 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.
  • Page 225 07-6 3) Oil Filter Module The oil filter module consists of lubrication system, cooling 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 2. OPERATING PROCESS 1) Operation Flow...
  • Page 227 07-8 3. LUBRICATION 1)Anti-friction The oil makes a thin film on the surface of sliding components to reduce the wear due to friction. 2)Cooling The friction makes the heat on the components. The oil absorbs the heat and radiates it or cools it down.
  • Page 228 08-3 0000-00 1. SPECIFICATION Description Specification Cooling system Type Water cooling, forced circulation Coolant Capacity 11.3L 740W X 380H X 27t (over 281,200㎣) Core size Radiator Flow type Cross flow Min. cooling capacity over 68,000kcal/h Type Long life coolant Antifreeze Mixing ratio 50 : 50 (water:antifreeze)
  • Page 229 08-4 2. INSPECTION Possible Cause Action Coolant level - Leak from the radiator - Replace the radiator is too low - Leak from the auxiliary reservoir - Replace the auxiliary reservoir - Leak from the heater core - Replace the heater - Leak from the coolant hose connections - Reconnect the hose or replace - Damaged coolant hose...
  • Page 230 08-5 0000-00 1) Coolant Level Check Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is cooled down. The coolant level should be between the MAX and MIN mark on the coolant reservoir. Check the coolant level.
  • Page 231 08-6 2) Leak Test Release the pressure in the system by loosening the pressure cap of the coolant reservoir slightly. Then, remove the pressure cap completely. Never open the cap until the coolant temperature becomes under 90℃ to prevent any burn. Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank.
  • Page 232 08-7 0000-00 3. CAUTIONS If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity can be decreased resulting in poor circulation in the cooling system which leads to overheated engine. Use of non-recommended coolant could cause damage to the cooling system and overheating of the engine.
  • Page 233 08-8 1. SYSTEM DESCRIPTION 1) Overview Coolant reservoir Long life coolant is used. Water pump Sealing Oil filter module Water pump pulley Impeller vane The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine. Thermostat When the engine coolant reaches 90℃, the thermostat...
  • Page 234 08-9 0000-00 Coolant temperature sensor Measures the coolant temperature 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 09-3 0000-00 1. SPECIFICATION Specification 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 ← Capacity 90AH...
  • Page 238 09-4 2. INSPECTION 1) Alternator Output Test Item How to check DTC set value / Action Disconnect the cable connected to the B Pass: If the measured current is 45 terminal on the alternator. Connect one A or higher. end of the ammeter to the B terminal and Fail: If the measured current is less the other end to the cable connected to than 45 A.
  • Page 239 09-5 0000-00 2) Troubleshooting for Alternator Item Cause Action Overcharged battery Defective alternator voltage Replace regulator defective alternator detection wiring Repair or replace Discharged battery Loose alternator drive belt Adjust the belt tension or replace Poor connection of related circuit Retighten the loose connection or or open circuit repair open circuit...
  • Page 240 09-6 3) Checking Battery...
  • Page 241 09-7 0000-00 (1) Checking ▶ Using battery tester PASS (11.0 V or more): Explain to the customer that the battery is reusable. Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the customer.
  • Page 242 09-8 (3) Starting with jumper cable If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to start the engine. ▶ Connecting order The positive (+) terminal of the discharged battery The positive (+) terminal of the booster battery The negative (-) terminal of the booster battery Connect one end of the other jumper cable to the body of the discharged vehicle, such as the engine block or a front towing hook.
  • Page 243 09-9 0000-00 (4) Maintenance If the charge warning lamp ( ) on the instrument cluster comes on while driving, there is a malfunction in the charge system including the battery. Therefore, carrying out the system check is needed. Make sure that the battery cables are firmly connected. If the terminals are corroded, clean them with a wire brush or sandpapers.
  • Page 244 09-10 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 to the electric load and ambient temperature change.
  • Page 245 09-11 0000-00 3) Charging The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge, slip ring and brush. ▶ Charging time according to vehicle conditions and environment Specification : Charging a fully depleted high- capacity battery takes twice or more as long as charging a fully depleted battery for small vehicles.
  • 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 10-3 1413-00 1. SPECIFICATION Description Specification Glow plug Rated voltage 12 V Operating voltage 6 to 16 V 1300°C Maximum temperature 1100°C Operating temperature Glow plug control unit EMS operating voltage 6 to 16 V -40°C to 110°C Operating temperature Dark current Max.
  • Page 250 10-4 2. TIGHTENING TORQUE Glow plug GCU (Glow plug Control Unit) Name Tightening torque 15 ± 1.5 Nm Glow plug 10 ± 1.0 Nm Glow plug control unit bolt...
  • Page 251 10-5 1413-00 1. OVERVIEW The pre-heating system for D20DTF engine has the glow plug to the cylinder head (combustion chamber), and improves the cold start performance and reduces the emission level. The pre-heating resistor (air heater) is used to heat the intake air. This enables the diesel fuel to be ignited in low temperature condition.
  • Page 252 10-6 2. SYSTEM OPERATION 1) Input/Output Diagram of Glow Plug Control Unit 2) System Diagram...
  • Page 254 10-8 3) Circuit Diagram...
  • Page 255 10-9 1413-00...
  • Page 256 10-10 4) System Operation Glow plug is installed in the cylinder head. It enhances the cold starting performance and reduces the exhaust gas during cold starting. ECU receives the various signals such as engine rpm, coolant temperature and vehicle speed through CAN communication lines.
  • Page 257 10-11 1413-00 (3) Operating Steps ▶ Pre-Glow: Step 1 If normal communication with the ECU is established 2 seconds after the power is supplied to the IGN terminal from the battery, the GCU supplies the battery power to raise the temperature of the glow plug to 1000℃...
  • Page 258 10-12 ▶ During cranking: Step 2 and step 3 Step 2: If the ECU receives the cranking signal after pre-heating (step 1), the GCU supplies the voltage of 6.8 V for 1 sec to raise the temperature to 1,100℃. Step 3: The GCU supplies the voltage of 5.1 V to keep the temperature at 1,000°C. Under fixed temperature: The AQGS unit supplies power for 30 seconds (Step 1 + Step 3) if no cranking signal is received after the step 1.
  • 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 11-3 1461-00 1. 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 11-4 2. TROUBLESHOOTING Possible Cause　　 Problem Action Low battery voltage Charge or replace Loose, corroded or damaged battery cable Repair or replace Engine will not crank Faulty starter or open circuit Faulty ignition switch or blown fuse Repair or replace Poor engine ground Repair Low battery voltage...
  • Page 263 11-5 1461-00 1. SYSTEM DESCRIPTION The starter (start motor) 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 264 11-6 2. OPERATING PROCESS 1) System Layout (1) Engine start SKM performs the authentication process for the SMART key and sends the engine start request to EMS if there is a normally coded SMART key when pressing the Engine Start/Stop button with the brake pedal depressed and gear shift lever in “P”...
  • Page 265 11-7 1461-00 (2) With SMART key system...
  • Page 266 11-8 (3) Without SMART key system...
  • 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 12-3 8530-00 1. OVERVIEW 1) System Description Auto cruise operated ECO cruise operated The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 273 12-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc.
  • Page 274 12-5 8530-00 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions 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 4.22 ~ 4.82V...
  • Page 276 12-7 8530-00 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate the vehicle speed to the operating range. * Operating range: - 38 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,.
  • Page 277 12-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 278 12-9 8530-00 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 38 km/h.
  • Page 279 12-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 38 km/h without an acceleration intervention.
  • Page 280 12-11 8530-00 5) ECO Cruise Control The ECO cruise control system has nearly same functions with the auto cruise control system. It is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. ECO cruise driving mode The engine ECU controls the sharp acceleration and deceleration to improve the fuel economy.
  • Page 281 12-12 6) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed. When the cruising speed is downed less than 38 km/h. When pushing the ON-OFF switch of the cruise control lever.
  • Page 282 12-13 8530-00 (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 faulty.
  • Page 283 13-3 1793-01 1. SPECIFICATION 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 5V ± 10% Supply voltage Signal range 5% ~ 95% ＜15mA Max.
  • Page 284 13-4 1. SYSTEM DESCRIPTION 1) Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. To meet Euro-V regulation, the capacity and response rate of E-EGR valve in D20DTF engine have been greatly improved.
  • Page 285 13-5 1793-01 2) Location and Components E-EGR cooler and bypass valve HFM sensor EGR cooler EGR bypass Used as a main map value to control the EGR. The cooler lowers the high temperature of the The coolant temperature, engine rpm, engine exhaust gas and the bypass valve directly load, intake air temperature (HFM: decreased at 60˚C or more), atmospheric pressure...
  • Page 286 13-6 2. OPERATING PROCESS 1) Schematic Diagram...
  • Page 287 13-7 1793-01 2) Input/Output Devices 3) Control Logic The EGR system controls the EGR amount based on the map values shown below: ※ Main map value: Intake air volume ※ Auxiliary map value: Compensation by the coolant temperature Compensation by the atmospheric pressure: Altitude compensation Compensation by the boost pressure deviation (the difference between the requested value and the measured value of boost pressure) Compensation by the engine load: During sudden acceleration...
  • Page 288 14-3 1114-00 1. SPECIFICATION Emission Regulation Euro-V Front Area 182.41cm 124 X 158 X 78L Size 124 X 158 X 194L Shell SUS430J1L X 1.5t CDPF Canister End Cone SUS430J1L X 2.0t (Single) Catalyst Capacity 4.2L CDPF Material of Filter AT (Aluminum-Titanium Alloy)
  • Page 289 14-4 2. CAUTIONS ▶ Standard pattern of soot accumulation (1) Abnormal Soot Accumulation (2) Normal Soot Combustion ▶ Cautions to protect the catalyst filter Use the designated fuel only. Observe the recommended service intervals of engine oil. Check the engine oil level frequently and add if necessary. Do not idle the vehicle unnecessarily.
  • Page 290 14-5 1114-00 (3) Warning Lamp Related to CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 291 14-6 ▶ Excessive overload of CDPF (warning lamp illuminated) If the vehicle is driven at a speed of 5 to 10 km/h for an extended period of time, the soot accumulated in the CDPF cannot be burned as the CDPF cannot reach the regeneration temperature.
  • Page 292 14-7 1114-00 1. OVERVIEW The DOC (Diesel Oxidation Catalyst) generates CO2 and H2O which are harmless through 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 14-8 2. COMPONENT Rear temperature Oxygen sensor CDPF Front temperature sensor (DOC + DPF) sensor Measures the Protects the temperature of fuel turbocharger. combustion. Engine ECU (D20DTF) Differential pressure sensor Electric throttle body Calculates the amount of PM collected by reading the Regulates the rate of air pressure difference between intake.
  • Page 294 14-9 1114-00 3. INPUT/OUTPUT DEVICES Front temperature sensor: This sensor is installed at the inlet of DOC and detects whether the DOC can burn (oxidize) the post-injected fuel or not. Rear temperature sensor: This sensor is installed at the inlet of DPF and monitors that the temperature of the exhaust gas is kept at 600℃.
  • Page 295 14-10 4. POST-INJECTION AND AIR MASS CONTROL A DPS (Differential Pressure Sensor) measures the pressure difference between before and after the CDPF and detects whether the soot is collected in the CDPF or not. If PM is collected in the CDPF (In this case the pressure difference between before and after the CDPF exceeds the specified value.
  • Page 296 14-11 1114-00 Front EGT sensor Rear EGT sensor HFM sensor Intake air volume ECU (DCM 3.7) Measures the temperature of Measures the temperature DOC. of DPF. The DOC performs the redox The DPF burns the soot reaction at between 300 and with hot exhaust gases 500℃...
  • Page 297 14-12 5. OPERATING PROCESS [Configuration and principle of operation] Collecting PM Oxidation (DOC) → Regeneration The exhaust gas When the exhaust gas enters The engine ECU detects the into the CDPF assembly, its amount of PM collected by passed through the CO, HC and PM are reduced the information from the exhaust manifold...
  • Page 298 14-13 1114-00 6. OPERATING TEMPERATURE...
  • Page 299 14-14 7. ELECTRIC CIRCUIT DIAGRAM...
  • Page 300 14-15 1114-00 8. CAUTIONS 1) Designated Engine Oil for CDPF (Low Ash Oil) Need to use the designated engine oil for CDPF The smoke from the vehicle may generate the particle material in the ambient air. CDPF is the device to reduce the smoke by collecting and recycling it. To ensure the performance of CDPF, the designated engine oil should be used.
  • Page 301 15-3 0000-00 1. ENGINE DATA LIST Data Unit Value ℃ 0.436 V (130℃) to 4.896 V (-40℃) Coolant temperature ℃ -40 to 130℃ (varies by ambient air Intake air temperature temperature or engine mode) 780 ± 20 Idle speed 750 ± 20 Engine load 18~25% Mass air flow...
  • Page 302 15-4 1. MAJOR COMPONENT Rear exhaust gas temp. Front exhaust gas temp. Injector (C3I) Oxygen sensor sensor sensor Camshaft position sensor Glow plug Variable swirl valve Electronic throttle T-MAP sensor Knock sensor (2) Oil level sensor body (Temp.+Pres.)
  • Page 303 15-5 0000-00 GCU (Glow plug Differential pres. D20DTF ECU Fuel temp. sensor control unit) sensor Coolant temp. sensor HFM (air mass/temperature) E-EGR Fuel rail pres. sensor E-EGR valve bypass valve...
  • Page 304 15-6 2. SYSTEM OPERATION 1) Input/Output of ECU (1) ECU Block diagram...
  • Page 305 15-7 0000-00 (2) Components for ECU Input Crankshaft posi. Accel. pedal Throttle HFM sensor Knock sensor sensor posi. sensor posi.sensor Exhaust gas T-MAP sensor temp. sensor Oxygen Differential sensor pressure sensor E-EGR valve Camshaft posi. Coolant temp. posi. sensor sensor sensor Fuel rail pres.sensor...
  • Page 306 15-8 (3) Components for ECU Input Start motor A/C compressor Injector Variable swirl Throttle posi. valve sensor E-EGR valve E-EGR cooler E-VGT bypass valve actuator PTC heater Cooling fan Engine room relay box - Glow plug unit - ABS & ESP unit - BCM - E-coupling unit - EPS...
  • Page 307 15-9 0000-00 2) ECU Control (1) Function a. ECU Function ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and analyzes to control respective actuators. ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft angle based on input data and stored specific map to control the engine power and emission gas.
  • Page 308 15-10 (2) Fuel Control a. Fuel Pressure Control Elements Pressure control consists of 2 principles. Determines rail pressure according to engine operating conditions. Controls IMV to make the rail pressure to reach to the required value. Pressure in the fuel rail is determined according to engine speed and load on the engine. When engine speed and load are high The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize combustion.
  • Page 309 15-11 0000-00 c. Fuel Injection Control Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors. Injection control consists as below. Injection timing Injection volume Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver.
  • Page 310 15-12 ▶ Pilot injection timing control The pilot injection timing is determined as a function of the engine speed and of the total flow. The elements are: A first correction is made according to the air and coolant temperatures. This correction allows the pilot injection timing to be adapted to the operating temperature of the engine.
  • Page 311 15-13 0000-00 2. Driver Demand The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes of the pedal position.
  • Page 312 15-14 3. Idle Speed Controller The idle speed controller consists of 2 principal modules: The first module determines the required idle speed according to: * The operating conditions of the engine (coolant temperature, gear engaged) * Any activation of the electrical consumers (power steering, air conditioning, others) * The battery voltage * The presence of any faults liable to interface with the rail pressure control or the injection control.
  • Page 313 15-15 0000-00 5. Pilot Flow Control The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined according to the engine speed and the total flow. A first correction is made according to the air and water temperature. This correction allows the pilot flow to be adapted to the operating temperature of the engine.
  • Page 314 15-16 e. MDP Learning Control MDP (Minimum Drive Pulse ) refers to the minimum power supply pulse for injection which the injector can perform. It is possible to control the fuel volume for each injector accurately through correct learning for the MDP value.
  • Page 315 15-17 0000-00 (3) Accelerometer Control a. Resetting the pilot injection The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the detection of the combustion noises.
  • Page 316 15-18 This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse value replaces the value obtained during the previous resetting. The first MDP value is provided by the C3I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
  • Page 317 15-19 0000-00 (4) Swirl control a. Overview Variable swirl valve The strong swirl caused by intake air is important element for anti-locking function in diesel engine. The swirl control valve partially closes the intake port to generate the swirl according to the engine conditions.
  • Page 318 15-20 b. Input/Output for variable swirl valve...
  • Page 319 15-21 0000-00 c. Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Squish: Squish is the air flows due to the piston head.
  • Page 320 15-22 Load Engine speed Swirl Amount of Remarks valve swirl Low speed, Increased EGR ratio, better air-fuel below 3,000 rpm Closed Heavy Low load mixture (reduce exhaust gas) High speed, Increase charge efficiency, higher over 3,000 rpm Open Light High load engine power The variable swirl valve actuator operates when turning the ignition switch ON/OFF...
  • Page 321 15-23 0000-00 f. Relationship between swirl and fuel injection pressure The injector for DI engine uses the multi hole design. For this vehicle, there are 8 holes in injector. If the swirl is too strong, the injection angles might be overlapped and may cause the increased PM and insufficient engine power.
  • Page 322 15-24 (5) EGR control a. Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. The major difference with the previous EURO 4 type, is that the DC motor with improved response rate according to the EURO 5 regulation.
  • Page 323 15-25 0000-00 c. Input/Output of E-EGR system...
  • Page 324 15-26 d. Bypass control for EGR cooler 1. Cooler temperature When the coolant temperature is below 70℃, the exhaust gas is bypassed the EGR cooler. 2. Exhaust gas temperature When the exhaust gas temperature is below 300℃, the exhaust gas is bypassed the EGR cooler. Otherwise, PM could be increased due to too low exhaust gas temperature.
  • Page 325 15-27 0000-00 f. Features As EGR ratio goes up, smoke volume will be As EGR temperature goes up, the higher. But, this lowers the combustion concentration of NOx will be higher. Thus, it chamber temperature and accordingly the is necessary to cool down the exhaust gas. concentration of NOx is decreased.
  • Page 326 15-28 (6) E-VGT control a. Overview E-VGT (Electric-Variable Geometry Turbine) turbocharger system in D20DTF engine uses the venturi effect that controls the flow rate of exhaust gas by adjusting the passage in turbine housing. The newly adopted DC motor actuator (E-actuator) controls the E-VGT system more precisely and faster.
  • Page 327 15-29 0000-00 c. Input/Output for E-VGT system...
  • Page 328 15-30 d. E-VGT system control Turbocharger system operates the E-VGT actuator according to the signals for engine epm, accelerator pedal position, atmospheric pressure, T-MAP, coolant temperature and intake air temperature. Turbocharger actuator is performed PWM control by ECU. In general, the boost pressure feedbacks the turbocharger operation and the boost temperature is used for calculating the precise density.
  • Page 329 15-31 0000-00 (7) Wide band oxygen sensor a. Overview For diesel engine, combustion is not performed at the optimum (theoretically correct) air-fuel ratio and the oxygen concentration is thin in most cases. So the wide-band oxygen sensor is used for this kind of engine, and this sensor is a little different from the one that used for gasoline engine.
  • Page 330 15-32 c. Input/Output for oxygen sensor...
  • Page 331 15-33 0000-00 d. Oxygen sensor control The wide band oxygen sensor uses ZnO2. It produces the voltage by movement of oxygen 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.
  • Page 332 15-34 (8) Cooling fan control a. Overview of cooling fan and A/C compressor The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. The water pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head.
  • Page 333 15-35 0000-00 c. Input/Output for cooling fan and A/C compressor...
  • Page 334 15-36 d. Cooling fan and A/C compressor control ▶ Conditions for cooling fan The cooling fan module controls the cooling fan relay, high speed relay and low speed relay. The cooling fan is controlled by the series and parallel circuits. Coolant temperature Refrigerant pressure A/C switch...
  • Page 335 15-37 0000-00 (9) PTC heater control a. Overview The supplementary electrical heater is installed in DI engine equipped vehicle as a basic equipment. The PTC system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor. This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment.
  • Page 336 15-38 c. Operation process The ceramic PTC has a feature that the resistance goes up very high at a certain temperature. 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 15-39 0000-00 d. Control conditions Operation Operating condition PTC Heater - Coolant temperature < 15℃ PTC HI ON (PTC2) - Coolant temperature 15℃ ≤ 65℃, intake air temperature ≤ -10℃ - Coolant temperature 15℃ < 65 to 60℃, intake air PTC LO ON temperature <-10℃...
  • Page 338 15-40 (10) Immobilizer control a. Overview The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized 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.
  • Page 339 15-41 0000-00 ▶ Key approval process When turning the ignition switch to ON position, the power is supplied to BCM and ECU. ECU communicate with the immobilizer key to check if it is valid crypto code. If it is valid, ECU start to control the engine when turning the ignition switch to START position.
  • Page 340 15-42 c. Components for immobilizer with Smart key system ▶ Components (For antenna, refer to Chapter “SKM”) Smart key slot Meter cluster Smart key Start motor D20DTF...
  • Page 341 15-43 0000-00 ▶ Key approval process in Smart key system equipped vehicle The key approval consists of two processes; immobilizer key approval and Smart key approval Immobilizer key approval: When inserting the Smart key into Smart key slot, the power is supplied to the key slot.
  • Page 342 15-44 (11) CDPF control a. Overview As the solution for environmental regulations and PM Particle Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter 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.
  • Page 343 15-45 0000-00 c. Input/Output for CDPF control...
  • Page 344 15-46 d. Operation process When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF, the sensor sends signal indicating the soot is 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.
  • Page 345 15-47 0000-00 e. Cautions Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. 1. Use only specified engine oil (Low Ash Oil) The vehicle equipped with CDPF should use specific engine oil to improve the engine performance and fuel economy, and ensure the service life of CDPF. 2.
  • Page 346 15-48 3) Input/Output for CAN communication (1) Configuration of CAN (P-CAN/B-CAN) Abbreviation Function Glow Control Unit Electronic Power Steering Unit Body Control Module CAN Topology communicate with system units. There are two types (P-CAN and B-CAN) of communication according to the communication speed. Instrument cluster, BCM and diagnostic connector use both types of communication.
  • Page 347 15-49 0000-00 (2) CAN communication flow chart Splice pack Wiring harness Location 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)
  • Page 348 15-50 (3) Input/Output for CAN communication...
  • Page 349 02-3 1116-01 1. SPECIFICATION Unit Description Specification Height 142.5 mm Weight 15.6 kg Flatness Below 0.05 mm Cylinder head Spark plug offset 2.5 mm Thickness of cylinder head gasket (when 0.7 mm compressed) Intake 0.1~0.35 mm Axial end play Exhaust 0.1~0.35mm Intake valve open BTDC 35/-10...
  • Page 350 02-4 2. TIGHTENING TORQUE Name Size Quantity Tightening torque 70 ± 7 Nm Heater core screw bolt 25 ± 2.5 Nm Ladder frame bolt M8 X 1.25 X 20 10 ± 1.0 Nm TGCC M6 X 1.0 X 25 30 ± 3.0 Nm Oil drain plug 10 ±...
  • Page 351 02-5 1116-01 Name Size Quantity Tightening torque 25 ± 2.5 Nm Intake manifold lower bracket bolt M8 X 1.25 X 16 40 ± 5 Nm Exhaust manifold nut 10 ± 1 Nm Heat protector bolt M6 X 1.0 X 25 10 ±...
  • Page 352 02-6 3. GUIDELINES ON ENGINE SERVICE G20DF engine is for FF (Front Engine Front Drive) type vehicle. Therefore, there are some deferent maintenance and repair works compared to the engine for FR (Front Engine Rear Drive) type vehicle. For safe and correct works, you must observe the working procedures and instructions in this manual.
  • Page 353 02-7 1116-01 ▶ Engine and accessories Engine has a lot of precise components. The specified tightening torque and correct procedures should be kept during service works. And, the working area is always clean and well prepared. When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set. Carefully read the disassembly and reassembly procedures in this manual before starting the works.
  • Page 354 02-8 ▶ Fuel and engine oil system The engine oil and fuel damages the painted surfaces and rubber material of the vehicle. Disconnect the negative cable from the battery before servicing the fuel system, and prepare the service plug grip. When working with the fuel or oil systems in enclosed area, always keep the working area well-ventilated and never allow anybody to smoke.
  • Page 355 02-9 1337-04 1) Drive Belt ▶ 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.
  • Page 356 02-10 2) Hydraulic Tensioner Assembly ▶ Overview The hydraulic tensioner maintains the belt tension to minimize the slip and vibration and provides long life span of the belt. Hydraulic tensioner consists of hydraulic tension 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.
  • Page 357 02-11 1337-04 3) Crankshaft Pulley (CRS) ▶ Overview The strut type tensioner 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. ▶...
  • Page 358 02-12 ▶ Location Front mounting assembly Right mounting assembly Location: Front side of transaxle housing and Location: Engine block side and body side front side of sub frame member Location Front mounting Location Right mounting Left mounting assembly Rear mounting assembly Location: Upper side of transaxle housing and Location: Rear side of transaxle housing and body side member...
  • Page 359 02-13 1990-01 ▶ Function Appearance Type and function Front mounting: Bracket + Insulator Type: Rubber type mounting Function: support torque reaction Rear mounting: 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-...
  • Page 360 02-14 1) Cylinder Head ▶ Overview The cylinder head assembly is located on the cylinder 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 ▶...
  • 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 Finger follower & HLA Intake camshaft CVVT Camshaft position Intake camshaft gear sensor...
  • Page 363 02-17 1211-01 2) Cylinder Head Cover ▶ Overview The cylinder head cover protects the valve system. It contains the breathing 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.
  • Page 364 02-18 3) Camshaft Assembly ▶ Overview The camshaft is hollow type, and contains 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 02-19 1211-01 4) Intake/Exhaust Valve Assembly (Installed on Cylinder Head) (1) Features Automatic adustment of valve clearance by hydraulic pressure system (Maintenance Free)_Hydraulic lash Decreased valve operating noise Decreased friction loss by 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...
  • Page 366 02-20 5) Cylinder Head Gasket ▶ Overview The cylinder head gasket is installed between cylinder block and cylinder head to seal the combustion gas from the combustion chamber, engine oil and coolant. ▶ Location Cylinder head gasket 3 Layer MLS Gasket Thickness : 0.7 mm (Compressed) PFP: Max.
  • Page 367 02-21 1311-01 ▶ Overview The drive chain is single chain drive system with simple design and variable performance, and it utilizes the hydraulic tensioner to reduce the wave impact generated by the chain. The silent chain provides the silence during the operation. To improve NVH, the shoulder bolt has been introduced.
  • Page 368 02-22 1) Timing Gear Case Cover ▶ Features Major function: Protecting the chain drive system, minor function: 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.
  • Page 369 02-23 1311-01 2) Hydraulic Auto 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. Layout and Location Hydraulic chain 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 02-25 1311-01 4) Timing Chain and Gear ▶ Timing chain A. Timing chain Teeth: 146 ea B. Oil pump chain Teeth: 58 ea Simple layout provides the optimized timing. Decreased chain vibration and noise Single stage layout: minimized chain load...
  • Page 372 02-26 5) Chain Rails The chain rails are used for optimizing the movement of chain drive system. And they also prevent the chain from contacting each other when the chain is loose, and 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.
  • Page 373 02-27 1130-13 1) Overview Dual mass flywheel (DMF) Drive plate - Manual transaxle - Automatic transaxle Dual mass flywheel reduces the unbalanced The drive plate initially drives the powertrain rotation of crankshaft in manual transaxle system by using the power from the start motor equipped vehicle.
  • Page 374 02-28 2) Operation of DMF Compensating the irregular operation of engine: The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more (less pulsation absorbing effect). Transaxle protection function: Reduces the torsional vibration to powertrain (transaxle) by reducing the irregularity of engine.
  • Page 375 02-29 1130-13 3) Features of DMF Reduced vibration noise from the powertrain by blocking the torsional vibrations Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation Reduced shifting shocks Smooth acceleration and deceleration 4) Advantages of DMF Improved torque 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.
  • Page 376 02-30 ▶ Overview Piston assembly contains piston, #1 ring, #2 ring, oil ring, 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. ▶ Layout and Components Bottom Components...
  • Page 377 02-31 1130-33 ▶ Functions Piston transfers the combustion energy from engine to connecting rod. A. Piston ring #1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank chamber, and prevents the engine oil getting into combustion chamber. #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.
  • Page 378 02-32 ▶ Assembling the piston Install 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˚...
  • Page 379 02-33 1130-25 ▶ Overview Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft. The big end is connected to connecting rod bearing and the crank pin journal, and the small end is connected to the piston pin. ▶...
  • Page 380 02-34 ▶ Selection of connecting rod bearing Select the bearing shell combination according to the table below: Conrod_UPR Conrod_LWR Clearance Grade Grade Blue 0.005 ~ 0.050 Yellow Yellow 0.005 ~ 0.050 Blue 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 02-36 ▶ Selection of crankshaft main bearing Bottom of cylinder block Crankshaft sprocket installing surface Engine name Main journal bearing 핀 펀치 마크별 베어링 선택 Diameter of crankshaft Diameter of crankshaft Mark Color main journal (mm) main journal in cylinder Color punch block (mm)
  • Page 383 02-37 1128-01 ▶ Overview The cylinder block 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 Front view Plug screw (water jacket plug) (70Nm) Expansion plug (intake: 4)
  • Page 384 02-38 ▶ Coolant and oil flows Coolant Cylinder head Coolant pipe Cylinder block water jacket Thermostat Coolant pump Engine oil Supply line to cylinder head Supply line to PCJ Main bearing Oil filter assembly Oil pump...
  • Page 385 04-3 1740-01 1. SPECIFICATION Unit Description Specification Filter type Dry, filter element 0.225 m² Filtering area Air cleaner element Clean every 7,500 km Service interval Change every 15,000 km Weight 1.45 kg Air cleaner assembly 25℃ Operating temperature Capacity 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 Bolt Electric Throttle Body T-MAP sensor Bolt Bolt Acoustic Cover Intake Manifold Brkt...
  • Page 387 04-5 0000-00 Air Cleaner Assy Snorkel Assy Element Assy Water Portector Air Cleaner MTG NO.2 Resonator Assy Insulator Collar RR Fascia MTG Screw Rivet Spring Clamp Bolt Resonance Duct Resonance O-Ring Screw Air Cleaner MTG NO.1 Air Cleaner to Engine Hose Assy Air Cleaner MTG Bolt...
  • Page 388 04-6 1. OVERVIEW To improve the engine performance, the VIS system has been introduced in the intake manifold. 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.
  • Page 389 04-7 0000-00 PCV valve Blow-by hose Purge control solenoid valve Electronic throttle body Air cleaner element...
  • Page 390 04-8 3. OPERATING PROCESS When Long Runner is operating When Short Runner is operating Intake air flows...
  • Page 391 04-9 1740-01 4. INPUT/OUTPUT DEVICES...
  • Page 392 04-10 5. CIRCUIT DIAGRAM...
  • Page 393 03-3 2221-01 1. SPECIFICATION Unit Specification Fuel Unleaded gasoline Fuel system Fuel injection MPI (Muilt Point Injecter) type Fuel supply Returnless Fuel System Capacity 57 L Fuel tank Material Plastic Fuel sender Dual sender type Fuel filter Service interval Change every 100,000 km Fuel pump Pressure 3.8 bar...
  • Page 394 03-4 2. SYSTEM LAYOUT Fuel tank assy Suction tube assy Fuel tank strap assy Harness wiring assy Heat shield assy Fuel pump plate cover Sub sender assy O-ring Main fuel pump assy clamp Fuel filler assy Fuel filler cap assy Feed tube assy Screw Return tube assy...
  • 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...
  • Page 396 03-6 1. OVERVIEW The fuel system is a returnless type that the fuel pressure regulator is mounted inside the fuel tank. The engine ECU 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.
  • Page 398 03-8 2. COMPONENTS Canister Fuel filter Fuel filter Fuel tank assembly Fuel pump and fuel sender assembly Canister Fuel neck hose Primary fuel sender Fuel tank assembly...
  • Page 399 03-9 2221-01 Engine ECU Engine compartment Secondary fuel sender Injector Fuel rail Purge control solenoid valve...
  • Page 400 03-10 3. SCHEMATIC DIAGRAM OF FUEL FLOWS...
  • Page 401 03-11 2221-01 4. INPUT/OUTPUT DEVICES The engine ECU calculates 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)
  • Page 404 05-5 1745-01 WCC Compl Hanger Exhaust FRT Pipe Assy Hanger UCC Compl Hanger Muffler Complete ?RR Exhaust FRT Heat Protector CTR Muffler Heat Protector Bolt RR Muffler Heat Protector Gasket Ring Clamp Gasket CTR Muffler Complete...
  • Page 405 05-6 3. CAUTIONS Do not park the vehicle on flammable materials, such as grass, leaves and carpet. Do not touch the catalyst or the exhaust gas ignition system when the engine is running. If a misfire occurs in the combustion chamber or the emission of pollutant exceeds the specified level, the catalyst can be damaged.
  • Page 406 05-7 1745-01 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. Harmful materials produced in the combustion process is treated and reduced in the exhaust system.
  • Page 407 05-8 2. COMPONENTS Engine ECU Engine CHECK lamp Exhaust manifold PCV valve Blow-by hose...
  • Page 408 05-9 2414-00 Exhaust No.1 Exhaust No.2 Exhaust No.3 (main muffler) Front oxygen sensor Rear oxygen sensor...
  • Page 409 05-10 3. WORK FLOW IN EXHAUST SYSTEM...
  • Page 410 05-11 1745-01 4. INPUT/OUTPUT DEVICES...
  • Page 411 06-3 1443-01 1. SPECIFICATION Description Specification 3 ~ 7 kΩ Internal resistance Center electrode Iridium alloy Spark plug Ground electrode Platinum alloy Electrode clearance 1.1 mm Change interval 160,000 km 7 ± 0.5A Primary operating current Generated voltage Max. 400 V / 5~20 kV (primary/secondary) Ignition coil Ignition type...
  • Page 412 06-4 2. LAYOUT Ignition Coil Bolt Spark Plug...
  • Page 413 06-5 1443-01 1. OVERVIEW The ignition system is to supply high voltage generated from the ignition coil to the spark plug. The G20DF engine is equipped with the independent type direct ignition system that the ignition coil is installed in each cylinder. The basic ignition timing in each cylinder is determined by the signals from camshaft position sensor and crankshaft position sensor.
  • Page 414 06-6 2. COMPONENTS Ignition coil Spark plug Injector Knock sensor Camshaft position sensor...
  • Page 415 06-7 1443-01 Crankshaft position sensor Engine ECU Coolant temperature sensor T-MAP sensor Electric throttle valve Accelerator pedal position sensor...
  • Page 416 06-8 3. INPUT/OUTPUT DEVICES...
  • Page 418 06-10 4. CIRCUIT DIAGRAM...
  • Page 419 06-11 1443-01...
  • Page 420 07-3 1535-01 1. SPECIFICATION Description Specification Lubrication type Gear pump, forced circulation Oil pump Type Internal gear Oil filter Type Full flow/Paper element MB 229.51 SEA 5W30 or API SN/GF-5 SAE 5W20 Engine oil Capacity 4.5 L Oil injection nozzle Type Flange and bolt type The engine oil filter element should be changed at the same time with the engine oil.
  • Page 421 Recheck the oil level after 5 minutes. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
  • Page 422 07-5 1535-01 3. LAYOUT Oil Pump Assy Bolt Seal Ring Oil Dipstick Tube Assy Oil Pan Oil Dipstick Gauge Assy Bolt O-Ring Drain Plug Bolt Bolt O-Ring Oil Pump Chain Sealant Oil Pump Chain Tensioner Assy Dust Cover...
  • Page 423 07-6 Oil Filter Assy O-Ring Oil Filter Cover Oil Filter Bypass Valve Assy Oil Filter Element Kit Oil Filter Housing Gasket Drain Plug Bolt Oil pressure switch...
  • Page 424 07-7 1535-01 1. OVERVIEW The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove heat from the friction part. As the engine runs, 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.
  • Page 425 07-8 3. OPERATING PROCESS 1) Operation Flow CVVT Cam journal Chain bearing tensioner Main oil gallery in cylinder block Oil jet Oil pressure Main journal bearing switch Oil pump Oil filter assembly Oil supply...
  • Page 426 09-3 1452-01 1. SPECIFICATION Unit Description Specification Type Crankshaft pulley : Alternator pulley 1 : 2.66 Normal output ← 70/140A Alternator (idle/2200rpm) ← Regulator voltage ← Length 12.5mm Brush ← Wear limit 7.0mm ← Type Battery ← Capacity 90AH...
  • Page 427 09-4 2. LAYOUT 1) Alternator Alternator assembly Bolt...
  • Page 428 09-5 1452-01 2) Battery Battery assembly Clamp - Battery Bolt Cab - Earth Cable assembly - Cable positive Box assembly - Battery sub Cable assembly - Battery ground Fuse - MID 80A Bolt - Earth Clamp - Battery cable Cap - Terminal Grommet - Ring terminal Connector - Battery Grommet - Ring terminal...
  • Page 429 09-6 3. INSPECTION 1) Alternator ▶ Output Test Item How to check DTC set value / Action Disconnect the cable connected to the Pass: If the measured current B terminal on the alternator. Connect is 45 A or higher. one end of the ammeter to the B Fail: If the measured current terminal and the other end to the cable is less than 45 A.
  • Page 430 09-7 1452-01 ▶ Troubleshooting Item Cause Action Defective alternator voltage regulator Replace Overcharged battery Defective voltage detection wiring Repair or replace Loose alternator drive belt just the belt tension or replace Poor connection of related circuit or Retighten the loose open circuit connection or repair Discharged battery...
  • Page 431 09-8 2) Battery ▶ Inspection...
  • Page 432 09-9 1452-01 ▶ Using battery tester PASS (11.0 V or more): Explain to the customer that the battery is reusable. Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the customer.
  • Page 433 09-10 ▶ Jump start If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to start the engine. ▶ Connecting order The positive (+) terminal of the discharged battery The positive (+) terminal of the booster battery The negative (-) terminal of the booster battery Connect one end of the other jumper cable to the body of the discharged vehicle, such as the engine block or a front towing hook.
  • Page 434 09-11 1452-01 ▶ Maintenance If the charge warning lamp ( ) on the instrument cluster comes on while driving, there is a malfunction in the charge system including the battery. Therefore, carrying out the system check is needed. Make sure that the battery cables are firmly connected. If the terminals are corroded, clean them with a wire brush or sandpapers.
  • Page 435 09-12 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 to the electric load and ambient temperature change.
  • 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 Capacity 12V 1.4kw Engagement Meshed type Start motor Rotating direction Clockwise Solenoid operating voltage Max. 8V Weight 2.5kg...
  • Page 439 11-4 2. LAYOUT Starter Bolt...
  • Page 440 11-5 1462-01 3. TROUBLESHOOTING Problem Possible Cause Action Low battery voltage Charge or replace Loose, corroded or damaged battery cable Repair or replace Engine will not Faulty starter or open circuit crank Faulty ignition switch or blown fuse Repair or replace Poor engine ground Repair Low battery voltage...
  • Page 441 11-6 1. OVERVIEW The starter (start motor) 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 15-3 1490-00 1. ENGINE DATA LIST Data Unit Value ℃ 0.436V (130℃) ~4.896V (-40℃) Coolant temperature -40~130℃ Intake air temperature ℃ (varies according to ambient air temperature or engine mode) 700±50(P/N), 600±(D) Idle speed Engine load 18~25% Mass air flow kg/h 16~25kg/h °TA...
  • Page 445 15-4 1. MAJOR COMPONENTS Rear oxygen Ignition coil MCC complete sensor Spark plug OCV (Oil Control Valve) Oil pressure PVC valve Injector Knock sensor switch...
  • Page 446 15-5 0000-00 Camshaft position Coolant Temp Front oxygen G20DF engine sensor sensor sensor Purge control solenoid valve Crankshaft position sensor Electronic throttle Magnetic trigger VIS solenoid valve T-MAP sensor body ring...
  • Page 447 15-6 2. SYSTEM OPERATION 1) Input/Output of ECU...
  • Page 448 15-7 0000-00 2) Components for ECU Input Rear oxygen Coolant temperature Camshaft position Crankshaft position sensor sensor sensor sensor Front oxygen sensor G20DF Engine ECU Electronic throttle body Knock sensor T-MAP sensor Refrigerant pressure sensor Clutch pedal signal Blower switch signal Brake pedal signal ABS &...
  • Page 449 15-8 3) Components for ECU Output OCV (Oil Control Valve) Start motor A/C compressor Injector VIS solenoid valve G20DF Engine ECU Ignition coil Purge control solenoid Cooling fan valve module ABS & ESP unit E-coupling unit Instrument cluster Diagnostic tool...
  • Page 450 15-9 1490-00 3. ECU CONTROL 1) Functions ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and analyzes to control respective actuators. ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft angle based on input data and stored specific map to control the engine power and emission gas.
  • Page 451 15-10 3) Injection Volume Control (1) Overview To keep the best engine conditions and to reduce the emission gas, ECU determines the injection volume and timing. (2) Components ▶ Input Components Accelerator pedal Front oxygen Coolant temperature Crankshaft position position sensor sensor sensor sensor...
  • Page 452 15-11 0000-00 (3) Input/Output for Injection Volume Control...
  • Page 453 15-12 (4) Basic Injection Volume Map...
  • Page 454 15-13 0000-00 4) Ignition System Control (1) Overview G20DF engine is equipped with the single 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 ▶...
  • Page 455 15-14 (3) Input/Output for Ignition System...
  • Page 456 15-15 0000-00 (4) Features Determines the ignition timing according to input signal The ECU always analyzes the following elements when determining the ignition timing. Crankshaft position sensor Camshaft position sensor Coolant temperature sensor Intake air temperature/air mass Warm-up of catalytic converter The ignition timing is retarded for about 20 seconds to operate the catalytic converter according to the operating temperature under the following conditions: The coolant temperature is 15°C ~ 40°C at starting.
  • Page 457 15-16 5) Warm-Up of Catalytic Converter (1) Components ▶ Input Components Coolant temperature Crankshaft position T-MAP sensor sensor sensor ▶ Output Components...
  • Page 458 15-17 0000-00 (2) Warm-up Control Function ▶ Idle speed control The idle speed is controlled according to the fuel/air mixture when the engine load is changed, the power steering wheel is turned to its end, the selector lever is in the "D" position and the A/C compressor is in operation.
  • Page 459 15-18 6) Cooling Fan Control (1) Overview of Cooling Fan and A/C Compressor The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. The water pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head.
  • Page 460 15-19 0000-00 (3) Input/Output for Cooling Fan and A/C Compressor...
  • Page 461 15-20 (4) Cooling Fan and A/C Compressor Control ▶ Conditions for cooling fan The cooling fan module controls the cooling fan relay, high speed relay and low speed relay. The cooling fan is controlled by the series and parallel circuits Cooling Refrigerant Coolant temperature...
  • Page 462 15-21 0000-00 7) Immobilizer Control (1) Overview The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized 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.
  • Page 463 15-22 ▶ Key approval process When turning the ignition switch to ON position, the power is supplied to BCM and ECU. ECU communicate with the immobilizer key to check if it is valid crypto code. If it is valid, ECU start to control the engine when turning the ignition switch to START position.
  • Page 464 15-23 0000-00 8) CAN Configuration (P-CAN/B-CAN) (1) CAN Configuration (P-CAN/B-CAN) Name Function Electronic Control Unit Transmission Control Unit Electronic Power Steering Unit Body Control Moudule 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.
  • Page 465 15-24 (2) Wiring Connection of CAN Communication Splice pack Wiring Location Under fuse & relay box in engine S101 Floor wiring (LH) compartment S102 Floor wiring (RH) Inside of right fender Behind instrument cluster (cowl cross S201 Main wiring member) Behind instrument cluster (cowl cross S202 Main wiring...
  • 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..........

  • Page 469: Specifications

    01-3 0000-00 1. SPECIFICATIONS 1) Dimensions *Unit: mm, ( ): option Top view 1,830 Side view 1,675 2,650 4,410(4,500) Front side Rear view 1,573(1,566) 1,558(1,551)
  • Page 470 01-4 2) Identifications 1) The engine number (ex: 671 950 0 0 2) The chassis number (ex: 999999) is stamped on the lower area of KPTP0A19S10P012345) is stamped on the cylinder block in exhaust manifold side. fire wall in engine compartment (front passenger side).
  • Page 471 01-5 0000-00 ▶ VIN NO. ▶ Engine NO.

  • Page 472: Specification

    01-6 2. SPECIFICATION Diesel 2.0 Engine Description (D20DTF(Low CO2)) General Overall length (mm) 4,410 (4,500: with trailer hitch) Overall width (mm) 1,830 Overall height (mm) 1,675 Gross vehicle 4WD : 2,065(2,110) weight (kg) 2WD : 1,905(1,920) Curb vehicle 4WD : 1,740(1,785) weight (kg) 2WD : 1,580(1,595) Fuel...
  • Page 473 01-7 0000-00 Diesel 2.0 Engine Description (D20DTF(Low CO2)) Manual Operating type Floor change type Transaxle Gear ratio 3.385 1.708 1.033 0.786 0.730 0.595 Reverse 3.747 Transfer Model Case Type Electronic control type Clutch Operating type Hydraulic type Disc type Dry single diaphragm type Power Type Rack and pinion...

  • Page 474: Recommended Fluids And Lubricants

    Ssangyong genuine oil (ATF DEXRON II) ≒ 1.0ℓ Power Steering Fluid * TOTAL FLUIDE DA (Extreme cold condition only) Use only Ssangyong genuine fluids. Use of non-recommended products could cause damage to the unit Keep the specified capacity and service interval.

  • Page 475: Scheduled Maintenance Services

    01-9 0000-00 4. SCHEDULED MAINTENANCE SERVICES...
  • Page 476 01-10...
  • Page 477 01-11 0000-00...
  • Page 479 MODIFIED ITEMS 1. MAJOR CHANGES......... 2. MAJOR CHANGES IN ENGINE....3. CHANGES IN CABIN......4. CHANGES IN CHASSIS......
  • Page 481 02-3 0000-00 1. MAJOR CHANGES Changed Item Description 1546-13 Oil cooler assembly Increasing the cooling efficiency 2435-00 Differential pressure sensor Improving the durability pipe mounting bracket 1491-01 D20DTF ECU Changed the internal logic 1127-01 Cylinder block Changed the layout (Turbocharger cooling system deleted) 2330-01 Intercooler assembly...
  • Page 482 02-4 2. MAJOR CHANGES IN ENGINE 1) Engine Compartment 1546-13 Oil cooler assembly 2435-00 Differential pressure sensor pipe mounting bracket D20DTF D20DTF(Low CO2) D20DTF D20DTF(Low CO2) To improve the fuel economy by reducing the To improve the durability, add the differential oil flow interference and increasing the oil pressure sensor pipe mounting bracket.
  • Page 483 02-5 0000-00 1491-01 D20DTF ECU (D20DTF(Low CO2)) Changed the software for D20DTF(Low CO2) engine and added pin number for EBS system. 2610-10 EBS system D20DTF D20DTF(Low CO2) 2313-01 Air cleaner assembly Increasing the volume (6.5 L→8 L) to improve Adopted EBS (Electronic Battery System). the fuel economy and to reduce the noise and NOx.
  • Page 484 02-6 2) Engine Assembly 1719-29 Intake duct assembly 1719-01 Intake manifold assembly D20DTF D20DTF(Low CO2) D20DTF D20DTF(Low CO2) Changed the layout (T-MAP boss deleted) Changed the layout (T-MAP boss added) D20DTF engine D20DTF(Low CO2) engine 1451-02 Alternator pulley 1451-01 Alternator connector D20DTF D20DTF(Low CO2) D20DTF...
  • Page 485 02-7 0000-00 1914-01 Turbocharger 1914-01 E-actuator D20DTF D20DTF(Low CO2) D20DTF D20DTF(Low CO2) Changed the number of pins in connector for Changed the turbocharger for D20DTF(Low new E-actuator CO2) engine D20DTF engine D20DTF(Low CO2) engine 2412-01 CDPF assembly 1525-21 Coolant outlet port D20DTF D20DTF(Low CO2) D20DTF...
  • Page 486 02-8 3) Turbocharger Turbocharger gasket Turbocharger turbine wheel (impeller) D20DTF D20DTF(Low CO2) D20DTF D20DTF(Low CO2) To improve the intake efficiency, changed the turbine wheel (impeller) to dual type from Adopted metal gasket (New) single type 1914-01 D20DTF 1914-01 D20DTF(Low CO2) E-VGT Turbocharger cooling line D20DTF...
  • Page 487 02-9 0000-00 3. CHANGES IN CABIN 6810-20 A/C controller assembly D20DTF D20DTF(Low CO2) Changed the function and circuit for EBS system 8010-01 Meter cluster Charge warning lamp 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).
  • Page 488 02-10 4. CHANGES IN CHASSIS 3190-01 Gear ratio D20DTF D20DTF(Low CO2) Gear ratio Gear ratio 3.539 3.385 1.909 1.708 1.179 1.033 0.814 0.786 0.737 0.730 0.628 0.595 Reverse 3.909 Reverse 3.747 4015-01 Rear sub frame D20DTF D20DTF(Low CO2) Added brackets (2WD:3, 4WD:7) for floor cover...
  • Page 489 02-11 0000-00 0000-00 Floor cover D20DTF D20DTF(Low CO2) - Floor cover LH - Different for 2WD and 4WD - Floor cover RH - Same for 2WD and 4WD - Under cover RR - 2WD only Reduce the air resistance to improve the fuel economy (New)
  • Page 491 02-3 0000-00 1. SPECIFICATIONS System Unit Description Specification Filtering type Dry, filter element 0.208m² Filtering area EU: Change every 20,000 km (But, shorten the service interval under severe Air cleaner element conditions) Service interval GEN: Clean every 7,500 km, change every 15,000 km (But, shorten the service Intake interval under severe...
  • Page 493 02-5 0000-00 1. MAJOR COMPONENTS (D20DTF(Low CO2)) CDPF Turbocharger T-MAP sensor Intercooler assembly Air cleaner assembly...
  • Page 494 02-6 2. COOLANT FLOWS IN COOLING SYSTEM...
  • Page 495 02-7 0000-00...
  • Page 496 02-8 3. LAYOUT OF INTAKE SYSTEM 1) Overview The intake system for D20DTF(Low CO2) engine 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.
  • Page 497 02-9 0000-00 HFM (Hot Film Air-Mass Sensor) HFM sensor, version 6 Refer to Chapter “Engine Control”. Air cleaner assembly Intercooler assembly Its volume is increased and air flowing Its volume is increased and cooling efficiency is improved. efficiency is improved.
  • Page 498 14-3 0000-00 1. SPECIFICATIONS Unit Description Specification 140A (25℃, 6500rpm) Alternator Rated output 76A/1800rpm, 140A/6500rpm, 25℃, 13.5V Battery Capacity 90Ah(20hr) Reserve capacity 180 minutes Starting current (when 710A engine cooed) Weight 23kg Resolving power (Electronic Battery Operating voltage 7~18V Sensor) -40~105℃...
  • Page 499 14-4 2. COMPARISON Description Item D20DTF D20DTF (Low CO2) Effective date From March, 2012 Applied engine D20DTF Battery capacity 12V 90Ah Alternator capacity Delphi 120A Delphi 140A Changed the diameter of belt pulley (Front view) Alternator Changed the regulator and control logic (Rear view) Without EEM logic With EEM logic Monitoring the battery conditions (voltage,...
  • Page 500 14-5 0000-00 3. BASIC INSPECTION 1) Battery Terminal Make sure the terminal connections are securely tightened. If the terminals are corroded, clean them or replace the battery. * Cleaning Remove the corrosion or dirt with a wire brush or sand paper, and then wash out with lukewarm soapy water.
  • Page 501 14-6 ▶ Measuring at (-) wiring Measure the voltage between battery wiring and body ground. Specified value below 0.3V If the voltage is out of the specified value, check the wiring mounting bolt for corrosion and looseness. If there is a poor contact due to corrosion or paint, wipe out the contact area and retighten it.
  • Page 502 14-7 0000-00 ▶ Measuring the voltage drop between lines Measure the voltage drop between alternator B+ and battery B+. below 0.3V Specified value If the value is 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”...
  • Page 503 14-8 4. INSPECTION - CHARGING CURRENT Perform the basic inspection. ▶ Setting up the testers ▶ Preparation Set up the ammeter and voltmeter as shown in the figure. Make sure to set up the tester while keeping its polarity.
  • Page 504 14-9 0000-00 ▶ Inspection Start the engine and turns on the headlamp, blower and heated wire at their full load. Then, measure the maximum output current (MSM measurement value) when racing the engine to 2,700 rpm. 60% of rated current (limit) Specified value The output current may not reach the limit value due to various parameters (high temperature or electric load etc.).
  • Page 505 14-10 5. INSPECTION - REGULATING VOLTAGE Perform the basic inspection. ▶ Setting up the testers ▶ Preparation Set up the ammeter and voltmeter as shown in the figure. Make sure to set up the tester while keeping its polarity. ▶ Inspection Turn the ignition ON and measure the voltage on the voltmeter.
  • Page 506 14-11 0000-00 6. INSPECTION - DARK CURRENT Perform the basic inspection. 1) When Using Multi-tester ▶ Setting up the tester ▶ Preparation Disconnect the negative cable from the battery. Set up the ammeter as shown in the figure above. Connect the “+” probe to ground wiring and “-“probe to “-“terminal of battery. ▶...
  • Page 507 14-12 2) When Using MSM ▶ Setting up the tester ▶ Preparation Disconnect the negative cable from the battery. Set up the ammeter and MSM as shown in the figure above. Make sure to set up the tester while keeping its polarity. Connect the negative cable to the battery.
  • Page 508 14-13 0000-00 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).
  • Page 509 14-14 2) Voltage Check (with load) Push the load switch to ON (to arrow direction) direction for less than 5 seconds. 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 14-15 0000-00 8. DTC SETTING CONDITIONS ▶ Charge 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...
  • Page 511 14-16 1. LAYOUT D20DTF(Low CO2) D20DTF Meter cluster (charge warning Battery sensor (EBS) lamp) Alternator (ALT)
  • Page 512 14-17 0000-00 2. OPERATING PROCESS ▶ System diagram ▶ Operation EEM monitors the electric loads and battery conditions and controls the voltage to improve the fuel economy and battery charging efficiency. EBS on “-“ terminal of battery sends the battery information (voltage, current, temperature and SOC) to engine ECU with LIN communication.
  • Page 513 14-18 ▶ Basic 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 14-19 0000-00 3. CAN COMMUNICATION (Charge Warning Lamp) ▶ 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 ▶...
  • 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........

  • Page 518: Exterior Lamp System Layout

    01-3 0000-00 1. EXTERIOR LAMP SYSTEM LAYOUT Front view Side repeater lamp Puddle lamp Front turn signal lamp Position lamp Headlamp assembly Front fog lamp Rear view High-mounted stop lamp Tail/stop lamp Rear turn signal lamp Backup lamp Rear fog light Reflector License plate lamp...
  • Page 519 01-4 Headlamp Turn signal High-beam/ lamp low-beam Position lamp Front fog lamp Puddle (approach) lamp Side repeater lamp...
  • Page 520 01-5 0000-00 Rear combination lamp Stop lamp and tail lamp Turn signal lamp Backup lamp Rear fog lamp License plate lamp High mounted stop lamp Vehicle with spoiler Vehicle without spoiler...

  • Page 521: Interior Lamp System Layout

    01-6 2. INTERIOR LAMP SYSTEM LAYOUT Glove box lamp Front room lamp Sun visor lamp...
  • Page 522 01-7 0000-00 Center room lamp Luggage lamp Door courtesy lamp...

  • Page 523: Switch System Layout

    01-8 3. SWITCH SYSTEM LAYOUT Steering wheel remote contro Start/stop switch Passenger door switch switch Cruise control switch Multifunction switch Lower main panel switch Drive door main switch Hazard warning switch FATC switch & Outside rearview mirror bezel assembly switch...
  • Page 524 01-9 0000-00 Front seat heated wire switch Front seat heated wire switch Overhead console (DLX) (STD) switch Center room lamp switch Luggage lamp switch Tailgate switch Driver power seat switch Rear door switch (RH) Rear door switch (LH)

  • Page 525: Schematic Diagram For Wiring And Electrical Devices

    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: Can Communication Configuration

    01-14 5. CAN COMMUNICATION CONFIGURATION The CAN topology is linked with CAN communication system, which consists of P-CAN and B- CAN. The instrument cluster and BCM (Body Control Module) communicate through 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.
  • Page 530 01-15 0000-00 2) CAN Communication Wiring Diagram Splice pack Wiring Location S101 Floor 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)
  • Page 532 02-3 8410-00 1. CAUTIONS WHEN WORKING ON ELECTRICAL UNITS Disconnect the negative cable from the battery advance when working electrical units. 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.) Do not drop or appy excessive impact to sensors and relays.
  • Page 533 02-4 Make sure a connector is connected securely. Loose connection results in malfunction. When disconnecting a connector equipped with a lock, press it down to the direction in the below figure. When checking voltage or continuity of the connector terminal with a circuit tester, connect the tester probe to the terminal at the harness side.
  • Page 534 02-5 8410-00 2. CHECKING CABLES AND WIRES Check for loose connection or rust. Check terminals and wires for corrosion due to electrolyte leakage. Check terminals and wires for open circuit. Check the wire insulation and coat for damage, cracks or deterioration. Check if the conductive parts of the terminals do not contact with vehicle body or other metal parts.
  • Page 535 02-6 1. OVERVIEW The fuse and relay 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.
  • Page 536 02-7 8410-00 3. OPERATING PROCESS 1) Fuse Box In Engine Compartment The relay & fuse box in engine 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.
  • 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 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 02-27 8410-00 4) Operating Process By Power Supply (1) Rear wiper relay The rear wiper motor relay is turned on when the rear wiper switch is turned on with the ignition key ON. This relay is turned off when the rear wiper switch is turned off. The power is supplied to the ICM no.
  • Page 557 02-28 (3) Outside mirror folding relay The power for the outside mirror folding relay is supplied through the fuse no. 45 in the engine compartment CE box and the relay is operated by the operation signals from the no. D16 and no. D17 of the BCM.
  • Page 558 02-29 8410-00 (5) Horn relay The power for the theft deterrent horn relay is supplied to the ICM terminal no. C5 through the battery SB1 and fuse no. 45 in the interior fuse box. The relay is operated by the signals from the BCM terminal no. A24. Refer to Conditions For Theft Deterrent for operating conditions.
  • Page 559 02-30 (7) Shift lock relay The shift lock relay is used in the models with A/T and receives power through the SB2 and fuse no. 31 in the interior fuse box with the IGN1 turned ON. If the operating conditions are met (stop lamp switch ON), the battery power is supplied to the ICM terminal no.
  • Page 560 03-3 8710-01 1. SPECIFICATION Pin No. Specification Remark Rated voltage DC 13.5 V DC 9.0 to 16.0 V Operating voltage DC 7.0 to 18.0 V (CAN) -30 to +80°C Operating temperature -40 to +85°C Storage temperature 134.2 KHz ± 4 KHz Frequency Transponder -40 to +85°C...
  • Page 561 03-4 2. FUNCTIONS 1) Functional List Function without with Wiper control Wiper mist & washer coupled wiper Auto washer coupled wiper Auto light-rain sensor coupled wiper (LIN) Speed sensitive intermittent wiper Wiper low/high control Key reminder warning Key reminder warning Ignition key reminder External buzzer control Anti-lock function when opening door...
  • Page 562 03-5 8710-01 Function without with Keyless entry Transmitter control Receiver Remote door lock Remote door unlock Remote panic Remote escort After 30 seconds delay auto door lock Door lock/unlock Lock/unlock control by door lock control control Lock/unlock control by central door lock switch Lock/unlock control by REKES signal Lock/unlock control by SKM REKES...
  • Page 563 03-6 Function without with 15 Theft deterrent control Theft deterrent mode control in control Theft deterrent mode control in smart BCM 16 Time lag power Time lag power window control window control 17 System power sleep System power sleep mode control mode 18 Flasher (blinking) LH turn signal control...
  • Page 564 03-7 8710-01 3. MAJOR CHANGES Emergency hazard warning flasher control Previous Current Operating condition Operating condition If the emergency braking signal is received, the If the emergency braking signal is received, the hazard warning flasher blinks 4 times/second hazard warning flasher blinks 4 times/second for 10 seconds.
  • Page 565 03-8 Seat belt reminder (SBR) Previous Current If the driver seat belt is not fastened with the If the driver seat belt is not fastened with the ignition switch ON, engine running and vehicle ignition switch ON, engine running and vehicle speed above 10 km/h, the seat belt reminder is speed above 25 km/h, the seat belt reminder is activated.
  • Page 566 03-9 8710-01 1. OVERVIEW & FUNCTIONS BCM (Body Control Module) controls the electric equipment on car body and outputs the control and warning signals as below. <Table 1> List Function List Function Wiper control Tailgate open control Ignition key reminder warning Theft deterrent Tail lamp control Time lag power window control...
  • Page 567 03-10 1) Wiper Control (1) Wiper mist & front washer coupled wiper ▶ Wiper mist When the multi-function switch is rotated for more than 0.1 second to activate the mist mode with IGN1 ON, the wiper relay is activated after 0.1 second. It will be deactivated when the wiper motor is in the parking position.
  • Page 568 03-11 8710-01 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.
  • Page 569 03-12 ▶ Auto washer coupled wiper When turning ON the auto washer switch with IGN ON and intermittent/automatic wiper switch OFF, the washer fluid is sprayed onto the windshield glass for 2 seconds and the wipers operate 4 times. After then, additionally, the washer fluid is sprayed for 1.5 seconds and the wipers operate 3 times again.
  • Page 570 03-13 8710-01...
  • Page 571 03-14 ▶ Rain sensor coupled wiper (LIN) System layout Data recognition & operation Data recognition time The system performs LIN communication regardless of the conditions of wiper and light switch when the ignition switch is in ON position. If the intermittent/automatic wiper switch is in "AUTO"...
  • Page 572 03-15 8710-01 ▶ Power-up reminder wiper If the intermittent/automatic wiper switch is in "ON" position, the wiper motor does not operate even when turning 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.
  • Page 573 03-16 ▶ Washer coupled wiper in rain sensing mode When the washer switch signal is received during intermittent operation coupled with rain sensor with IGN ON and intermittent/automatic washer switch operation, the wipers operate in washer coupled mode regardless 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.
  • Page 574 03-17 8710-01 ▶ Processing method for abnormal wiper parking signal 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 runs only when the rain sensor requires the wiper operation. When the parking terminal is shorted to power with IGN2 ON and intermittent wiper switch in "ON"...
  • Page 575 03-18 ▶ Processing method for rain sensor malfunction If the BCM is received the signal for sensor malfunction from the rain sensor unit when turning the wiping speed control switch to 2 from 3 stage with IGN ON and intermittent/automatic wiper switch in "ON"...
  • Page 576 03-19 8710-01 ▶ Speed sensitive intermittent wiper The BCM without rain sensor operates the wiper as follows: When turning the ignition switch to ON from OFF position with the intermittent 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.
  • Page 577 03-20 ▶ Wiper low/high control The wiper low relay is activated when the wiper low switch is operated and the wiper high relay activated when the wiper high switch is operated. The wiper motor returns to parking position and stops, even when turning off the ignition switch during wiper operation.
  • Page 578 03-21 8710-01 2) Ignition Key Reminder ▶ Key reminder warning (This function has priority over the "Tail lamp on warning".) When opening the driver door while 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.
  • Page 579 03-22 ▶ Ignition key reminder When opening a front door or turning on the door lock switch while the ignition key is inserted into the key cylinder, the doors are locked for 0.5 seconds, 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.
  • Page 580 03-23 8710-01 ▶ Anti-lock function when a door is open If any of doors (except tailgate and engine hood) is open, the doors are locked once but immediately unlocked when receiving the lock signal. The door remains unlocked for 0.5 seconds when 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"...
  • Page 581 03-24 3) Tail Lamp ▶ Tail lamp left ON warning (sunroof and ignition key reminder functions have priority) The buzzer sounds for 10 seconds with the interval of 0.02 s ON and 1.38 s OFF when opening the driver door with the key removed (without SKM)/with IGN OFF or ACC (with SKM) and tail lamp ON.
  • Page 582 03-25 8710-01 ▶ Tail lamp auto 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) after tail lamp auto OFF.
  • Page 583 03-26 4) Door Ajar Warning While the BCM without SKM controls the warning lamp, the BCM with SKM controls the warning lamp and sends the signal via the BCAN communication. But, this control is available only when any of doors or tailgate, except engine hood, is open. The instrument cluster controls the door ajar warning lamp according to the signal from the BCM.
  • Page 584 03-27 8710-01 5) Seat Belt ▶ Seat belt warning When turning the ignition switch (IGN1) to ON from OFF position, the BCM sends the driver and front passenger seat belt warning signals to the instrument cluster module through the CAN communication, and the buzzer sounds for 0.6 seconds with the interval of 0.02 s ON and 1.38 s OFF.
  • Page 585 03-28 ▶ Seat belt reminder Operating conditions for seat belt reminder are as follows: IGN ON, engine running (over 300 rpm), vehicle speed of 25 km/h or higher, driver seat belt unfastened, passenger seat belt unfastened and passenger seat occupied. 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 586 03-29 8710-01...
  • Page 587 03-30 6) Sunroof ▶ Sunroof warning When removing the ignition key with the sunroof open (without SKM) or when opening the driver door with IGN OFF or ACC and sunroof open (with SKM), the indoor buzzer sounds for 10 seconds with the interval of 0.02s ON/1.58s OFF. When opening and closing the driver door or closing the sunroof during indoor buzzer operation, the buzzer stops its operation immediately.
  • Page 588 03-31 8710-01 7) Room Lamp ▶ Door coupled room lamp and dimming control When opening any of doors while the room lamp switch in overhead console is pressed in ("Door" coupled position), the room lamps come on. If the key is removed and door stays open, the room lamps automatically goes off after 10 minutes.
  • Page 589 03-32 ▶ 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 room lamp and sensor room lamp switch is ON position.) The room lamps go off automatically 10 minutes after the key is removed.
  • Page 590 03-33 8710-01 9) Defogger (Heated Wire) Timer ▶ Front defogger timer control When turning ON the front defogger switch with IGN2 ON (engine speed over 300 rpm), the front defogger operates for 12 minutes. When turning OFF the front defogger switch 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.
  • Page 591 03-34 ▶ Rear defogger timer control When turning ON the rear defogger switch with IGN2 ON (engine speed over 300 rpm), the rear defogger and outside rearview mirror defogger operate for 12 minutes. When turning OFF the rear defogger switch 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.
  • Page 592 03-35 8710-01 10) Keyless Entry ▶ Transmitter (REKES key) When the user operates the switch of the remote control key, the vehicle control messages formatted by its CPU are sent to the main unit wirelessly. The, the CPU control the vehicle and the main unit controls the vehicle operation.
  • Page 593 03-36 ▶ 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 warning flasher blinks twice. However, when pressing this button once again within 4 seconds, the hazard warning flasher blinks twice and buzzer sounds once.
  • Page 594 03-37 8710-01 ▶ Remote door unlock When briefly pressing (below 2.0 sec) the UNLOCK button on the transmitter, the doors are unlocked. The door unlock relay is turned ON for 0.5 seconds when receiving the door unlock message from the transmitter. The turn signal lamps blink only when all doors are successfully unlocked.
  • Page 595 03-38 ▶ Remote escort(Domestic) When pressing (over 0.5 sec) the LOCK switch on the transmitter, the escort function is activated. When the escort message is received from the transmitter, the headlamp relay is activated for 20 seconds and is deactivated automatically. ▶...
  • Page 596 03-39 8710-01 11) Door Lock/Unlock Control The BCM with SKM receives wake-up source for driver door lock/unlock switch, passenger door lock/unlock switch, rear door (left/right) lock switch, central door lock/unlock switch status through the electric wire (hardwire). The status for key cylinder switch and latch position switch is received through the door lock/unlock switch.
  • Page 597 03-40 ▶ Door lock/unlock control by central door lock switch When pressing the central door lock/unlock switch, BCM sends the LOCK or UNLOCK signal according to the previous condition 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.
  • Page 598 03-41 8710-01 ▶ Door lock/unlock control by SKM smart key's remote control If the BCM receives the LOCK command through the BCAN communication (REKES lock 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.
  • Page 599 03-42 ▶ Lock/unlock control by SKM passive entry The SKM searches for the verified smart key, sends door lock or unlock signal to the BCM through the BCAN communication depending on the door status and sends the output for 0.5 seconds when operating the outside door handle switch with IGN OFF, ACC ON or IGN ON.
  • Page 600 03-43 8710-01 ▶ Auto door lock control Door lock output is activated when the vehicle speed is maintained above 30 km/h with IGN1 ON. However, if all the doors are locked or fail, lock output is not activated. If any of doors is not locked after Step (1), BCM activates the door lock output up to 5 times. If the door is still unlocked, BCM considers the door as Fail.
  • Page 601 03-44 ▶ Auto door unlock (crash unlock) control The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to "ON" position. After the 7 seconds, the air bag signal is activated. If the air bag signal is turned ON (crash) from OFF, BCM sends the door unlock signal for 5 seconds after 0.04 seconds.
  • Page 602 03-45 8710-01 12) Panic Alarm ▶ Panic alarm by REKES signal When receiving the panic signal with Power OFF, ACC and IGN ON, the horn and turn signal lamps operate for T1 with the interval of 0.5s ON/0.5s OFF. When receiving the door lock or panic signal during the panic operation, the panic alarm stops.
  • Page 603 03-46 ▶ Panic alarm by SKM smart key's remote control When the BCM receives "Panic command by smart key remote control" as a BCAN signal, it activates panic alarm by operating the horn and turn signal lamp for 30 seconds with a interval of 0.5s ON/0.5s OFF.
  • Page 604 03-47 8710-01 13) Headlamp ▶ Escort control by REKES signal When pressing the door lock button on the REKES or smart key remote control for more than 2 seconds in the theft deterrent mode, the 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.
  • Page 605 03-48 ▶ Escort control by SKM smart key remote control When the BCM receives the "Panic command from smart key remote control" through the BCAN signal in theft deterrent mode, it supplies voltage to the headlamp relay and maintains the output voltage for 20 seconds.
  • Page 606 03-49 8710-01 14) Tailgate ▶ Tailgate control in BCM without SKM When pressing the tailgate switch for more than 0.1 second with driver door unlocked and vehicle speed below 3 (±0.1) km/h, the tailgate open relay is turned ON for about 1 second, with power OFF, ACC ON or IGN ON.
  • Page 607 03-50 15) Theft Deterrent Alarm ▶ Theft deterrent alarm control in BCM without SKM Entering into theft deterrent mode by REKES remote control When receiving the door lock signal with the key removed, all doors including tailgate and engine hood closed, all doors are locked and the theft deterrent mode is activated. At this moment, the turn signal lamps blink twice.
  • Page 608 03-51 8710-01 Disarming by REKES remote control When unlocking the doors or turning the ignition switch to ON position. When receiving the door unlock signal in theft deterrent mode, all doors are unlocked and the turn signal lamps blink once (the horn does not sound). When receiving the door unlock signal with the theft deterrent mode disarmed, the turn signal lamps blink once (the horn does not sound).
  • 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 03-53 8710-01 ▶ Theft deterrent alarm control in BCM with SKM Entering into theft deterrent mode by smart key remote control When receiving the door lock signal from the smart key remote control with power OFF or ACC ON and tailgate and engine hood closed, the doors are locked and the theft deterrent mode is activated.
  • Page 611 03-54 Entering into theft deterrent mode by SKM passive entry When receiving the signal from the outside door handle switch with power OFF or ACC ON, tailgate and engine hood closed and driver door unlocked, the doors are locked and the theft deterrent mode is activated.
  • Page 612 03-55 8710-01 Disarming If the door unlock signal is received from the smart key remote control with power OFF or the outside door handle switch signal is received with the driver door locked, the doors are unlocked, turn signal lamps blink once, exterior buzzer sounds twice at the intervals with 50 ms ON/450 ms OFF and theft deterrent mode is deactivated.
  • Page 613 03-56 Re-entering into theft deterrent mode after tailgate open If all the doors, excepting tailgate, are in theft deterrent mode and the BCM is received 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.
  • Page 614 03-57 8710-01 16) Time Lag Power Window Control When turning the ignition switch to ON position, the power 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.
  • Page 615 03-58 18) Flasher (Blinking) Function ▶ Turn signal lamp control When the BCM is received the multifunction switch signal, it operates the turn signal lamp and interior buzzer with the intervals of 400 ms ON/400 ms OFF for 75 times/min. The turn signal lamps are operational only when IGN1 is ON.
  • Page 616 03-59 8710-01 ▶ Right turn signal lamp control When the BCM is received the multifunction right turn signal lamp switch signal, it operates the right turn signal lamp and interior buzzer with the intervals of 400 ms ON/400 ms OFF for 75 times/min.
  • Page 617 03-60 ▶ Hazard flasher switch control When pressing the hazard flasher switch, the left/right turn signal lamps blink with the intervals of 400 ms ON/400 ms OFF for 75/min and the interior buzzer sounds with same interval. When pressing the hazard flasher switch again during its operation, the turn signal lamps and horn stop the operation.
  • Page 618 03-61 8710-01 ▶ Hazard flasher indicator control When pressing the hazard flasher switch, the hazard flasher indicator blinks with the interval of 75/min. When pressing the hazard flasher again switch during Step (1), the indicator stops its operation. This function is available if the battery is connected (B+). ▶...
  • Page 619 03-62 ▶ Emergency hazard flasher control (coupled with ABS) System layout Operating conditions: When receiving the emergency hazard flasher ON signal from ESP and ABS. 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.
  • Page 620 03-63 8710-01 OFF conditions: The BCM flashes the emergency auto hazard flasher with interval of 1.25 times/sec.: The emergency hazard flasher does not operate if the vehicle speed is over 50 km/h when the emergency stop signal is received. The emergency hazard flasher operates if the vehicle speed is 50 km/h or lower when the emergency stop signal is received.
  • Page 621 03-64 19) DRL (Daytime Running Light) Control When receiving the DRL activation signal, the tail lamps are turned ON when turning the ignition switch to ON position, and the headlamps are turned ON when the engine speed is 300 rpm or higher.
  • Page 622 03-65 8710-01 21) 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.
  • Page 623 03-66 22) Outside Mirror Folding/Unfolding Control ▶ Folding/unfolding control When pressing the mirror folding/unfolding switch with IGN ON, the mirrors are folded or unfolded according to the mirror condition. If the outside rearview mirror was folded, the mirror should be unfolded, and vice versa. Folding/unfolding output is activated for 16±6 seconds. This operation time should be completed even when the ignition switch is turned to OFF position during its operation.
  • Page 624 03-67 8710-01 ▶ Auto folding/unfolding control Setting Set auto folding function: When pressing the mirror folding switch for over 3 seconds, the auto folding function is set and the internal buzzer sounds once (ON: 0.1 sec, OFF: 0.2 sec). Release auto folding function: When pressing the mirror folding switch for over 3 seconds, the auto folding function is set and the internal buzzer sounds twice (ON: 0.1 sec, OFF: 0.2 sec).
  • Page 625 03-68 ▶ With SKM Approach lamp ON When turning the ignition switch to OFF from ON position and opening the driver door, the approach lamps come ON. When receiving the UNLOCK signal from the smart key remote control or outside door handle switch signal in the theft deterrent mode, the approach lamps come ON for 30 seconds.
  • Page 626 03-69 8710-01 2. IMMOBILIZER/REMOTE CONTROL KEY CODING 1) System Overview While the communication between BCM/SKM and ECU is based on the CAN communication, the communication between transponder and BCM/SKM is based on LF (Low frequency) 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.
  • Page 627 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 as lighting equipment, security keys or security cards.
  • Page 628 03-71 8710-01 4) Components of REKES Key Remote control PCB Key plate Transponder Battery cover Side & main cover Battery: CR2032 ▶ How to replace battery Remove the battery cover using a flat screwdriver to replace the battery. ▶ How to replace transponder Remove battery cover and battery Remove rubber cover and screw then remove key plate Remove side cover and main cover...
  • Page 629 03-87 0000-00 1. REKES KEY Insert the ignition key into the key cylinder and turn it to ON position. Select vehicle type and system (BCM) on the diagnostic program and perform the diagnosis.
  • Page 630 03-88 Select REKES key coding menu and enter the password. (default value: "0000") Press "Next". Operate the PANIC button on the first REKES key for more than 2 seconds.
  • Page 631 03-89 0000-00 Listen for a beep from the vehicle and proceed second REKES key coding. Operate the PANIC button on the second REKES key for more than 2 seconds. 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 Listen for a beep from the vehicle. Once the registration is completed, press "OK" button. * REKES key can be registered up to 5.
  • Page 633 03-91 0000-00 2. TRANSPONDER (BCM) Insert the ignition key into the key cylinder and turn it to ON position. Select vehicle type and system (BCM) on the diagnostic program and perform the diagnosis.
  • Page 634 03-92 Select Transponder registration menu and enter the password. (default value: "0000") Press "Next". Press "Next" with the first key in the key box.
  • Page 635 03-93 0000-00 When first transponder coding is completed, insert the second key into the key cylinder within 10 seconds and press "Next". When second transponder coding is completed, insert another key into the key cylinder within 10 seconds and press "Next" for additional coding or press "Done" to exit the program.
  • Page 636 03-94 Once the registration is completed, press "OK" button. If the transponder registration fails, press "Previous" and perform the procedures again.
  • Page 637 03-95 0000-00 3. EMS REGISTRATION Insert the ignition key into the key cylinder and turn it to ON position. Select vehicle type and system (BCM) on the diagnostic program and perform the diagnosis.
  • Page 638 03-96 Select EMS registration menu and enter the password. (default value: "0000") Press "Next".
  • Page 639 03-97 0000-00 Select EMS registration menu and enter the password. (default value: "0000") Press "Next". Once the EMS registration is completed, turn the ignition off and press "OK".
  • Page 640 03-98 Once the EMS registration is completed, press "OK" to exit the program.
  • Page 641 03-99 0000-00 4. VARIANT CODING Turn the ignition on and select vehicle type and system (BCM) on the diagnostic program for diagnosis. When you select Variant coding menu and select "Variant check", the following confirmation window is displayed. If there is no change, press "OK" button.
  • Page 642 03-100 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. If the variant coding is completed successfully, turn the ignition off and press "OK" button as instructed in the screen.
  • Page 643 03-101 0000-00 Wait for 15 seconds. Turn the ignition on and press "OK" button.
  • Page 645 04-3 8712-03 1. SPECIFICATIONS Item Specification Rated voltage DC 12 V Operating voltage DC 9 V ~ 16 V -30°C to +80°C Operation temperature Modulation method Dark current 5.5 mA + Auto A/P (12 mA) Maximum humidity Range 10 m or more (OPEN SITE) Voltage drop 1.0 V or less 433.920±0.015 MHz...
  • Page 646 04-4 1. SYSTEM LAYOUT The vehicles with smart key system are equipped with the SKM (Smart Key Module) unit. The SKM, which does not use the traditional key or remote controller to access the vehicle, provides 3 functions. The passive UNLOCK function unlocks the door after confirming the smart key information and the driver's door conditions when the driver carrying a smart key touches the door handle.
  • Page 647 04-5 8712-03 Smart key Slot Rear bumper antenna Front interior antenna Rear interior antenna...
  • Page 648 04-6 2. INPUT/OUTPUT DIAGRAM ▶ Major functions Passive LOCK/UNLOCK by outside door handle switch 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)
  • Page 649 04-7 8712-03 3. OPERATIONS 1) Coding (1) Coding process ▶ Coding for each unit (2) Operation with/without smart key/EMS registration Passive Ignition status change STARTING THE LOCK/UNLOCK ENGINE 10 times Smart key registration EMS REGISTRATION Smart key & EMS registration...
  • Page 650 04-8 (3) Coding after replacing components When replacing smart key and SKM: Register smart key and EMS When replacing EMS: Register EMS (4) VIRGIN power control If the SKM is not coded at all, the power control is performed as follows: ▶...
  • Page 651 04-9 8712-03 2) Smart Key Function The passive LOCK/UNLOCK is performed by the input from the outside door handle switch. (For driver's door LOCK/UNLOCK) Searching for a smart key signal from the outside the vehicle is prioritized in theft deterrent mode.
  • Page 652 04-10 Passive start operation range Passive START actuation area: Vehicle interior...
  • Page 653 04-11 8712-03 (2) Passive LOCK When the system searches for a smart key by the input from the outside door handle switch, the SKM sends the passive LOCK signal to the BCM if all the doors are closed and a normal smart key is found outside the vehicle.
  • Page 654 04-12 ▶ Interruption of door LOCK & Smart key function by outside door handle switch When the door LOCK signal is received from the driver/passenger door handle switch with the ignition status OFF or ACC ON, the SKM identifies the verified smart key and sends the passive LOCK signal to the BCM through the BCAN if the ignition is turned to OFF.
  • Page 655 04-13 8712-03 (3) Passive UNLOCK When the system searches for a smart key by the input from the outside door handle switch, the SKM sends the passive UNLOCK signal to the BCM if all the doors are closed and a normal smart key is found outside the vehicle.
  • Page 656 04-14 (4) Passive tailgate open When a normal smart key is found by the signal from the tailgate open switch, the system sends the tailgate open control signal to the BCM. ▶ Passive tailgate open hardware input/output control The SKM receives the tailgate open switch signal from the BCM through the BCAN communication.
  • Page 657 04-15 8712-03 (5) Puddle (approach) lamp control The SKM sends the signals for [AUTO approach], [REKES UNLOCK] and [Passive UNLOCK] through the BCAN to control the puddle (approach) lamp by AUTO puddle (approach) lamp ON, REKES UNLOCK and Passive entry UNLOCK. ▶...
  • Page 658 04-16 (6) Limitations/Interruption of smart key function The SKM searches for a smart key inside the vehicle when it receives the information on entering the theft deterrent mode from the BCM. If a normal smart key is identified, the SKM memorizes this as a function-limited key (Silent Smart Key) or a function interrupted key (Deactivation Smart Key) according to the conditions.
  • Page 659 04-17 8712-03 3) REKES Control Function When the SKM receives the REKES signals by the buttons on the smart key, it transmits the corresponding signals through the BCAN. The SKM sends the escort signal after sending the REKES LOCK signal when the escort switch is operated.
  • Page 660 04-18 (4) Remote keyless panic & escort The SKM transmits the signals for [REKES panic] and [REKES escort] by the panic button of the smart key to the BCM. ▶ Remote keyless panic & escort 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.
  • Page 661 04-19 8712-03 4) Smart Key Verification Time Control (1) Pre-verification timer When the operation signal from the START switch is received, the START & power control functions can be performed without smart key verification. Condition SKM operation - when door closed signal is input with - B+ or ACC ON Once the vehicle interior - when brake is applied with - B+ or ACC ON verification is completed, 30 sec.
  • Page 662 04-20 5) Start & Power Mode Control The smart key system performs the smart key verification inside the vehicle to operate the 'Passive/Emergency start' and 'Power mode control'. It performs the following functions according to the verification result. Power mode control: Ignition status change Immobilizer communication with EMS Start request transmission to EMS (1) Hardware interface...
  • Page 663 04-21 8712-03 (2) Ignition status change The ignition status is changed to OFF, ACC ON, IGN ON and engine cranking by one START/STOP button. The SKM cuts the power for IGN2 and ACC relays while the engine is cranking as cutting the electric load is necessary.
  • Page 664 04-22 When the ignition status is changed, the SKM communicates according to the body network conditions as follows: OFF → ACC: Keep communicating for 5 sec. OFF → IGN: Keep communicating ACC → IGN: Keep communicating IGN → Cranking: Keep communicating Cranking→...
  • Page 665 04-23 8712-03 Except brake switch signal input For the vehicles with A/T, when the START switch is pressed for 10 sec. or more, the ignition status is changed to IGN ON and the engine start request signal is sent regardless of the brake signal, provided that the initial ignition status is ACC ON and the gear selector lever is in P or N position.
  • 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 04-26 7) START Switch Control (1) START switch indicator ▶ Ignition status indicator on START switch Status Turning on conditions IGN OFF, IGN ON & engine ON Green Engine can be started by START switch operation/Engine is cranking (IGN OFF & brake switch ON, ACC ON & brake switch ON, IGN ON & brake switch ON, etc.) Yellow ACC ON...
  • Page 669 04-27 8712-03 8) SKM Warning Control (1) Smart key not found warning (Key out warning) If no verified smart key is identified as being in the vehicle with IGN ON or ACC ON, 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 found warning).
  • Page 670 04-28 Smart key not found warning deactivation conditions If below conditions are met, the SKM sends the signal for [Smart key not found warning deactivation] to deactivate the warning. A smart key is found while the smart not found warning signal is output. <IGN1 off>...
  • Page 671 04-29 8712-03 (3) Smart key verification fail warning When the verification is requested for ignition status change or engine starting and no verified smart key is in the vehicle, the SKM sends the [smart key verification status] signal, which indicates that the verification has failed, for up to 10 sec. until the verification fail conditions are deactivated.
  • Page 672 04-30 Ignition status change (OFF ->ACC) / (OFF ->IGN)/(ACC ->IGN) / (IGN -> engine ON) If above conditions are met again, the SKM re-verifies the transponder and sends the verification status for another 10 sec. When the ignition status is changed by a smart key verification while the transponder verification is processed, the SKM sends the signal for [transponder verification fail], and sends the smart key verification status for 10 sec.
  • Page 673 04-31 8712-03 (8) Brake not working alert The SKM sends the brake not working alert signal for 10 sec. every time the ignition status is changed after the 1st cycle (OFF-ACC-IGN-ACC-OFF) while the brake is not operated. ▶ Warning cancellation requirements when the brake pedal is depressed, the system is reset and alert deactivation signal is sent.
  • Page 674 04-68 1. SMAKRT KEY CODING Insert the smart key into the immobilizer holder in the glove box, and turn the ignition on. When the smart key is lost, start coding after performing LIMPHOME IGN CONTROL. Start diagnosis of the system by selecting the vehicle model and system (SKM) in the diagnostic program.
  • 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".
  • 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".
  • Page 677 04-71 8712-03 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) Once the registration is completed, press "OK" button.
  • Page 678 04-72 2. EMS REGISTRATION Insert the smart key into the immobilizer holder in the glove box, and turn the ignition on. Start diagnosis of the system by selecting the vehicle model and system (SKM) in the diagnostic program.
  • Page 679 04-73 8712-03 Select "EMS registration" from the diagnosis menu and then enter the password. The initial password is "0000".
  • Page 680 04-74 When the registration is completed, turn the ignition off and then click "OK" button. Wait for about 30 sec.
  • Page 681 04-75 8712-03 When the registration is completed, click "OK" button.
  • 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. Click "Next" button.
  • 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.
  • Page 685 05-3 8010-01 1. SPECIFICATION Pin No. Specification Rated voltage DC 13.5 V Operating voltage DC 9 V ~ 16 V CAN operating DC 7 V ~ 18 V voltage Inspection voltage DC 13.5 V Operating -30℃ ~ +80℃ temperature -40℃ ~ +85℃ Storage temperature IGN OFF: 1 mA, 12 V Measurement condition (at 25℃): 60 seconds after that ignition is...
  • Page 686 05-4 2. MAJOR CHANGES 1) Steering wheel heating indicator added SVC class Previous Current One indicator added since steering wheel heating function is equipped. 2) Pre-warning indicator rearranged SVC class Previous Current Rearranged pre-warning indicator which comes on and goes off when turning ignition on. 3) Winter mode indicator added STD class Previous...
  • Page 687 05-5 8010-01 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). 4) Warning lamps according to ISO standards Both SVC and STD class Previous Current...
  • Page 688 05-6 6) Average fuel economy reset and calibrated automatically when refilling Both SVC and STD class Previous Current Reset by user Reset by user and automatic reset when refilling 7) Instant fuel consumption display changed SVC class Previous Current Changed from figure type to bar graph type. 8) Pre-warning indicator for engine overheat removed SVC class STD class...
  • Page 689 8010-01 1. OVERVIEW There are two types 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.
  • Page 690 05-8 ▶ Engine RPM gauge Speedometer...
  • Page 691 05-9 8010-01 3. Description of Warning Lamps & Indicators 1) SVC...
  • Page 692 05-10 2) STD...
  • Page 693 05-11 8010-01 3) Details of Warning Lamps and Indicators ▶ Headlamp high beam indicator Indicator (blue) This lamp comes on when the headlamp high beam is operated. ▶ Front fog lamp indicator Indicator (green) This indicator comes on when the fog lamp switch is operated after the tail lamps comes on.
  • Page 694 05-12 ▶ Low fuel level warning lamp Warning lamp This lamp comes on if the fuel level is approx. 10 ℓ or below. (amber) However, the fuel level may change slight depending on vehicle condition, inclination of the road, etc. Also, it blinks if there is a short or open circuit between the fuel level sensor and cluster.
  • Page 695 05-13 8010-01 ▶ Indicator (amber) This indicator comes on when the ESP system is faulty. ▶ ESP OFF indicator Indicator (amber) This indicator comes on when pressing the ESP OFF switch. ▶ Engine check warning lamp Indicator (amber) This lamp comes on if any sensor or device related to the engine control is defective.
  • Page 696 05-14 ▶ Brake warning lamp (brake fluid) Indicator This lamp comes on when the parking brake is applied or the brake (red) 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. ▶...
  • Page 697 05-15 8010-01 ▶ Hazard indicator Indicator (red) This indicator comes on when the hazard warning flashers are switched (applies to STD class) ▶ ECO indicator Indicator (green) This indicator comes on when the ECO cruise system is activated. This indicator goes off when the brake pedal is depressed. (ECO deactivated) ▶...
  • Page 698 05-16 ▶ Passenger seat belt reminder Indicator (red) 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. ▶ Left turn signal indicator Indicator (green) The left turn signal indicator blinks if the light switch is pushed down to the left, and both turn signal indicators blink if the hazard warning flasher switch is pressed.
  • Page 699 05-17 8010-01 ▶ Winter mode indicator Indicator This indicator comes on when the winter mode switch is switched on (green) and goes off when the switch is off. This comes on together with the winter mode display on the LCD screen.
  • Page 700 05-18 4. OPERATING PROCESS 1) SVC 2) STD...
  • Page 702 05-20 3) Block Diagram ▶...
  • Page 703 05-21 8010-01...
  • Page 704 05-22 ▶...
  • Page 705 05-23 8010-01...
  • Page 706 05-24 4) Display Sequence ▶ Display sequence for STD main LCD & SVC DOT LCD Operating time of Trip Function switch Below 1 second Mode change (ODO → TRIP A → TRIP B → DTE → AFC → IFC → (60 to 980 ms) ILLUMINATION →...
  • Page 707 05-25 8010-01 5) Illumination & Brightness (1) Operations for Power Supply ▶ Operations for power supply in SVC When the ignition switch is turned to ON position, the message "WELCOME" is displayed for 2 seconds on the DOT LCD and the seat belt reminder comes on for 4 seconds. However, if a signal with higher priority is received, the seat belt reminder comes on only for 2 seconds to display it.
  • Page 708 05-26 When the ignition is switched 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.
  • Page 709 05-27 8010-01 ▶ Operations for power supply in STD The operation input before the LCD backlight 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.
  • Page 710 05-28 (2) Illumination Level ▶ Brightness in SVC Dial Illumination DOT LCD ODO, GAGE LCD Operating power pointer previous Night Night Night OFF (however, level 6 for initial After Level 6 Level 6 operation with B+ & IGN1 ON) (B-CAN After Wake Maintains...
  • Page 711 05-29 8010-01 6) System Analysis (1) SVC ▶ Symbols in SVC...
  • Page 712 05-30 ▶ Symbols in SVC (via CAN)
  • Page 713 05-31 8010-01 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. The pre-warning of the MICOM control warning is performed 400 ms after turning the ignition switch to ON position.
  • Page 714 05-32 (2) STD ▶ Symbols in STD...
  • Page 715 05-33 8010-01 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. The pre-warning of the MICOM control warning is performed 400 ms after turning the ignition switch to ON position.
  • Page 716 05-34 ▶ Symbols in STD (via CAN)
  • Page 717 05-35 8010-01...
  • Page 718 05-36 7) Odometer (ODO) and Trip Meter (TRIP) The total driving distance (0 to 999,999 km or 0 to 999,999 miles) and the trip distance (0.0 to 999.9 km or 0.0 to 9,999.9 miles) are calculated by using the value of pulse per 1 km which is programmed in the EEPROM.
  • Page 719 05-37 8010-01 ▶ STD Class Odometer Display & Data Storage 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 If the signal indicating value actual vehicle speed above 300 km/h is received, the data is not accumulated.
  • Page 720 05-38 8) Display Mode (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). ▶...
  • Page 721 05-39 8010-01 (2) Average Fuel Consumption 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. Function Signal Remark Display type 3 digits LCD Display range 0.0 km ~ 99.9 km (0 miles~99.9 miles) Resolution...
  • Page 722 05-40 When the ignition is switched on and the vehicle is drived more than 10 km, average fuel consumption 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) 0.0 ~ 20(ℓ/100km, km/ℓ)/ 0.0 ~ 50(MPG) Display range...
  • Page 723 05-41 8010-01 (4) Illumination Mode ▶ 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.
  • Page 724 05-42 9) Buzzer ▶ Specifications Function Signal Part name PKM17EPP-2002-B0 (MURATA, Piezoelectric Sound Components) Permitted input voltage 25 VP-P or less -20˚C to +70˚C Operating temperature -30˚C to +80˚C Storage temperature Sound pressure level 70 dB/min (3 Vp-p, 2 kHz, square wave, 10 cm) 10.9 nF ±30% (120 Hz) Capacitance ▶...
  • Page 725 05-43 8010-01 10) PAS (Parking Aid System) (1) Sensor Operating Process The ultrasonic sensors transmit ultrasonic waves and receive the reflected waves from an obstacle to detect it in the following order: L → C → R. (2) Self Diagnosis Mode ▶...
  • Page 726 05-44 ▶ Buzzer interval when measuring distance Exception/error handling Timeout processing time for buzzer interval after measuring distance/self diagnosis: 600 ms - If timeout is reached, 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.
  • Page 727 05-45 8010-01 ▶ DOT LCD message display Message Pin No. Operating condition Pin No. Message Operating condition Ambient temperature: TRIP switch indicates air temperature outside control Reset: Press and hold the Trip switch Trip A for more than 1 second Reset: Press and hold the Trip switch Trip B for more than 1 second...
  • Page 728 05-46 Message Pin No. Pin No. Message Operating condition Operating condition Domestic Export This message comes on the LCD display, if the smart key is not in the vehicle when the door is open and closed in the ignition ON or ACC mode. This message comes on the LCD display for approx.
  • Page 729 05-47 8010-01 Message Pin No. Operating condition Pin No. Message Operating condition Domestic Export This message comes on for 10 seconds if incorrect signal on vehicle power control, ignition switch or gear shift position is received or the signal is not received from the SKM after the smart key is verified.
  • Page 730 05-48 Message Pin No. Operating condition Pin No. Message Operating condition Domestic Export Cruise control This message comes on when the ECO cruise mode is deactivated. This message comes on when the engine is faulty. This message comes on when the tail lamps are Lamp ON with the ignition in the "OFF"...
  • Page 731 05-49 8010-01 Message Pin No. Operating condition Pin No. Message Operating condition Domestic Export The message "SET WINTER MODE" is displayed on the LCD display when the winter mode is activated. The message "RELEASE WINTER Winter mode MODE" is displayed when it is deactivated. (SVC class) The message "WINTER MODE"...
  • Page 732 05-50 5. SELF DIAGNOSIS 1. Self diagnosis for gauge Speedometer: Check the whole speed range (minimum to maximum). Tachometer: Check the whole rpm range (minimum to maximum). 2. Self diagnosis for symbols All symbols ON (except the wired type symbols: air bag, passenger air bag, turn signal indicators, hazard warning lamp, high beam, front fog lamp) 3.
  • Page 733 07-2 1. LAMP SPECIFICATIONS 1) Exterior Lamps Item Type Amount Front lamp Headlamp (high beam/low beam) Item BULB: H4 Type Amount 2 EA Turn signal lamp Headlamp (high beam/low beam) BULB: PY21W BULB: H4 2 EA 2 EA Front lamp Position lamp Turn signal lamp BULB: PY21W...
  • Page 734 07-3 8310-00 2. AUTOMATIC LIGHT SENSOR SPECIFICATIONS Pin No. Specification Operating voltage 9 V to 16 V Load Max. 200 mA (relay load) -30℃ to 85℃ Operating temperature -40℃ to ±120℃ Storage temperature Mounting location Top center of inner side of windshield glass ▶...
  • Page 735 07-4 1. EXTERIOR LAMP 1) Layout Headlamp Turn signal lamp High-beam /low-beam Position lamp Front fog lamp Puddle (approach) lamp Side repeater lamp...
  • Page 736 07-5 8310-00 Rear combination lamp Stop lamp and tail lamp Turn signal lamp Backup lamp Rear fog lamp License plate lamp High mounted stop lamp Vehicle with spoiler Vehicle without spoiler...
  • Page 737 07-6 2) Operation (1) Headlamp High-beam/low-beam Most of the functions of the headlamp is controlled by the multifunction switch. The functions performed by REKES or SMART key are controlled by the BCM. The BCM controls the headlamp and tail lamp by using the data sent through the LIN communication from the automatic light sensor when the multifunction switch is in AUTO position.
  • Page 738 07-7 8310-00 (2) Fog lamp ▶ Front Front fog lamp ▶ Rear (EU only) Rear fog light The front fog lamp is operated with the fog lamp switch only when the tail lamp is lit. The rear fog lamp is not installed to Korean models and 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.
  • Page 739 07-8 (3) Tail lamp ▶ Front Tail lamp ▶ Rear Tail lamp The tail lamp is operated by the BCM when the BCM receives a signal from the multifunction switch. ▶ Tail lamp warning The buzzer sounds for 10 seconds with the interval of 0.02 s ON and 1.38 s OFF when opening the driver door with the key removed (without SKM)/with IGN OFF or ACC (with SKM) and tail lamp ON.
  • Page 740 07-9 8310-00 (4) Turn signal lamp / Side repeater lamp ▶ Front Turn signal lamp ▶ Rear Turn signal lamp The turn signal lamp is operated by the BCM when the BCM receives a signal from the multifunction switch. The BCM cycles the turn signal lamp and buzzer (ON/OFF) 75 times per minute.
  • Page 741 07-10 (5) Auto light (LIN) Auto light switch Automatic light sensor unit The auto light sensor unit is installed to the back side of the ECM mirror located upper center of the windshield, and detects the illuminance change. The BCM communicates with the auto light sensor when the ignition is turned on, and turns on or off the tail lamp and headlamp automatically according to the signals from the sensor when the multifunction switch is set to AUTO light.
  • Page 742 07-11 8310-00 (7) Puddle (approach) lamp Approach (puddle) lamp ▶ Lamp control for models without SKM Approach lamp ON 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 the driver door, the approach lamps come ON.
  • Page 743 07-12 2. INTERIOR LAMPS 1) Layout Glove box lamp Front room lamp Sun visor lamp...
  • Page 744 07-13 8310-00 Center room lamp Luggage lamp Door courtesy lamp...
  • Page 745 07-14 2) Operation (1) Front room lamp/Center room lamp Front room lamp Center room lamp Operating the front room lamp and center room lamp switches illuminates the driver/passenger side lamps and center room lamp. ▶ Room lamp control by door coupled room lamp operation If a door except the tailgate is opened after the ignition is turned off, provided that door coupled front room lamp switch is pressed, the front room lamp and center room lamp are illuminated for 2 sec.
  • Page 746 07-15 8310-00 (2) Luggage lamp The luggage lamp is turned on when the tailgate is Luggage lamp opened with the switch 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 Glove box lamp opened after the tail lamp is illuminated.
  • Page 747 08-3 7810-00 1. WIPER CONTROL ▶ Wiper mist & washer coupled wiper ▶ Auto washer coupled wiper ▶ Rain sensor coupled wiper operation (LIN) ▶ Speed sensitive intermittent wiper ▶ Wiper low/high control 2. CAUTIONS ON RAIN SENSOR When the wiper switch is in the AUTO position, the wiper will operate for 1 cycle if the initial engine start is made.
  • Page 748 08-4 3. MAJOR CHANGES Windshield wiper blade Wiper blade design and wiper arm pressure Previous Current Wiper arm pressure Wiper arm pressure Driver side = 900 ± 50 g Driver side = 950 ± 50 g Passenger side = 600 ± 50 g Passenger side = 650 ±...
  • Page 749 08-5 7810-00 1. WIPER AND WASHER SYSTEM 1) AUTO Washer Coupled Wiper Function Operating part for rear wiper/washer AUTO washer switch (press) If you press the AUTO washer switch briefly with the ignition key ON and INT-AUTO switch "OFF", the washer motor is operated for about 2 seconds to spray washer fluid once after the switch is turned ON and the wiper relay is turned ON for 4 cycles.
  • Page 750 08-6 3) Fluidic Washer Nozzle This vehicle has the fluidic washer nozzle, which is designed to use fluid movement occurring in the washer fluid spraying process. Washer nozzle When installing the washer nozzle, make sure that the mounting surface is clean and free of dirt or debris, since the water may come into the engine compartment in accordance with a seamless contact condition between the mounting surface of the nozzle and the curved surface of the engine hood.
  • Page 751 08-7 7810-00 2. RAIN SENSING SYSTEM In the rain sensing wiper operation system, the rain sensing unit only sends the information about the amount of rain drops to the BCM, and it does not operate the wiper directly. The wiper and washer are controlled by the BCM according to the driver's choice.
  • Page 752 08-8 ▶ The rain sensor detects the amount of rain drops and sends 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.
  • Page 754 08-10 3. SYSTEM LAYOUT (INCLUDING RAIN SENSOR) WIPER AND WASHER SWITCH Rain sensor unit Wiper Front wiper Rear wiper Rear washer hose and nozzle For vehicles with rear For vehicles without rear spoiler spoiler...
  • Page 755 08-11 7810-00 Front nozzle assembly Washer fluid reservoir assembly Reservoir tank Washer motor Washer motor...
  • Page 756 08-12 4. WIPER AND WASHER OPERATION 1) Windshield Wiper Control Function MIST The wiper operates for 1 cycle when pushing up the lever. The lever will return to the "OFF" position when released. Stop the operation. AUTO Wiper speed controls automatically according to the vehicle speed or amount of rain (rain sensing wiper).
  • Page 757 08-13 7810-00 (1) Wiper mist When the multifunction switch is pushed to the MIST position for 0.1 sec. or more 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.
  • Page 758 08-14 (2) Wiper LO/HI control The wiper LOW relay is turned on when the multifunction wiper switch is at the LO position. The wiper HIGH relay is turned on when the wiper switch is at the HI position. When the wiper switch is at the HI position, both the LOW relay (constant operation) and HIGH relay are operated.
  • Page 759 08-15 7810-00 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 760 08-16 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.
  • Page 761 08-17 7810-00 (2) AUTO washer coupled wiper 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 while, washer fluid is sprayed once more and the wiper operates 3 times.
  • Page 762 08-18 3) Rear Wiper Control Function Rear wiper switch 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 stop in the Rear Wiper Operation mode and only the wiper will keep operating.
  • Page 763 08-19 7810-00 4) Rear Washer Control Function 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 764 08-20 5) Rain Sensor Coupled Wiper Control Function AUTO operation and sensitivity control AUTO: Wiper operates automatically by rain sensor FAST <----> Auto delay/auto speed control A position that can control sensitivity against rains on the windshield transmits wiping demand signal accordingly.
  • Page 765 08-21 7810-00 (1) Rain sensor coupled wiper operation (LIN) ▶ System layout...
  • Page 766 08-22 (2) Power-up reminder wiper If the intermittent/automatic wiper switch is in "ON" position, the wiper motor does not operate even when turning the ignition switch to ON from OFF position. 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.
  • Page 767 08-23 7810-00 (3) Washer coupled wiper operation during rain sensor coupled operation When the washer switch signal is received during intermittent operation coupled with rain sensor with IGN ON and intermittent/automatic washer switch operation, the wipers operate in washer coupled mode regardless of the communication with the rain sensor.
  • Page 768 08-24 (4) Sensitivity control (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 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.
  • Page 769 08-25 7810-00 (5) For abnormal wiper parking signal 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. When the parking terminal is shorted to power with IGN2 ON and intermittent wiper switch in "ON"...
  • Page 770 08-26 (6) For faulty rain sensor 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.
  • Page 771 08-27 7810-00 (7) Speed sensitive intermittent wiper For the vehicles without rain sensor, the BCM operates the wiper as follows: When turning the ignition switch to ON from OFF position with the intermittent 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.
  • Page 772 08-28 ▶ Speed sensitive intermittent wiper interval...
  • Page 773 09-3 8790-00 1. SPECIFICATION Pin No. Specification Pin No. Specification Insulating No heat & fire due to Rated voltage DC 12.0 V resistance current leak Operating voltage DC 9.0 V ~ 16.0 V Unit: 100 mA or less Max. permissible current Operating -30℃...
  • Page 774 09-4 3. MAJOR CHANGES Parking aid unit Parking aid unit logic Changed sensor self-diagnosis buzzer sound interval (65 ms → 60 ms)
  • Page 776 09-6 1. OVERVIEW When the gear selector lever is shifted into “R", the parking aid system is activated and three sensors in the rear bumper detect the distance to any 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.
  • Page 777 09-7 8790-00 2. CONFIGURATION Installation of PAS sensor Parking aid unit PAS sensor...
  • Page 778 09-8 3. OPERATING PROCESS When PAS 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. 1) Block Diagram...
  • Page 779 09-9 8790-00 2) Rear PAS Sensor While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously. Sensor detection range Within 20 cm from the ground (Objects may not be detected in this range.)
  • Page 780 09-10 ▶ Circuit diagram of ECU ▶ Internal circuit diagram of sensors...
  • Page 781 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 782 09-12 4. OUTPUT SPECIFICATIONS FOR SENSOR SELF- DIAGNOSIS BUZZER SOUND ▶ Buzzer interval during self diagnosis Self diagnosis is performed once when the ignition is switched on (gear shift lever in "R" position). If the system is defective (Fail) due to open sensor or communication problem, the information for the failed sensor is displayed as buzzer sound.
  • Page 783 10-3 8910-05 1. SPECIFICATION Unit Description Specification General Rated voltage DC 14 V (Negative ground) Speaker 4 Ohm Output 45 W x 4 channels Current consumption 10 A (at maximum power) MP3[WMA], CD Sampling frequency 8 times oversampling DA converter 4 DAC system Pick-up type Astigma 3-beam...
  • Page 784 10-4 Unit Description Specification USB MP3[WMA] Frequency response 20Hz ~ 20kHz Total harmonic 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 -30˚C ~ +60˚C...
  • Page 785 10-5 8910-05 2. MAJOR CHANGES Audio assembly CDP (MP3) + Bluetooth CDP(MP3) + RDS + Bluetooth The “CALL” button for Bluetooth system has been added. 3. RDS (RADIO DATA SYSTEM) AUDIO RDS (Radio Data System) is a broadcasting service which a growing number of FM stations are now providing.
  • Page 786 10-6 1. LAYOUT Audio CDP (MP3) Radio USB/AUX Bluetooth hands-free Remote control switch on steering wheel Front door tweeter speaker Front door speaker...
  • Page 787 10-7 8910-05 Audio assembly CDP (MP3) + Bluetooth CDP(MP3) + RDS + Bluetooth USB/AUX Hands-free microphone Rear door speaker...
  • Page 788 10-8 1) Audio Control Switch ▶ CDP (MP3) + Bluetooth Name Power/Mute/Pause/Enter/Volume button Station memory button (1~6) and Audio function button Bluetooth hands-free CALL button Bluetooth hands-free END button Previous (≪) and Next (≫) button SCAN/INFO button BAND/AS button SETTING button Display window (LCD) USB/AUX button Disc Play button...
  • Page 789 10-9 8910-05 ▶ CDP (MP3) + RDS + Bluetooth Name Display window RDS button AF/TA button SEEK button CALL button Disc slot CD/AUX/USB button POWER button with VOLUME dial Station memory button (1~6) BAND/AST button SCAN / INFO button with dial EQ/SOUND button END button Disc Eject button...
  • Page 790 10-10 2) Steering Wheel Audio Switch If your vehicle has this feature, some audio controls can be adjusted at the steering wheel. They include the following: Steering wheel audio switch ▶ MUTE [ Press: to turn the system on, to mute on/off Press and hold: to turn the system off ▶...
  • Page 791 CHASSIS GENERAL INSTRUCTIONS 1. MAJOR CHANGES......... 1. GUIDELINES FOR SERVICE WORKS..2. MOUNTING LOCATIONS (CHASSIS)..2. JACK-UP POINTS........3. CHASSIS COMPONENT LAYOUT..3. STANDARD BOLTS SPECIFICATIONS.. 4. SUB FRAME AND STEERING GEAR BOX LAYOUT........SPECIAL TOOLS AND EQUIPMENT 5. FRONT SUSPENSION COMPONENT LAYOUT..........
  • Page 793 01-3 0000-00 1. MAJOR CHANGES 1) Gear Shift Lever and Cable (Manual Transaxle) Gear shift lever assembly Gear shift lever bracket The gear shift lever bracket has been changed to adopt the premium console. Gear shift cable assembly The connection and socket to lever has been changed.
  • Page 794 01-4 2) Steering Wheel Angle Sensor SWAS: Steering Wheel Angle Sensor Sensor connector Sensor connector 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.
  • Page 795 01-5 0000-00 3) Steering Wheel Heating System Steering wheel heating unit Lower main switch cluster Steering wheel heating unit The steering wheel heated wire and the heating unit are installed in the steering wheel assembly. Steering wheel heating switch The steering wheel heating switch has been added on the lower main switch cluster.
  • Page 796 01-6 4) Parking Brake Lever Assembly Parking brake lever assembly (Automatic transaxle equipped vehicle) The parking brake lever bracket has been changed to adopt the premium console. Parking brake lever assembly (Manual transaxle equipped vehicle) The parking brake lever bracket has been changed to adopt the premium console.
  • Page 798 01-8 2. MOUNTING LOCATIONS (CHASSIS) HECU (Hydraulic & Electronic Control Unit) HECU for ABS HECU for EPS Moto Moto ECU (Electronic ECU (Electronic HU (Hydraulic Unit) (Hydraulic Unit) Control Unit) Control Unit) The HECU (Hydraulic & Electronic Control Unit) determines the slip conditions of vehicle wheels by calculating each wheel's speed and the increment/decrement 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.
  • Page 799 01-9 0000-00 Sensor cluster TGS Lever assembly The TGS communicates with TCU (Transmission Control Unit), ECU, ESP HECU and instrument cluster to let the driver select the desired transmission gear and to maintain the desired driving condition. Also, the tip switch is The sensor cluster is linked installed on the lever knob and to the sensors on the unit...
  • Page 800 01-10 3. CHASSIS COMPONENT LAYOUT 1) 4WD Vehicle With Automatic Transmission M11 6-speed A/T assembly Inhibitor switch Oil pan Torque converter M11 6-speed automatic transmission is available as 4WD- and 2WD-type, and provides 6 speeds for forward travel and 1 reverse travel. It is also equipped with the torque converter with inner Propeller lock-up clutch and electronically controlled...
  • Page 801 01-11 0000-00 2) 2WD Vehicle With Manual Transmission The 2WD vehicle with manual transmission is a front wheel drive type vehicle that doesn't have PTU, propeller shaft, E-coupling and rear axle which are applied to 4WD vehicle. Its under structure is very simple. M6LF1 manual transmission Control shaft assembly Transmission side...
  • Page 802 01-12 4. SUB FRAME AND STEERING GEAR BOX LAYOUT Front sub frame with HPS type steering gear box assembly Rear side HPS type steering gear box assembly Front sub frame Front side assembly The front sub frame consists of 4 body bush mountings and 2 transmission bush mountings which reduce the vibration from the powertrain and road, and also control the torque.
  • Page 803 01-13 0000-00 Rear sub frame assembly for 4WD Rear side Body mounting Body mounting Axle mounting Body mounting Body mounting Front side The rear sub frame for 4WD vehicle consists of 4 body (bush) mountings and 2 axle (direct) mountings which reduce the vibration from the powertrain and road, and also control the torque.
  • Page 804 01-14 5. FRONT SUSPENSION COMPONENT LAYOUT Front suspension supports the vehicle weight and absorber the vibration from tires. And, in 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.
  • Page 805 01-15 0000-00 Front coil spring assembly Coil spring Shock absorber assembly The coil spring is made by winding solid steel rod to form the coil shape. 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.
  • Page 806 01-16 6. REAR SUSPENSION COMPONENT LAYOUT Multi-link type suspension is the independent suspension. It provides good ride comfort and drivability by reducing the coil spring weight. Also, it increases the space for passenger compartment by lowering the floor. This type of suspension consists of multiple links such as trailing arm, upper arm, lower arm and track rod.
  • Page 807 01-17 0000-00 Stabilizer bar assembly Stabilizer bar Bushing Clamp Link The stabilizer bar assembly is not activated if the left/right wheels move up/down simultaneously, but if both wheels move up/down differently it is activated with frame to minimize the tilting of the body.
  • Page 808 01-18 7. BRAKE SYSTEM AND ESP SYSTEM LAYOUT A. Indicators on instrument cluster ESP indicator Parking brake ABS warning lamp warning light 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.
  • Page 809 01-19 0000-00 G. Brake pedal F. Parking brake 4WD and 2WD 2WD Rear side Front 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 appearance and mounting status because the knuckle shape is different from...
  • Page 810 01-20 8. STEERING SYSTEM LAYOUT 1) HPS (Hydraulic Power Steering) The hydraulic pump is a vane The oil reservoir sends the oil There is a shock absorber type pump and consists of to the power steering pump which is folded in the axial the flow control valve and and receives the oil from the direction when the vehicle is...
  • Page 811 01-21 0000-00 2) EPS (Electric Power Steering) Colum shaft assembly Fuse Column shaft The ECU controls the The vehicle with EPS has electric power steering EPS fuse (80A) mounted to BLAC motor system depending on the the positive (+) terminal of driving conditions, based the battery, and this fuse on the signals from the...
  • Page 812 01-22 1. GUIDELINES FOR SERVICE WORKS 1) For Safety To perform the service works easily ans safely, the service technicians must keep the proper working procedures and rules. This manual provides the useful instructions to the service technicians so that they can perform the servive works with standard working process, skills, tips in time.
  • Page 813 01-23 0000-00 2) Equipment Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are integrated into a module. Therefore, 2-post lift and general equipment are necessary when working on the engine and transmission. Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission...
  • Page 814 Check the oil level when the engine is still warm and add the specified engine oil if necessary. (7) Coolant Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material), and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed. (8) Engine drive belt Check all drive belts on the engine for wear, crack and looseness.
  • Page 815 01-25 0000-00 2. JACK-UP POINTS ▶ Stand jack-up points and installation status (front side) Stand jack-up points and installation status (front side) Installation status Jack-up points Jack-up points for 2-post lift for 2-post lift Stand jack-up points and installation status (rear side) Installation status...
  • Page 816 01-26 3. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 817 01-27 0000-00 1. SPECIAL TOOLS ▶ Chassis Name and Part Number Special tool Part number: T99300010A Name: Centering pin for clutch Use: Installing the clutch disc and pressure plate to engine. Part number: T99410010A Name: Remover and installer fo rear knuckle bushing Use: Installing and removing the rear knuckle bushing.
  • Page 818 01-28 1) Equipment for Engine Assembly Name and Part Number Equipment Name: Engine and transmission 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).
  • Page 819 01-29 0000-00 2) Special Tools for Manual Transaxle Name and Part Number Tool Part number: T88310011A-16 Name: Special tool set for manual transaxle This tool 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...
  • Page 820 01-30 Name and Part Number Tool Part number T88310011A-3 T88310011A-8 Name: Installer for bearing outer race Use: With the handle (T88310011A-8), installing the bearing outer race on T88310011A-8 following shafts. 1. Input shaft on transaxle housing 2. No.2 output shaft on transaxle housing 3.
  • Page 821 01-31 0000-00 Name and Part Number Tool Part number T88310011A-5 Name: Installer for bearing outer race Use: With the handle (T88310011A-8), installing T88310011A-8 the bearing outer race on following shafts. T88310011A-8 1. No.1 output shaft on clutch housing 2. No.1 output shaft on transaxle housing Part number T88310011A-6 Name: Installer for bearing...
  • Page 822 01-32 Name and Part Number Tool Part number T88310011A-8 Name: Handle Use: Installing the bearing outer race. Part number T88310011A-9 Name: Bearing support Use: Supporting the shaft when installing the gear, hub bearing or input shaft bearing. Part number T88310011A-10 Name: Installer for taper roller bearing Use:...
  • Page 823 01-33 0000-00 Name and Part Number Tool Part number T88310011A-12 Name: Installer for taper roller bearing Use: With the bearing support (T88310011A-9), installing the taper roller bearing on differential assembly. Part number T88310011A-13 Name: Installer for taper roller bearing Use: With the bearing support (T88310011A-9), installing the taper roller bearing on...
  • Page 824 01-34 Name and Part Number Tool Part number T88310011A-16 Name: Installer for oil seal Use: Installing the oil seal on control shaft.
  • Page 825 02-3 3680-01 1. GENERAL INFORMATION ▶ Automatic transaxle (M11) Inhibitor switch The Model 11 six speed automatic transaxle is available in two variants: four wheel drive and two wheel drive. Six forward speeds One reverse gear A toruqe converter with an integral converter lock-up clutch with slip control capabilities Oil pan Electronic shift and pressure controls...
  • Page 826 02-4 ▶ ▶ Tip switches on steering wheel Meter cluster The shiftable gear can be adjusted by pressing This indicator shows the current position the "UP (D+)" or "DOWN(D-)" switch when the of the gear. gear selector lever is in “M” position. Shift down Shift up ▶...
  • Page 827 02-5 3680-01 2. SPECIFICATIONS 1) Specifications Descriptions Specification Gear ratio 1st gear 4.156 2nd gear 2.375 3rd gear 1.522 4th gear 1.144 5th gear 0.859 6th gear 0.676 Reverse gear 3.178 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...
  • Page 828 02-6 2) Sectional Diagram Clutch pack Single planetary gear-set Oil pump Double planetary gear-set Torque converter Input shaft Intermediate shaft Differential assembly...
  • Page 829 02-7 3680-01 3. TIGHTENING TORQUE Size x Tightening torque Descriptions Numbers (Nm) Engine side mounting bolt 17 mm X 4 85.0 to 100 Oil pan and engine side 14 mm X 4 56.0 to 62.0 Automatic transaxle mounting bolt Oil filler plug 16 mm 25.0 to 30.0 Oil drain plug...
  • Page 830 02-8 1. OVERVIEW Engine power reaches the transaxle via a torque converter with integral converter lock-up clutch. The six forward gears and one reverse gear are obtained from a single planetary set, followed by a double planetary set. This type of gear-set arrangement is commonly known as Lepelletier type gear-set.
  • Page 831 02-9 3680-01 2. FEATURES 1) Advantages ▶ Early Downshift with Hard Braking and Skip Shifts When heavy braking is detected, the transaxle downshifts early and skips gears to provide increased engine braking to provide gear selection for tip-in. ▶ Gear Hold going Uphill/Downhill If the accelerator pedal is released when traveling uphill, upshifts are prevented to reduce busyness on grades.
  • Page 832 02-10 2) Transaxle Cooling The transaxle cooling system ensures rapid warm-up and constant operating temperature resulting in reduced fuel consumption and refined shift quality. It also includes a cooler by-pass within the hydraulic system to allow sufficient lubrication to the transaxle drivetrain in the event of a blockage in the transaxle cooler.
  • Page 833 02-11 3680-01 3. MODES AND FUNCTIONS 1) Mode Switch ▶ W: Winter mode (pressed "OUT") To select the winter mode, press the mode switch. The winter mode indicator (W) in the instrument cluster comes on. To return to standard mode, press the switch again.
  • Page 834 02-12 ▶ 1st Gear State STD type The 1st gear state will display on the instrument cluster. Unlike the normal 1st gear, engine braking will be available in this manual 1st state. ▶ 2nd Gear State The 2nd gear state will display on the instrument cluster.
  • Page 835 02-13 3680-01 4. LIMP HOME MODE ▶ When the transaxle is defective In the event of a system fault, the TCU also provides for failure mode effect control (FMEC) to maintain maximum functional operation of the transaxle. In the event of a total loss of control or electrical power, the basic transaxle functions (Park, Reverse, Neutral and Drive) are retained.
  • Page 836 02-14 5. TRANSAXLE ELECTRONIC CONTROL SYSTEM 1) General Information The transmission control unit (TCU) and its input/output network control the following transmission operations: Shift timing Line pressure Clutch pressure (shift feel) Torque converter clutch also uses these signals when determining transaxle operating strategy. Using all of these input signals, the TCU can determine when the time and conditions are right for a shift, or when to apply or release the torque converter clutch.
  • Page 837 02-15 3680-01 This information is used by the TCU to decide which shift pattern to select and for shift energy management. Electro-hydraulic solenoid valves and variable bleed solenoids control the transaxle gear changes. Six variable bleed solenoids and four on/off solenoids are used to direct transaxle fluid flow to control the fluid pressure within the three clutches and two bands.
  • Page 838 02-16 3) Shift Map Selection The driver can manually select between normal (S) and winter modes (W) via the mode switch. Depending on the transaxle temperature, uphill and downhill grades and altitude, shift maps will be selected by the TCU to suit the driving conditions. The following maps are available. ▶...
  • Page 839 02-17 3680-01 6. CAN NETWORK ▶ Schematic Diagram of Network Communication The TCU sends signals 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...
  • Page 840 02-18 7. POWER TRANSFER Power transfer modes are as follow: Manual: 1st gear (position M) Drive: 1st gear Drive: 2nd gear Drive: 3rd gear Drive: 4th gear - limp home mode Drive: 5th gear Drive: 6th gear 1) Gear Selection and Engagement Element Engagement element (clutch/band) Gear Gear ratio...
  • Page 841 02-19 3680-01 2) Power Flowing Sequence Torque converter Input shaft Front planetary gear This is a fluid clutch. Transfers the power Generates the gear Transfers the power from from torque ratio and transfers engine to transaxle and converter to front the power.
  • Page 842 02-20 3) Power Flow ▶ Front planetary gear Front sun gear (FSG) Planetary hear pinion (PP) Ring gear (Internal) ▶ Intermediate gear ▶ Rear planetary gear Drive gear Forward sun gear (FSG) Driven gear Reverse sun gear (RSG) ▶ Differential gear Short pinion (SPP) Long oinion (LPP) Pinion...
  • Page 844 02-22 3) Hydraulic Circuit Diagram...
  • Page 845 02-23 3680-01...
  • Page 846 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 847 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 848 02-26 (5) Drive 4th (4th Auto) - 1.144 : 1 ▶ Power flow (6) Drive 5th (5th Auto) - 0.859 : 1 ▶ Power flow...
  • Page 849 02-27 3680-01 (7) Drive 6th (6th Auto) - 0.676 : 1 ▶ Power flow (8) Reverse - 3.178 : 1 ▶ Power flow...
  • Page 850 02-28 (9) Neutral / Park ▶ Power flow...
  • Page 851 03-3 3190-01 1. SPECIFICATION Specification Item Remark D20DTF + D20DTF G20DF DG20DD Low CO₂ Model name WM6F1 Overall length 370 mm Distance between shafts 205 mm / 70 mm Weight (except transmission fluid) 62 kgf (2WD) / 63 kgf (4WD) Gear ratio 3.538 3.385...
  • Page 852 03-4 Item Specification Remark Transmission Transmission fluid SAE 75W / 85, API GL-4 fluid Capacity 1.65 L Replacement interval Replacement Inspect and replenish every 60000 interval km (or 3 years) Normal driving condition: Fill for Life (Severe driving condition: Change every 120000 km) Inspect and replenish every 60000 km (or 4 years)
  • Page 853 03-5 3190-01 2. TIGHTENING TORQUE Part name Tightening torque Remark 1. Drive gear mounting bolt of differential carrier 166.6 to 176.4 Nm 10 EA 2. Reverse shaft mounting bolt 74.5 to 89.2 Nm 3. Transmission case mounting bolt 19.6 to 26.5 Nm 22 EA 4.
  • Page 854 03-6 3. MAJOR CHANGES IN MANUAL TRANSAXLE 1) Gear Shift Lever and Cable Gear shift lever assembly Gear shift lever bracket The gear shift lever bracket has been changed to adopt the premium console. Gear shift cable assembly The connection and socket to lever has been changed.
  • Page 855 03-7 3190-01 1. OVERVIEW 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 Front view Rear view...
  • Page 856 03-8 1) Characteristics of WM6F1 M/T Both Forward and Reverse gears use the helical gear and are made of high-strength material. Drives the clutch with a concentric slave cylinder mounting bolt. Shifting the transmission gears is performed through the remote control cable. A pull type clutch is used for Reverse gear shifting.
  • Page 857 03-9 3190-01 2) Internal Configuration...
  • Page 858 03-10 3) Schematic Diagram 4) Gear Ratio Speed gear Final gear Number of Number of Total gear ratio Item Gear ratio Gear ratio teeth teeth Input Output Input Output 3.538 16.059 1.909 8.664 4.538 1.179 5.349 0.814 3.694 0.737 2.898 0.628 2.47 3.933...
  • Page 859 03-11 3190-01 2. POWER FLOWS Sectional view of WM6F1 M/T 1st speed gear 2nd speed gear 3rd speed gear...
  • Page 860 03-12 4th speed gear 5th speed gear 6th speed gear Reverse gear...
  • Page 861 03-13 3190-01 3. SHIFTING MECHANISM Shift lever Selector lever Control shaft 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 lug 3rd/4th speed gear shift fork 1st/2nd, 3rd/4th speed gear shift rail...
  • Page 862 04-3 0000-00 1. SPECIFICATION Description Specification Operating type Hydraulic type Clutch cover Type Diaphragm spring strap Adjusting type SATIC (Self Adjusting Technology with Integrated Cassette) type Clutch pedal Type Suspended type 135 ± 3 mm Max. operating travel 7.1 ± 3 mm Pedal free play (Longitudinal) Pedal free play (Transverse) 3 mm...
  • Page 863 04-4 2. TIGHTENING TORQUE Tightening torque Description Amount Upper (17 mm) 85.0 to 100 Nm 54.0 Nm + 20° Front (14 mm) Clutch housing bolt Rear (14 mm) 51.3 to 56.7 Nm Lower (14 mm) 56.0 to 62.0 Nm Pressure plate assembly bolt (Hexagon 6 mm) 21.0 to 27.0 Nm Concentric slave cylinder bolt (Hexagon 5 mm) 10 to 16 Nm...
  • Page 864 04-5 0000-00 1. OVERVIEW The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric slave cylinder fitted to the clutch housing as a hydraulic pressure. (The hydraulic pressure is transmitted in the following order: Clutch pedal - Clutch master cylinder - Clutch pipe - Clutch damper - 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.
  • Page 865 04-6 2. SATIC (SELF ADJUSTING TECHNOLOGY WITH INTEGRATED CASSETTE) 1) System Description ▶ Function On the conventional clutch, the pedal force tends to increase in proportion to the degree of disc run-out. However, the SATIC clutch has the adjusting function which activates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out.
  • Page 866 04-7 0000-00 2) Overview ▶ 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.
  • Page 867 04-8 3) Layout Clutch disc Clutch cover assembly Clutch setting jig Dual mass flywheel (DMF) Concentric slave cylinder...
  • Page 868 04-9 0000-00 3. DUAL MASS FLYWHEEL (DMF) The dual mass flywheel (DMF) is of having a mass divided into two halves. While one mass is connected to the engine crankshaft, which is affected by the mass moment of inertia of the engine, the other mass is affected by one of the transmission. The divided dual masses are connected to the coil spring and damping system internally.
  • Page 869 05-3 3310-02 1. SPECIFICATION Description Specification Structure 2-piece type with CV joint, spider, and rubber coupling Weight below 12.0 kg Joint type CV joint, spider, rubber coupling Spider Numbers one (installed on center bearing side) Ø24 mm External diameter Ø62.5 mm Overall size 1,069 x Ø60 mm Dimension...
  • Page 870 05-4 1. OVERVIEW The propeller shaft is a thin steel pipe which transfers the power from the transmission to the E- coupling, and has high resistance to torsion and bending. The propeller shaft has the universal joint (cross axle) mounted on the center of the shaft and splines for the slip joint on the E-coupling side to accommodate the height and length changes which occur as the shaft rotates at high speed.
  • Page 871 05-5 3310-02 2. COMPONENT End cap Plain washer VL joint assembly AL washer Washer Center bearing assembly Bolt Ball bearing Circlip Dust shield Clamp (big) Intermediate shaft Boot Fork yoke Clamp (small) Rubber coupling Stub shaft Alignment support Bending absorber Bolt Paper damper Washer...
  • Page 872 06-3 4110-01 1. SPECIFICATION Component Item Specifications Front drive Joint type Inside: Tripod joint shaft Outside: Ball joint 2WD, Inside: 23° Max. allowed angle Outside: 46° To compensate the bending Installation of equivalent angle length shaft Rear drive Joint type Inside: Cross groove joint shaft Outside: Ball joint...
  • Page 873 06-4 1. COMPONENT For AWD vehicle For 2WD vehicle Front drive shaft (LH) E-coupling - 4WD Front drive shaft (RH) Rear differential carrier - 4WD Intermediate shaft Rear drive shaft (LH) - 4WD Power transfer unit(PTU) - 4WD Rear drive shaft (RH) - 4WD Propeller shaft - 4WD...
  • Page 874 06-5 4110-01 2. TORQUE STEER Torque steer is a condition in which a vehicle pulls to either side because of an inequality of traction between the left and right driving wheels when a large torque is applied to the front wheel of a FWD or 4WD.
  • Page 875 06-6 3. REAR AXLE 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 and independently of each other with the universal joint and the slip joint.
  • Page 876 07-3 0000-00 1. SPECIFICATION Unit Description Specification Gear ratio 2.929 (Power Transfer Unit) Numbers of helical gear 22/39 Numbers of hypoid gear 23/38 IDEMITSU LW 80W/90 ≒ 0.58 L Oil capacity -40 to 150°C Operating temperature E-coupling Maximum torque 1,000 Nm -40 to 120°C Operating temperature Numbers of main clutch...
  • Page 877 07-4 1. OVERVIEW The AWD system in this vehicle is the electronic 4WD system and controls the traction to rear wheels according to the driving conditions. 1) Driving Mode (1) AUTO mode (Normal driving mode) Normally the vehicle is in 2WD mode. Automatically change to this mode when the vehicle needs higher traction.
  • Page 878 07-5 0000-00 2. SYSTEM LAYOUT E-coupling control unit PTU assembly E-coupling (located on the floor under driver seat) 1) Components (1) PTU (Power Transfer Unit) The power transfer unit in the front wheel drive model changes the angle of engine torque to 90° and transfer it to E-coupling to distribute the torque to rear wheels.
  • Page 879 07-6 The power transfer unit in the front wheel drive model changes the angle 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 Hypoid gear Helical gear...
  • Page 880 07-7 3270-01 2) Torque Flow and 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 881 07-8 1) Component E-coupling assembly Companion flange assembly E-coupling Drive pinion nut Bearing race assembly Wiring harness assembly Front cover Bolt Dust seal...
  • Page 882 07-9 3280-01 2) Sectional Diagram Companion flange X-ring Housing Rotor clutch Main clutch Pilot clutch Pressure plate Armature Ball Magnet Rubber coupling Drive pinion (to rear differential) Propeller shaft The housing is engaged with propeller shaft through companion flange and rubber coupling and turns with propeller shaft.
  • Page 883 07-10 3) Operation (1) When E-Coupling is not operating (2WD: No current to magnet) The torque from PTU is 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.
  • Page 884 07-11 3280-01 (2) When E-Coupling is operating (AWD: supplying current to magnet) The torque from PTU is transferred to housing through propeller shaft, rubber coupling and companion flange. As soon as the current is supplied to magnet, the magnet flux is generated in rotor clutch, pilot clutch and armature according to the amount of current.
  • Page 885 07-12 1) System Layout E-Coupling controls the clutch engagement force by the magnetic coil. E-Coupling determines the clutch engagement force according to CAN signals (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).
  • Page 886 07-13 3280-17 2) Circuit Diagram...
  • Page 887 07-14 3) Block Diagram of Input & Output...
  • Page 888 07-15 3280-17 4) System Protection for 4WD (1) Abnormal tire detection function If an abnormal tire installed, E-Coupling control unit reduces the torque to rear wheels. In this mode, E-Coupling operates as if it is in 2WD mode. E-Coupling control unit recognizes the abnormal tire by calculating the differences in CAN signals from wheel speed sensors.
  • Page 889 08-3 0000-00 1. SPECIFICATION System Description Specification Front Suspension type Macperson strut type suspension Spring type Coil spring Stabilizer type Torsion bar type Shock absorber Type Cylindrical reciprocation type Max. length (extended) 554 mm Min. length 372 mm (compressed) Min. length Inner diameter (A) Upper: 84.0 mm (compressed)
  • Page 890 08-4 1) Wheel Alignment System Description Specification 76.8 ± 5 mm Front Ground clearance (A) Trim height : wheel 433 mm center ↔ Wheel house -0.15 ± 0.5˚ Camber (maintenance free) 4.8 ± 0.5˚ Caster (maintenance free) 0.0 ± 0.1˚ Total toe-in (adjust by tie rod) 12.85˚...
  • Page 891 08-5 0000-00 2. TIGHTENING TORQUE ▶ Front suspension assembly...
  • Page 892 08-6 ▶ Rear suspension assembly...
  • Page 893 08-7 0000-00 1. OVERVIEW The suspension is the device to connect the axle 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 Front suspension...
  • Page 894 08-8 1) Front Suspension (Macperson Strut Type) Front suspension supports the vehicle weight and absorber the vibration from tires. And, in this type of suspension, the steering linkage tie rod is mounted on the knuckle. Macperson strut type suspension Macperson strut type suspension is the independent suspension which has the spring on the strut integrated with shock absorber.
  • Page 895 08-9 0000-00 2) Rear Suspension (Multi-link Type) Multi-link type suspension is the independent suspension. It provides good ride comfort and drivability by reducing the coil spring weight. Also, it increases the space for passenger compartment by lowering the floor. This type of suspension consists of multiple links such as trailing arm, upper arm, lower arm and track rod.
  • Page 896 08-10 1. SYSTEM LAYOUT 1) Front Suspension Damper strut assembly Lower arm Stabilizer bar assembly Stabilizer bar link...
  • Page 897 08-11 0000-00 2) Rear Suspension Shock absorber Stabilizer bar assembly Stabilizer bar link Coil spring and link Trailing/upper arm/track rod Upper arm Coil spring Trailing arm Coil spring link Track rod...
  • Page 898 08-12 Coil spring Lower arm The coil spring is made by The lower arm relieves the load to knuckle. winding solid steel rod to form This enables to absorb the various impacts the coil shape. Its energy according to the load shapes and to ensure absorption rate per weight is the drivability.
  • Page 899 08-13 4410-00 Damper/shock absorber assembly 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.
  • Page 900 08-14 A. Upper arm D. Track rod Upper arm is installed between knuckle and Track rod is installed between knuckle and sub frame and controls the lateral load and rear sub frame and controls and vehicle height. compensates the lateral load. Knuckle side Frame side B.
  • Page 901 08-15 4520-00 E. Stabilizer bar assembly If the spring with lower spring constant is applied on the vehicle in order to increase the 'ride comforts', the vehicle's slope increases on turning due to the centrifugal force. Because its trend increases for the independent suspension system, the stabilizer bar should be applied to the system in order to make a balance the vehicle.
  • Page 902 09-3 4850-00 1. SYSTEM OVERVIEW 1) Terms and Definition CBS: Conventional Brake System ABS: Anti-Lock Brake System EBD: Electronic brake-Force Distribution ESP: Electronic Stability 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...
  • Page 903 09-4 3) Parts Arrangement Vehicle with Vehicle with ESP Part name Vehicle with ABS/EBD HECU Front wheel speed sensor Applied Applied Rear wheel speed sensor ABS warning lamp EBD indicator Longitudinal G sensor 2WD: N/A, 4WD: Applied Not applied Not applied Sensor cluster (Yaw rate sensor, lateral/longitudinal G sensor)
  • Page 904 09-5 4850-00 4) Changes in Parking Brake Lever Assembly Parking brake lever assembly (A/T) The parking brake lever bracket has been changed to adopt the premium console. Parking brake lever assembly (M/T) The parking brake lever bracket has been changed to adopt the premium console.
  • Page 905 09-6 5) Component A. Meter cluster-ABS, EBD, ESP B. Master cylinder and C. HECU indicator/warning lamp booster ABS warning lamp Parking brake warning lamp ESP indicator D. Front brake assembly Caliper Disc E. Rear brake assembly Caliper Disc F. Front/rear wheel speed sensor G.
  • Page 906 09-7 4850-00 2. SPECIFICATION Unit Description Specification Front brake Type Ventilated disc Ø298 mm Outer diameter of disc Ø43.0 x 2 mm Inner diameter of caliper cylinder Thickness of disc 26 mm (wear limit: 24 mm) Thickness of brake pad 10.5 mm (wear limit: 2 mm) Pad wear indicator Mechanical type...
  • Page 907 09-8 1. OVERVIEW Even though a driver cuts off the power, while driving, the vehicle continues to move due to the law of inertia. Therefore, a braking device is needed to stop the vehicle. The brake system normally uses the frictional discs that converts the kinetic energy to the thermal energy by frictional operation.
  • Page 908 09-9 4850-00 2. SECTIONAL DIAGRAM ▶ Front disc brake Brake pad Wheel disc Brake caliper Brake hose Brake hub Drive shaft Brake disc Knuckle Brake hose bracket mounting bolt (12 mm): Shock absorber 9.8 ~ 12.8Nm Brake disc Air breather screw: 8.8 Back plate ~ 10.8Nm Brake hose bolt...
  • Page 909 09-10 ▶ Rear disc brake Wheel disc Caliper Brake hub Knuckle Brake hose Brake disc Brake disc 1) Tightening torque 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...
  • Page 910 09-11 4850-00 3. SYSTEM LAYOUT ▶ Hydraulic line Brake booster HECU (Hydraulic & Electric Control Unit) Brake reservoir and master cylinder Rear disc brake and caliper Front disc brake and caliper...
  • Page 911 09-12 4. CIRCUIT DIAGRAM OF STOP LAMP...
  • Page 912 09-13 4850-00...
  • Page 913 10-3 4890-00 1. SPECIFICATION Specification Unit Description Clock frequency 32 MHz 50 MHz HECU Memory 128 KB 512 KB Switch Orifice Orifice Wheel speed ABS / ESP sensor - 40°C to 150°C - 40°C to 150°C Operating temperature - 40°C to 115°C - 40°C to 115°C Operating frequency 1 to 2,500 Hz...
  • Page 914 10-4 ▶ Circuit diagram of wheel speed sensor ABS / ESP...
  • Page 915 10-5 4890-00 1. SYSTEM OVERVIEW 1) What is ABS? When braking suddenly or braking on slippery roads, the vehicle keeps moving forward but the wheels are locking and not rotating. If these happen, the vehicle may lose stability or rotate resulting in an accident.
  • Page 916 10-6 2. COMPONENT 1. ABS hydraulic device and control unit 2. ABS warning lamp Located under the power steering fluid reservoir and contains the pressure sensor. EBD warning lamp (ABS warning lamp + Brake warning lamp) 4. Wheel speed sensor 4.
  • Page 917 10-7 4890-00 ▶ HECU ECU (Electronic Control Unit) ECU calculates the wheel speed, acceleration and deceleration with the information from wheel speed sensor, and determines the wheel slip to control the valve and motor. HU (Hydraulic Unit) The hydraulic circuit contains the primary circuit and secondary circuit for ABS operation.
  • Page 918 10-8 ▶ G-sensor (only for 4WD) G-sensor For the vehicle with the ABS, a speed difference between the wheels is not noticeable as all the wheels are slipping during abrupt braking. Therefore, the vehicle needs the speed information from other sensors other than the wheel speed sensor.
  • Page 919 10-9 4890-00 3. ABS CONTROL LOGIC The principal ABS control logic is the determination of the reference speed by choosing one wheel meeting a certain condition, while sensing 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.
  • Page 920 10-10 4. WARNING LAMPS ABS warning lamp Brake warning lamp (EBD warning lamp: ABS warning lamp + Brake warning lamp) 1) ABS Warning Lamp ABS warning lamp module indicates the self diagnosis and malfunction. ABS warning lamp ON: When turning the ignition switch to ON position, ABS warning lamp comes on for 3 seconds for self-diagnosis and goes off if the system is OK (initialization mode).
  • Page 921 10-11 4890-00 2) EBD (Electronic Brake-force Distribution) Warning Lamp (Brake Warning Lamp) EBD warning lamp when the system performs the self diagnosis and when it detects the malfunction of EBD system. However, the brake warning lamp comes on regardless of EBD when the parking brake is applied.
  • Page 922 10-12 5. SYSTEM OPERATION 1) Block Diagram of ABS HECU...
  • Page 923 10-13 4890-00 2) Basic Theory of ABS Function To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles. (1) Stopping distance The stopping distance depends on the vehicle weight and initial speed when braking starts. This also applies for vehicle with ABS, where ABS always tries to set an optimum brake force on each wheel.
  • Page 924 10-14 ▶ Slip The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the slip is greatest, that is 100 %. If the wheel is running freely and un-braked, the slip is the lowest, equal to 0 %. Slip can be calculated from the vehicle speed Vveh and the wheel speed Vw.
  • Page 925 10-15 4890-00 ▶ KAMM circle Before we go into the Kamm circle, you should know that a tire offers a maximum of 100 % transmissibility. It is all the same for the tire whether we require 100 % in the direction of braking or in the direction of the acting lateral force, e.g.
  • Page 926 10-16 3) Basic ABS Control ▶ Operation of ABS control unit Applications of the ABS control unit The signals produced by the wheel sensors are evaluated in the electronic control unit. From the information received, the control unit must first compute the following variables: Wheel speed Reference speed Deceleration...
  • Page 927 10-17 4890-00 4) ABS Control Pattern The ABS control is performed by comparing 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 928 10-18 5) EBD (Electronic Brake Force Distribution) System ▶ System description As an add-on logic to the ABS base algorithm, EBD works in a range in which the intervention thresholds for ABS control are not reached yet. EBD ensures that the rear wheels are sensitively monitored for slip with respect to the front axle. If slip is detected, the inlet valves for the rear wheels are switched to pressure hold to prevent a further increase in pressure at the rear-wheel breaks, thus electronically reproducing a pressure-reduction function at the rear-wheel brakes.
  • Page 929 10-19 4890-00 6. HYDRAULIC CIRCUIT OF ABS 1) Normal Brake Operation (ABS is not working) Mode If the driver depress the brake pedal so that the ABS does not operate, the hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve.
  • Page 930 10-20 2) DUMP (ABS is working) Mode Even when the hydraulic pressure on each circuit is constant, the wheel can be locked as the wheel speed decreases. This is when the ABS HECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels.
  • Page 931 10-21 4890-00 3) HOLD (ABS is working) Mode As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the hydraulic valve modulator operates the inlet valve control solenoid to stop increasing the hydraulic pressure by closing the inlet valve.
  • Page 932 10-22 4) RISE (ABS is working) Mode As the wheel speed increases, the inlet valve opens and the wheel's pressure increases due to the master cylinder pressure. In addition, the pump circulates the oil in the low pressure chamber to the wheel. As the hydraulic 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.
  • Page 933 10-23 4890-00 7. CIRCUIT DIAGRAM...
  • Page 934 11-3 0000-00 1. SPECIFICATION Description Unit 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 None Max. detection angle speed: 1500 °/Sec sensor Operating voltage: 9 to 12 V...
  • Page 935 11-4 2) Specification of Steering Wheel Angle Sensor Description Specification Operating voltage 9 to 16 V Maximum output current 10 mA ±100°/Sec Maximum detection angle speed -30 to 75 ℃ Operating temperature Supplying voltage 9 to 16 V (battery voltage) Output voltage (HI) approx.
  • Page 936 11-5 0000-00 2. MAJOR CHANGES 1) Steering Wheel Angle Sensor SWAS (Steering Wheel Angle Sensor) Sensor connector Sensor connector 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.
  • Page 937 11-6 1. OVERVIEW The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer, understeer or cornering.
  • Page 938 11-7 0000-00 2. COMPONENTS 1. HECU assembly 2. Steering wheel angle 3. ESP OFF switch sensor Located under the power Located on column shaft with Located on the left side of steering fluid reservoir and contact coil. instrument panel. contains the pressure sensor. 5.
  • Page 939 11-8 3. PRECAUTIONS The warning lamp flashes and warning beep sounds when the ESP is operating When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flashes and beep comes on every 0.1 second. The ESP system is only a supplementary device for comfortable driving.
  • Page 940 11-9 0000-00 4. WARNING LAMPS ABS warning lamp Brake warning lamp ESP OFF indicator ESP warning lamp/indicator EBD warning lamp 1) ABS ABS warning lamp module indicates the self-diagnosis and malfunction. ABS warning lamp ON: Warning Lamp When turning the ignition switch to ON position, ABS warning lamp comes on for 3 seconds for self-diagnosis and goes off if the system is OK (initialization mode).
  • Page 941 11-10 2) EBD (Electronic Brake-force Distribution) Warning Lamp (Brake Warning Lamp) EBD warning lamp when the system perform the self diagnosis and when it detects the malfunction of EBD system. However, the brake warning lamp comes on regardless of EBD when the parking brake is applied.
  • Page 942 11-11 0000-00 5. SYSTEM DESCRIPTION 1) Block Diagram of ESP HECU...
  • Page 943 11-12 2) Operation of ESP System The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer, understeer or cornering.
  • Page 944 11-13 0000-00 ▶ ESP controls during understeer The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeer with the yaw rate sensor and lateral sensor. Then, the ESP system applies the braking force to the rear inner wheel to compensate the yaw moment value.
  • Page 945 11-14 3) Vehicle Control During Cornering The figure below shows the vehicle controls by the ESP system under various situations such as when the brake 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.
  • Page 946 11-15 0000-00 4) HBA (Hydraulic Brake Assist System) (1) Purpose HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster.
  • Page 947 11-16 5) ARP (Active Roll-Over Protection) The ARP (Active Roll-over Protection) system is a safety assistant device that minimizes, by controlling brakes and the engine, the physical tendency of the vehicle rollover during sharp lane changes or U-turns. For the system, software is added to the existing ESP system and no additional device or switch is needed.
  • Page 948 11-17 0000-00 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 949 11-18 7) Emergency Hazard Flasher Control (Coupled with ABS) (1) System layout (2) Emergency stop signal function When ABS system is operating (or sudden braking), the hazard warning flashers will blink for 10 seconds to inform the emergency situation to the 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...
  • Page 950 11-19 0000-00 The BCM flashes the emergency auto hazard flasher with interval of 1.25 times/sec.: The emergency hazard flasher does not operate if the vehicle speed is over 50 km/h when the emergency stop signal is received. The emergency hazard flasher operates if the vehicle speed is 50 km/h or lower when the emergency stop signal is received.
  • Page 951 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 952 11-21 0000-00 ▶ Circuit description When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes, the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet valve are closed.
  • Page 953 11-22 1) Idling and Normal Braking Condition In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel via the separation valve and inlet valve.
  • Page 954 11-23 0000-00 2) DUMP (ESP is working) Mode The pressure decreases just before the wheel speed drops and the wheels are locked. The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
  • Page 955 11-24 3) HOLD (ESP is working) Mode The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more.
  • Page 956 11-25 0000-00 4) RISE (ESP is working) Mode The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is operated. When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the corresponding wheel gets locked.
  • Page 957 11-26 5) Hydraulic Circuit of HBA The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels.
  • Page 958 11-27 0000-00 7. CIRCUIT DIAGRAM ▶ Wheel speed sensor, Stop lamp switch, Self diagnostic connector, Warning lamp (ABS/ESP)
  • Page 959 12-3 0000-00 1. SPECIFICATION (HPS) Component Item Specification Steering wheel Type 3-spoke Φ 380 mm Outside diameter Number of revolutions 3.11 rotations Heated wire Simple ON/OFF Gear box Type Rack and pinion Gear ratio 46.94 ± 73 mm Rack stroke 39°...
  • Page 960 12-4 2. TIGHTENING TORQUE Item Tightening torque Remark 1. Power steering reservoir mounting bolt 8.8 to 13.7 Nm 12 mm x 2 EA 25 ± 2.5 Nm 2. Power steering Upper mounting bolt/nut 13 mm x 1 EA pump 25 ± 2.5 Nm Lower mounting bolt 12 mm x 2 EA 3.
  • Page 961 12-5 0000-00 3. DIFFERENCES BETWEEN HPS AND EPS HPS (Hydraulic Power Steering) EPS (Electric Power Steering) Crankshaft pulley (DDU) Auto tensioner Tensioner pulley Vacuum pump A/C compressor pulley Alternator pulley Water pump pulley No.1 idle pulley No.2 idle pulley Power steering pump...
  • Page 962 12-6 4. MAJOR CHANGES 1) Steering Heating System Steering wheel heating unit Lower switch cluster Steering wheel heating unit The steering wheel heated wire and the heating unit are installed in the steering wheel assembly. Steering wheel heating switch The steering wheel heating switch has been added on the lower switch cluster.
  • Page 963 12-7 0000-00 1. SYSTEM DESCRIPTION The power steering has been designed to make the wheel move more easily than in a manual steering system. The hydraulic power assists the process utilizing hydraulic fluid. The fluid increases pressure in the power steering pump and aids the movement of the steering mechanism.
  • Page 964 12-8 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. Installation of power steering pump Installation of reservoir and hose and pipe...
  • Page 965 13-3 4610-00 1. SPECIFICATION Unit Description Specification System operation Operating type Motor driven power steering system - 40°C to 80°C Operating temperature Rated voltage 12 V Rated current 85 A Operating voltage Network 8 to 16 V C-EPS ECU 8 to 16 V Full Performance 10 to 16 V Type...
  • Page 966 13-4 2. TIGHTENING TORQUE...
  • Page 967 13-5 4610-00 3. DIFFERENCES BETWEEN HPS AND EPS HPS (Hydraulic Power Steering) EPS (Electric Power Steering) Crankshaft pulley (DDU) Auto tensioner Tensioner pulley Vacuum pump A/C compressor pulley Alternator pulley Water pump pulley No.1 idle pulley No.2 idle pulley Power steering pump...
  • Page 968 13-6 1. OVERVIEW The electric power steering, EPS, does not have any belt-driven steering pump constantly running, so it is lightweight and the motor consumes energy only when the steering wheel is turned by the driver, and this leads to improvement in fuel efficiency. Also, the elimination of a belt-driven pump and its accessories greatly simplifies manufacturing and maintenance.
  • Page 969 13-7 4610-00 2. OPERATION Output torque = 1) Steering force (manual torque) + 2) Assist torque When the driver turns the steering wheel, a torque is generated and the torque sensor and the steering angle sensor in the EPS system detect the rotation of the steering column to run the electric motor.
  • Page 970 14-3 4170-00 1. SPECIFICATION Description Specification Remark 16 inch 215 / 65R 16 Standard Tire 17 inch 225 / 60R 17 Optional 18 inch 225 / 55R 18 Optional Tire inflation pressure 32psi 16 inch 6.5 J X 16 Standard Wheel 17 inch 6.5 J X 17...
  • Page 971 14-4 1. OVERVIEW A radial tire uses a cord angle of 90 degrees. That is, the cord material runs in a radial or direct line from one bead to the other across the tread. In addition, a radial tire has a belt overwrap under the tread surface to provide greater structural stability.
  • Page 972 14-5 4170-00 2) Tire Unit Indication Aspect ratio (%) = Nominal section height (H) / Nominal section width (W) X 100 3) Tire Inflation Pressure (32 psi) Proper inflation pressure Excessive inflation pressure Low inflation pressure Tread width Tread width Tread width The contact area between the The contact area between the...
  • Page 973 14-6 2. ABNORMAL TIRE SYMPTOM 1) Standing Wave 32psi Specified tire inflation pressure During driving, the rotating tire repeats deformation and restoring movement in is tread. This happens when the tire pressure is low in high speed driving. However, when the wheel rotating speed is fast, the tire is deformed even before it is restored to its original shape and the trembling wave appears on the tread portion.
  • Page 974 14-7 4170-00 2) Hydro Planing When the vehicle is driven on a road surface covered with water at high speed, tires do not contact 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.
  • Page 975 14-8 3. WHEEL BALANCE If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic.
  • Page 976 15-3 4012-00 1. SPECIFICATION Unit Construction Front sub Body mounting: frame 4-points bush Transaxle mounting: 2-points bush Weight: 22.37 kg Rear sub Body mounting: frame (4WD) 4-points bush Axle mounting: 4-points bush Weight: 16.61 kg Rear sub Body mounting: frame (2WD) 40 points direct mounting Spring link:...
  • Page 977 15-4 2. TIGHTENING TORQUE ▶ Front sub frame - based on 4WD 1. Transaxle mounting (Front) Bolt (17 mm) / 68.6 to 88.2 Nm Nut (17 mm) 2. Front mounting (LH & RH) 88.2 to 107.8 Nm Bolt (17 mm) 3.
  • Page 978 15-5 4012-00 ▶ Rear sub frame - based on 4WD 5. Front mounting (LH & RH) 88.2 to 107.8 Nm Bolt (17 mm) 6. Rear mounting (LH & RH) Bolt (17 mm) 88.2 to 107.8 Nm 7. Rear axle mounting 8.
  • Page 979 15-6 1) Sectional Diagram and Bolts for Front Sub Frame Installation Sectional diagram 1. Front 2. Rear Mounting bracket Mounting bolt 3. Transaxle mounting (Front) For manual transaxle For automatic transaxle (diesel) Mounting nut 29.4 to 39.2 Nm 4. Transaxle mounting (Rear) 9.4 to 39.2 Nm Bolt...
  • Page 980 15-7 4012-00 2) Sectional Diagram and Bolts for Rear Sub Frame Installation Sectional structure 1. Front 2. Rear 3. Rear axle - Front (4WD) 4. Rear axle - rear (4WD)
  • Page 981 15-8 The front sub frame consists of 4 body bush mountings(A) and 2 engine bush mountings(B) which reduce the vibration from the powertrain and road, and also control the torque. And the two engine bush mountings consist of an engine mounting which supports the engine powertrain and a transmission mounting.
  • Page 982 15-9 4015-01 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 consists of 4 body mountings (direct mountings).
  • Page 983 01-3 6810-00 1. SPECIFICATION Description Specification Core size (㎣) Heater 200 x 165.5 x 25 Capacity (kcal/h) 4,800 Core size (㎣) Evaporator 254.8 x 196.75 x 60 Capacity (kcal/h) 4,700 Blower Supply power (W) 240 + 10% Max (at 12 V) 2900±200 Max Fan speed (rpm) (Rec.Mode: 420㎥/h)
  • Page 984 01-4 2. MAJOR CHANGES 1) Heater & Evaporator Module (Wiring Specification) Ambient temperature sensor signal Blower max signal wiring added wiring added to vehicle wiring to vehicle wiring connecting connecting connector (2 circuits) connector (1 circuit) : manual A/C : manual A/C & FATC Manual A/C: Wiring pin added to controller assembly connector FATC: Wiring pin added to existing connector of controller assembly The driving circuit for the manual A/C ambient temperature sensor is added, giving the change to...
  • Page 985 01-5 6810-00 2) Manual A/C Controller Manual air conditioner controller Previous Current Connector added The driving circuit for the ambient temperature sensor is added to the manual air conditioner controller for ambient temperature display on the instrument cluster. Pin No. Function Water temp.
  • Page 986 01-6 1. SYSTEM LAYOUT Line & port Low pressure hose High pressure hose Electric fan A/C condenser & receiver drier A/C compressor Integrated receiver drier...
  • Page 987 01-7 6810-00 FATC Incar sensor Sun-load sensor Refrigerant pressure sensor Engine ECU Ambient temperature sensor...
  • Page 988 01-8 2. HEATER AND A/C CONTROL 1) Full Automatic A/C Control Temperature dial Fan speed dial Mode dial Recirculation switch A/C switch ▶ Temperature dial Temperature dial To adjust the temperature, turn this dial as required. Turning the dial to HI increases the temperature and LO decreases the temperature.
  • Page 989 01-9 6810-00 ▶ Mode dial The air flow direction can be controlled by turning the dial. Face/Foot-Level Foot-Level (bi-level mode) (foot mode) Foot/Defrost-level (foot/defrost mode) Face-Level (vent mode) Defroster switch Use this switch to remove for Airflow is changed or ice from the windshield. automatically according to When choosing this mode, the the setting temperature.
  • Page 990 01-10 2) Manual A/C Control Fan speed dial Mode dial Temperature dial A/C switch Recirculation switch ▶ Fan speed dial Fan speed dial The fan speed can be adjusted by rotating the switch. To stop the operation, A/C switch turn the dial to the "OFF" position.
  • Page 991 01-11 6810-00 ▶ Mode dial Foot-Level (foot mode) Face/Foot-Level (bi-level mode) Foot/Defrost-level (Foot & defrost mode) Face-Level (vent mode) Defrost mode Use this switch to remove fog or ice from the windshield. When pressing this switch, the airflow direction will be changed to windshield and door glasses, the A/C is operated automatically and the air source mode is set to fresh air mode.
  • Page 992 01-12 3. A/C COOLING CYCLE 1) System flow "Compression -> Condensation -> Expansion -> Evaporation" 2) Functions (1) Compressor Condition: Gas Function: Circulates the refrigerant and increases the pressure and temperature for easier evaporation. (2) Condenser Condition: Gas/Liquid Function: Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure.
  • Page 993 01-13 6810-00 3) Description for Each Cycle (1) Compression The evaporated refrigerant in the evaporator enters to the compressor. And the refrigerant gas is compressed until it can be liquefied at ambient temperature. Thus, the low refrigerant pressure is maintained so that the liquid refrigerant can be evaporated actively at low temperature (around 0℃).
  • Page 994 01-14 4. A/C COOLING CIRCUIT...
  • Page 996 01-16 5. CIRCUIT DIAGRAM...
  • Page 997 01-17 6810-00...
  • Page 998 02-3 8810-00 1. SPECIFICATIONS Operating voltage 9 to 16 V System diagnosis and SDM self diagnosis voltage 9 to 16 V Ignition voltage for side air bag and pretensioner 9 to 16 V Communication voltage for front impact sensor 9 to 16 V Communication voltage for side impact sensor 9 to 16 V -40℃...
  • Page 999 02-4 3. OPERATING CONDITIONS A. Front Air Bag System ▶ The air bag deploys when: A front collision occurs, which occupants cannot be protected by seat belt. ▶ The air bag can deploy when: Underbody impact 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.
  • Page 1000 02-5 8810-00 2) Side Air Bag System ▶ Curtain air bag The curtain air bags are installed to the upper end of both doors. The air bags provide head protection for the front and rear outboard occupants in a side collision. ▶...
  • Page 1001 The air bag warning lamp is illuminated for 3 to 7 sec. after the engine is started to check the system. Drive the vehicle after this warning lamp is turned off. If this warning lamp stays ON, the system may be defective. Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Center.
  • Page 1002 02-7 8810-00 As the air bag system is very hot after being deployed, allow at least 30 minutes for the system to cool down sufficiently before touching it. It can cause serious burns. When an occupant fastens the seat belt in an unstable or inclined posture, the air bag system cannot protect the occupant properly.
  • Page 1003 02-8 4. CAUTIONS FOR AIR BAG OPERATION When turning on the ignition switch, the air bag warning lamp is illuminated for about 6 sec. and then goes off. If the air bag warning lamp comes on or does not go off while the vehicle is driven, the air bag system is faulty.
  • Page 1005 02-10 1. SYSTEM CONFIGURATION Passenger air bag module Driver air bag module SDM unit assembly Driver side air bag Seat Belt Pretensioner...
  • Page 1006 02-11 8810-00 Height adjuster Front impact sensor assembly Air bag warning lamp (IP) Side air bag sensor assembly Inflatable curtain air bag module...
  • Page 1007 02-12 2. OPERATING CONDITIONS Once the ignition starts, the SDM starts to diagnose the air bag system during the ignition process. If the system is OK, the SDM is armed for a specific impact on the vehicle. The ignition time takes about 6 sec.
  • Page 1008 02-13 8810-00 3. DEPLOYMENT 1) Air Bag System Deployment (Firing Loop) According to the collision deceleration rate 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.
  • Page 1009 02-14 2) Air Bag Deployment Signal Output (Crash Out) When a situation which requires air bag deployment occurs, they system outputs the air bag deployment signal (crash out). If another air bag-required situation occurs while the deployment signal is sent, the second crash out will be delayed until the current 200 ms crash out is completed.
  • Page 1010 02-15 8810-00 ▶ Collision signal interface The open collector driver raises or lowers the voltage of the pin no. 58 by switching on and off the drive transistor. The vehicle module can be operated normally only by the logic of open collector interface and can be maintained in a pull-up state.
  • Page 1011 02-16 3) CAN Communication Interface (FIS and SIS) The CAN communication interface uses the PWM for the supply current and the current loop and communicates with the SDM to transmit the information. The serial communication and power for the satellite are supplied through the communication line. Stage Initial stage Tracking/Check (Self test)
  • Page 1012 02-17 8810-00 4. AIR BAG WARNING LAMP OPERATIONAL CONDITIONS ▶ When there are no active and past faults The air bag warning lamp is operated as shown below if there is no fault occurred in the previous ignition cycle and the SDM is running without any active fault right after starting the ignition cycle. ▶...
  • Page 1013 02-18 ▶ When there is any active fault or past faults occurred 10 times or more If there is any active fault or past faults occurred 10 times or more in the last ignition cycle, the SDM operates the warning lamp as shown below. If below conditions are met, the SDM is operated in the same way.
  • Page 1014 02-19 8810-00 5. CIRCUIT DIAGRAM ▶ 8810-01 Air bag (Curtain air bag/Side air bag)
  • Page 1015 03-3 7410-00 1. SPECIFICATIONS Front heated Front heated Pin No. Rear seats (passenger seat) (driver seat) Type Manual Manual 6 steps Manual 4 steps 4:6 split Automatic Power (Electric) 6 steps ±25 mm Height adjuster Manual (pumping type) ± 25 mm Automatic Sliding 240 mm...
  • Page 1016 03-4 2. WARNINGS FOR POWER SEAT ▷ Adjust the driver's seat before driving. ▷ Make sure that the seat is firmly secured after adjusting. ▷ Never drive the vehicle with the head restraint removed or lowered excessively. Otherwise, your neck, spine or other parts of the body can be severely injured in the event of an accident.
  • Page 1017 03-5 7410-00 4. MAJOR CHANGES 1) Rear Center Seat Belt Rear center seat belt Previous Current 2-point type 3-point type 2) Front Seat Back Board Front seat back board Previous Current Hook: Installed Hook: Not installed Pocket: Net type Pocket: Fabric seat - Net type Leather seat - Band type...
  • Page 1018 03-6 3) Front Buckle Driver's Front buckle Front buckle Previous Current Pad is attached to buckle No pad is attached to buckle...
  • Page 1019 04-3 7340-00 1. SPECIFICATIONS 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 1.4 ± 0.5 sec./100 mm (at opening and closing) Current for 25 A or higher and torque (load) for 7.5 Nm Motor overload stop conditions...
  • Page 1020 04-4 1. SYSTEM LAYOUT OPEN TILT Sunroof switch Sunroof assembly Sunroof motor & control unit...
  • Page 1021 04-5 7340-00 2. OPERATING PROCESS 1) Sunroof Switch ▶ Sunroof switch The sunroof switches are included in the overhead console switches and consists of the TILT, CLOSE and OPEN switches. ▷ TILT Opens only rear section of the sunroof. ▷ CLOSE Closes the sunroof.
  • Page 1022 04-6 2) Sunroof Sliding Opening/Closing Open: 2-step open Push up the switch 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.
  • Page 1023 04-7 7340-00 3) Sunroof Tilt Up/Down This function is to raise or lower the rear section of the sunroof. Tilt Up Pull down the switch The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof closed.
  • Page 1024 04-8 4) Sunroof Safety Function To prevent any body parts from being trapped by the sliding sunroof, an Anti-Pinch Function automatically opens the sunroof when an object is trapped. 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.
  • Page 1025 04-9 7340-00 3. SUNROOF OPEN WARNING 1) Warning Sound When removing the key and then opening the door with the sunroof open, the warning sound is heard. Closing the door stops the warning sound. 2) Message on Instrument Cluster The following message is displayed on the screen in the instrument cluster. Supervision type General precaution for sunroof Even though the sunroof can be operated when the engine is not running, operating the...
  • Page 1026 04-10 4. ZERO POINT SETTING If the sunroof is stopped midway due to a discharged battery or power failure, you need to re- calibrate the starting point of the sunroof. In addition, the following cases need reset of the starting point for the sunroof.
  • Page 1027 04-11 7340-00 5. CIRCUIT DIAGRAM...
  • Page 1028 05-3 5110-01 1. MAJOR CHANGES 1) Luggage Lid Front view Previous Current Latch type Band type Rear view Previous Current No anchor system for keeping lid open Retaining hook...
  • Page 1029 06-3 5110-00 1. MAJOR CHANGES 1) Radiator Grille Radiator grille Previous Current Grille mesh Grille mesh The radiator grille mesh type is changed to chrome plated grille.
  • Page 1030 GENERAL INFORMATION 1. 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..........

  • Page 1032: Major Dimension

    07-3 5110-01 1. MAJOR DIMENSION Top view Side view Front side Rear view...

  • Page 1033: Jack Points

    07-4 2. JACK POINTS 1) 2WD...
  • Page 1034 07-5 5110-01 2) 4WD...

  • Page 1035: Sealing Application Points

    07-6 3. SEALING APPLICATION POINTS 1) Dash Panel, Engine Tunnel, Floor, Etc.
  • Page 1036 07-7 5110-01 2) White Body...
  • Page 1037 07-8...
  • Page 1038 07-9 5110-01 3) Front & Rear Door Panel...
  • Page 1039 07-10 4) Engine Hood Panel...

  • Page 1040: Deadener Application Points

    07-11 5110-01 4. DEADENER APPLICATION POINTS...

  • Page 1041: Under Coating

    07-12 5. UNDER COATING...

  • Page 1042: Major Welding Points

    07-13 5110-01 6. MAJOR WELDING POINTS 1) Cross Sectional View of Major Panels...
  • Page 1043 07-14 2) Side Panel...
  • Page 1044 07-15 5110-01 3) Front Panel...
  • Page 1045 07-16 4) Apron Panel...
  • Page 1046 07-17 5110-01 5) Dash & Cowl Panels...
  • Page 1047 07-18 6) Front H-Frame Panel...
  • Page 1048 07-19 5110-01 7) Front Floor Panel...
  • Page 1049 07-20 8) Rear Floor Panel...
  • Page 1050 07-21 5110-01 9) Rear End Panel...
  • Page 1051 07-22 10) Roof Panel...

  • Page 1052: Major Body Dimensions

    07-23 5110-01 7. MAJOR BODY DIMENSIONS 1) Under Body Unit: mm...
  • Page 1053 07-24 2) Vehicle Structure Unit: mm...
  • Page 1054 07-25 5110-01 3) Side Structure Unit: mm...
  • Page 1055 07-26 4) Windshield Glass Area Unit: mm...
  • Page 1056 07-27 5110-01 5) Tail Gate Area Unit: mm...
  • Page 1057 07-28 6) Front End Unit: mm...
  • Page 1058 07-29 5110-01 7) Engine Compartment Unit: mm...
  • Page 1059 07-30 8) Back Panel Unit: mm...

  • Page 1060: Gap Chart

    07-31 5110-01 8. GAP CHART 1) Side Body Unit: mm...
  • Page 1061 07-32 2) Front Unit: mm...
  • Page 1062 07-33 5110-01 3) Rear Unit: mm...

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