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SSANGYONG ACTYON 2010.01 Manual

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1. DIMENSIONS........................................

2. SPECIFICATIONS.................................

3. VEHICLE IDENTIFICATION...................

4. MAINTENANCE INTERVAL...................

5. RECOMMENDED FLUIDS AND

LUBRICANTS........................................

6. JACK-UP POINTS (DOTTED CIRCLES).

7. PIN ARRANGEMENT OF DIAGNOSTIC

CONNECTOR........................................

8. ELECTRIC COMPONENTS AND

LAYOUT................................................

9. STANDARD BOLTS SPECIFICATIONS.

3

1. MAJOR CHANGES...............................

4

6

7

11

12

13

14

16

GENERAL

0000-00

GENERAL

18

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Summary of Contents for SSANGYONG ACTYON 2010.01

Page 1: Table Of Contents
GENERAL 0000-00 GENERAL GENERAL MODIFIED ITEMS 1. DIMENSIONS........1. MAJOR CHANGES....... 2. SPECIFICATIONS......... 3. VEHICLE IDENTIFICATION....4. MAINTENANCE INTERVAL....5. RECOMMENDED FLUIDS AND LUBRICANTS........6. JACK-UP POINTS (DOTTED CIRCLES). 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR........8. ELECTRIC COMPONENTS AND LAYOUT..........9.
Page 2 0000-00 GENERAL undefined...
Page 3: General
0000-00 4110-01 GENERAL GENERAL 1. DIMENSIONS GENERAL undefined...
Page 4: Specifications
0000-00 2. SPECIFICATIONS GENERAL undefined...
Page 5 0000-00 GENERAL undefined...
Page 6: Vehicle Identification
0000-00 3. VEHICLE IDENTIFICATION Engine Number (G23D) Chassis Number The engine number is stamped on the The chassis number is stamped on upper rear left-hand side of the cylinder the frame behind the front right tire. block. Engine Number (D20DT) Vin Label Certification Label The engine number is...
Page 7: Maintenance Interval
0000-00 4. MAINTENANCE INTERVAL 1) Diesel Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
Page 8 0000-00 * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) ENGINE CONTROL SYSTEM Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. Replace or change. (3)* Refer to "Recommended fluids and lubricants".
Page 9 0000-00 2) Gasoline Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
Page 10 0-10 0000-00 * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. Replace or change.
Page 11: Recommended Fluids And Lubricants
0-11 0000-00 5. RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants. Do not mix any different types or brands of oils or fluids. This may cause damages. Keep the specified levels when adding or replacing the fluids.
Page 12: Jack-Up Points (Dotted Circles)
0-12 0000-00 6. JACK-UP POINTS GENERAL undefined...
Page 13: Pin Arrangement Of Diagnostic Connector
0-13 0000-00 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR It is installed under the instrument panel and consists of 16 pins 1) Functions of Terminal GENERAL undefined...
Page 14: Electric Components And Layout
0-14 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement GENERAL undefined...
Page 15 0-15 0000-00 2) Components Locator GENERAL undefined...
Page 16: Standard Bolts Specifications
0-16 0000-00 8. STANDARD BOLTS SPECIFICATIONS GENERAL undefined...
Page 17 0-17 0000-00 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 18: Modified Items
0-18 0000-00 MODIFIED ITEMS 1. MAJOR CHANGES Air vents changed 3722-02 Shift lever changed The appearance of the shift lever has Chrome paint is applied to the airflow been changed. direction control lever. Parking brake lever changed The thickness and the appearance of the lever have been changed for grip comfort.
Page 19 ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT....2. ENGINE CONTROLS LAYOUT....3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM....4. INTAKE SYSTEM LAYOUT....5. EXHAUST SYSTEM LAYOUT....6. LUBRICATION SYSTEM LAYOUT..7. COOLING SYSTEM LAYOUT....8. FUEL SYSTEM LAYOUT....... 9.
Page 21: General
01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL undefined...
Page 22 01-4 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL undefined...
Page 23: Engine Controls Layout
01-5 0000-00 2. ENGINE CONTROLS LAYOUT 1) ECU Related Componets FUNCTION FUNCTION Coolant reservoir HFM sensor VGT turbo charger Engine oil dipstick Engine Oil separator(PCV valve ) Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter &...
Page 24 01-6 0000-00 2) Engine And Sensors Camshaft Position Sensor Injector Glow Plug Fuel Pressure Sensor Booster Pressure Sensor Common Rail (Common Rail) ENGINE GENERAL undefined...
Page 25 01-7 0000-00 HP Pump Knock Sensor (1 EA) & Crankshaft Vacuum Modulator Water Temperature Sensor Position Sensor Water temp. sensor Knock sensor ENGINE GENERAL undefined...
Page 26 01-8 0000-00 3) Engine Accessories Related to ECU IP Interior Fuse Box (Passenger Side) Installed Engine ECU main relay Hazard warning lamp VGT & EGR vacuum modulators, HFM HP pumpIMV Engine ECU Mounting Location ENGINE GENERAL undefined...
Page 27 01-9 0000-00 HFM Sensor Accelerator Pedal Module Fuel Filter Sensor Integrated with 2 PPSs Priming Fuel Pump Filter Service Interval (Fuel Filter) Replace every 30,000 km (Draining water from fuel filter: Only whenever replacing the engine oil) Replace every 25,000 km General (Draining water from fuel filter: whenever replacing the engine oil)
Page 28: Electrical Components And Preheating System
01-10 0000-00 3. ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Battery Preheat Warning Lamp Glow Plug (Cluster) Engine compartment Alternator Starter motor fuse box PTC / FFH: 12V - 2.2kw 12V - 115A ENGINE GENERAL undefined...
Page 29 01-11 0000-00 Preheat Control Unit FUNCTION Glow plug terminal (#1 ~ #4) No G5 for 4 cylinders (Without D20DT) IG1 power supply terminal Glow plug control signal (ECU113) Ground terminal Battery main wire Preheat completion transmit terminal : No use for vehicle without remote engine start K-line (ECU 34) ENGINE GENERAL...
Page 30: Intake System Layout
01-12 0000-00 4. INTAKE SYSTEM Intake outlet hose Air cleaner Front air duct Terbocharger intercooler Supplying Compressed Air with Intake Manifold Turbocharger's Operation To corresponding cylinders Coolant port Air cleaner Inter cooler Turbo charger From intercooler ENGINE GENERAL undefined...
Page 31 01-13 0000-00 Recirculation of Exhaust Gas when Turbocharger Intercooler EGR Valve Operates EGR valve Intake com pressed air Exhaust gas HFM Sensor Plug-in sensor Temperature Pretension Air cleaner Turbo - charger - Sensor graph ENGINE GENERAL undefined...
Page 32: Exhaust System Layout
01-14 0000-00 5. EXHAUST SYSTEM EEGR Pipe Passage for recirculation of exhaust gas DOC (Diesel Catalytic Converter) Exhaust Manifold To turbo - To EGR charger pipe From cylinders ENGINE GENERAL undefined...
Page 33 01-15 0000-00 VGT Turbocharger EGR Valved Vacuum modulator To exhaust Intake com - pipe (DOC) pressed air Exhaust Exhaust gas manifold PCV Oil Separator Turbocharger Vacuum Modulator Cylinder head cover (oil + gas) Blow-by gas Vacuum (air duct hose) pump Inlet port Turbo - charger...
Page 34: Lubrication System Layout
01-16 0000-00 6. LUBRICATION SYSTEM Oil dipstick gauge Cylinder Head Cover Oil Pressure Warning Lamp (Cluster) Oil Pan and Baffle Plate (Integrated Type) Oil Strainer ENGINE GENERAL undefined...
Page 35 01-17 0000-00 Oil Filter & Oil Cooler PCV Oil Separator Cylinder head cover (oil + gas) Blow-by gas cooler filter (air duct hose) Inlet port (oil gauge pipe) The first separation will happen when blow- by gas passes through baffle plates in cylinder head cover.
Page 36: Cooling System Layout
01-18 0000-00 7. COOLING SYSTEM Coolant reservoir Coolant inlet hose Return hose Coolant outlet hose PWM electric Radiator Coolant Port Water Pump & Pipe Thermostat (inside) Coolant - Cylinder outlet port Radiator block Reservoir (Coolant inlet hose) Radiator Assembly Cooling Fan and Fan Clutch ENGINE GENERAL undefined...
Page 37 01-19 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL undefined...
Page 38: Fuel System Layout
01-20 0000-00 8. FUEL SYSTEM HP Pump Injector Fuel Filter & Priming Pump Priming pump Fuel filter Connector HP Pump Fuel return port Fuel return port Fuel tempera - ture sensor Venturi IMV connector IMV valve High pres - sure fuel supply port Low pres - sure fuel supply port ENGINE GENERAL undefined...
Page 39 01-21 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL undefined...
Page 40: Fuel Supply System
01-22 0000-00 9. FUEL SUPPLY SYSTEM According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals.
Page 41: Cleanness
01-23 0000-00 10. CLEANNESS 1) 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 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.
Page 42 01-24 0000-00 2) Job Procedures 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 43 01-25 0000-00 Follow the job procedures. If you find a defective component, replace it with new one. Disconnect the negative battery cable. For safety reasons: check pressure is low before opening the HP systems (pipes) Use special tools and torque wrench to perform the correct works. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones.
Page 44 01-26 0000-00 Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. Clear the high pressure offset value by SCAN-100 after replacing high pressure pump. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.
Page 45 01-27 0000-00 3) 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 46: Maintenance And Repair
01-28 0000-00 11. MAINTENANCE AND REPAIR 1) Maintenance And Lubrication ▶ Normal Vehicle Use The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to "Wheels and Tire"...
Page 47 01-29 0000-00 ▷ Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. Brake System Service ▷ Check the disc brake pads or the drum brake linings.
Page 48: Guidelines For Service Work Safety
01-30 0000-00 12. GUIDELINES FOR SERVICE WORK SAFETY 1) General To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures. Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service...
Page 49 01-31 0000-00 2) Cautions on Inspection/Service During service works, be sure to observe below general items for your safety. For service works, be sure to disconnect battery negative (-) terminal if not starting · and inspection. While inspecting vehicle and replacing various consumable parts, be sure to take ·...
Page 50 01-32 0000-00 3) 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 51 01-33 0000-00 ▶ Fuel and lubrication system Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system.
Page 52: During Service Work For Inspection
01-34 0000-00 13. DURING SERVICE WORK FOR INSPECTION Before lifting up the vehicle with lift, correctly support the lifting points and lift When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work.
Page 53 01-35 0000-00 Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new. If reused, normal functions cannot be maintained. Align the disassembled parts in clean according to disassembling order and group for easy assembling. According to installing positions, the bolts and nuts have different hardness and design.
Page 54: During Service Work For Electric Devices
01-36 0000-00 14. DURING SERVICE WORK FOR ELECTRIC DEVICES Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key.
Page 55: Owner Inspections And Services
01-37 0000-00 15. OWNER INSPECTIONS AND SERVICES 1) While Operating The Vehicle ▶ Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. ▶ Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking.
Page 56 01-38 0000-00 2) At Each Fuel Fill A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately. ▶ Engine Oil Level Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
Page 57 01-39 0000-00 5) At Least Twice A Year Power Steering System Reservoir Level ▶ Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 4G, Power Steering System. Brake Master Cylinder Reservoir Level ▶...
Page 58 01-40 0000-00 7) At Least Annually Lap and Shoulder Belts Condition and Operation ▶ Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors. Movable Head Restraint Operation ▶ On vehicles with movable head restraints, the restraints must stay in the desired position. ▶...
Page 59: Standard Bolts Specifications
01-41 0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL undefined...
Page 60 01-42 0000-00 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 61 02-2 1212-01 1212-01 ENGINE ASSEMBLY GENERAL 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
Page 62 02-3 1212-01 Vacuum modulator ABS/ESP Brake fluid modulator EGR valve reservoir Battery Fuel filter & priming pump Washer fluid reservoir Power steering oil PWM electric reservoir fan & fan shroud ENGINE ASSEMBLY undefined...
Page 63 02-4 1212-01 1) Engine Structure Front View Cam position sensor 12 ± 1.7 Nm Oil dipstick gauge Oil separator (with PCV) VGT Turbo charger EGR pipe Water pump pulley Alternator Crankshaft pulley Oil pan Auto tensioner Air conditioner compressor Auto tensioner pulley Power steering pump pulley Power steering pump EGR valve...
Page 64 02-5 1212-01 Top View Oil separator Injector cover (10 ± 1.0 Nm → 180 + 20°) Oil pipe (40 ± 4.0 Nm) Fuel pressure sensor Water outlet port EGR valve Oil filler Booster pressure sensor 10 ± 1.0 Nm Common rail (25 ±...
Page 65 02-6 1212-01 Right Side View EGR valve Knock sensor 20 ± 2.6 Nm Power steering pump oil reservoir Power steering pump HP pump assembly Air conditioner compressor Engine mounting bracket Vacuum modulator for VGT turbocharger actuator Flywheel Crank position sensor 0.8 ±...
Page 66 02-7 1212-01 Left Side View Cylinder head jack valve screw VGT Turbo charger assembly Cylinder block assembly Engine mounting bracket Oil pan Alternator Water pump EGR pipe Oil dipstick gauge Oil separator (with PCV) ENGINE ASSEMBLY undefined...
Page 67 02-8 1212-01 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY undefined...
Page 68 02-9 1212-01 2) Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE ASSEMBLY undefined...
Page 69 02-10 1212-01 3. TIGHTENING TORQUE ENGINE ASSEMBLY undefined...
Page 70 02-11 1212-01 ENGINE ASSEMBLY undefined...
Page 71 02-12 1212-01 ENGINE ASSEMBLY undefined...
Page 72 04-3 2313-01 2321-01 ENGINE INTAKE SYSTEM GENERAL 1. ENGINE INTAKE SPECIFICATIONS 1) Specifications Element Type Dry-Element Type - Initial cleaning: 5,000 km, Clean or change every 10,000 km as required. However, change every 30,000 km. Service Interval - If the vehicle is operated under severe condition (short distance driving, extensive ldling or driving in dusty condition): More frequent maintenance is required.
Page 73 04-4 2313-01 OVERVIEW AND OPERATION PROCESS 1. INTAKE SYSTEM LAYOUT 1) Work Flow of Intake System VGT Turbocharger Exhaust pipe Turbocharger (diesel catalytic actuator converter) Intake (air cleaner) pressed air (intercooler) Exhaust gas HFM Sensor Air Cleaner The HFM sensor is installed in the air intake passage between the air cleaner and the intake manifold.
Page 74 04-5 2313-01 EGR Valve and Its Location (* For details, refer to "EGR" section.) Intake air Intake Intake Intake manifold manifold Exhaust Exhaust gas Vacuum Modulator Intake Manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum valve pump IP interior fuse (RH) Engine ECU No.63-7.5A No.
Page 75 04-6 2313-01 2) Layout ENGINE INTAKE SYSTEM undefined...
Page 76 04-7 2313-01 3) Components (1) Intake Manifold Assembly The intake manifold assembly is built for the optimized mixture of the EGR gas in the intake chamber when the compressed air in the turbocharger is sent to the intake port. The intake port is composed of the dual port (tangential and helical port) which increases the swirl ratio in mid/low operating range, improves acceleration/fuel consumption and decreases particle materials.
Page 77 04-8 2313-01 The SUS + Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect. Intake Manifold Coolant emission port Coolant emission port Incoming of intake air and Incoming of intake air (No exhaust gas (Operation of operation of EGR valve) EGR valve)
Page 78 04-9 2313-01 (2) Turbocharger Intercooler Assembly The turbocharger is designed to improve the engine power by introducing more air (oxygen) into the engine. However, the intake air is heated during the compression process in the turbocharger compressor and the density is lowered. The intercooler is the device which cools (50 ~ 60°C) the air entering the engine from high temperature (100 ~ 110°C)
Page 79 04-10 2313-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE INTAKE SYSTEM undefined...
Page 80 05-3 1913-01 1913-01 ENGINE EXHAUST SYSTEM GENERAL 1. INSPECTION BEFORE DIAGNOSIS The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in related system as the first priority.When abnormal condition occurs with the EGR system, the basic approach is, as described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan tool or vacuum tester.
Page 81 05-4 1913-01 ▶ HUBER EGR System for IDI Engine (Including the EGR Valve Potentiometer) The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator, one is same as being the modulator for EGR valve whereas the HUBER EGR system's the other modulator controls ALDA of injection pump and the DI engine's the other modulator controls waist gate of the turbo charger.
Page 82 05-5 1913-01 OVERVIEW AND OPERATION PROCESS 1. EXHAUST SYSTEM LAYOUT EGR Valve and Installation Location Intake air Intake (intercooler) manifold Intake Intake manifold manifold EGR pipe EGR pipe (LH) Exhaust Manifold Exhaust manifold To turbo- To EGR EGR pipe (RH) charger valve Diesel catalytic converter →...
Page 83 05-6 1913-01 2) Exhaust Gas Flows ENGINE EXHAUST SYSTEM undefined...
Page 84 06-3 1533-01 1533-01 LUBRICATION SYSTEM GENERAL 1. SPECIFICATIONS ▶ Severe Condition: When most trips include extended idling and/or frequent low-speed operation as in stop- and-go traffic. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km) When operating in dusty, sandy and salty areas In hilly or moutainous terrain...
Page 85 06-4 1533-01 OVERVIEW AND PERATION PROCESS 1. LAYOUT AND OVERVIEW 1) Lubrication System Oil dipstick gauge PCV Oil Separator The first separation will happen when blowby Cylinder head cover (oil + gas) gas passes through baffle plates in cylinder head cover. Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port.
Page 86 06-5 1533-01 Oil pressure Warning Lamp Cylinder Head Cover (Cluster) Oil Pan and Baffle Plate Oil Strainer Oil Filter & Oil Cooler (Integrated Type) cooler filter LUBRICATION SYSTEM undefined...
Page 87 06-6 1533-01 2) Lubrication System Layout Cylinder Head Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 Return hole: φ 14 Chain nozzle: φ 1 HP pump bearing: φ 6 Cylinder Block LUBRICATION SYSTEM undefined...
Page 88 06-7 1533-01 2. LUBRICATION DIAGRAM Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of cylinder head LUBRICATION SYSTEM undefined...
Page 89 07-3 2112-01 9210-05 ENGINE COOLING SYSTEM GENERAL 1. ENGINE COOLING SPECIFICATIONS COOLING SYSTEM undefined...
Page 90 07-4 2112-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS ENGINE COOLING Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor COOLING SYSTEM undefined...
Page 91 07-5 2112-01 2. COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side · Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side · Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump COOLING SYSTEM undefined...
Page 92 07-6 2112-01 3. FUNCTION DESCRIPTION OF COOLING SYSTEM Intake manifold Cylinder head Coolant outlet port Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1) Improved shape and gasket material to prevent coolant from leaking ·...
Page 93 08-3 1451-01 1461-01 ENGINE ELECTRICAL SYSTEM GENERAL 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE ELECTRIC DEVICES undefined...
Page 94 08-4 1451-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ELECTRIC IN ENGINE Fuel Pressure Camshaft Position Coolant Temperature Fuel Temperature Sensor Sensor Sensor Sensor Booster Pressure Oil Pressure Switch Crankshaft Position Knock Sensor Sensor Sensor (1 EA) ENGINE ELECTRIC DEVICES undefined...
Page 95 08-5 1451-01 2. COMPONENTS OF ELECTRIC DEVICES IN ENGIN Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE ELECTRIC DEVICES undefined...
Page 96 08-6 1451-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1) Preheating ENGINE ELECTRIC DEVICES undefined...
Page 97 08-7 1451-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1) Starting & Charging ENGINE ELECTRIC DEVICES undefined...
Page 98 09-3 1491-01 1491-01 EGINE CONTROL SYSTEM GENERAL 1. ENGINE ECU AND OTHER COMPONENTS Coolant reservoir Return hose Coolant inlet hose Coolant outlet hose Radiator Water Pump and Pipe Coolant Port Thermostat (inside) Cylinder block Coolant outlet Radiator port Reservior (coolant inlet hose) Engine Oil Filter and Cooler Oil Filter cap Oil cooler...
Page 99 09-4 1491-01 2. TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE CONTROL SYSTEM undefined...
Page 100 09-5 1491-01 3. SIDE VIEW Coolant Temperature Knock Sensors (1 EA) Sensor Fuel Temperature Sensor Fuel Pressure Crankshaft Position Regulating Valve Sensor ENGINE CONTROL SYSTEM undefined...
Page 101 09-6 1491-01 OVERVIEW AND OPERATION PROCESS 1. ECU INPUTS/OUTPUTS Inputs Output Control Booster pressure sensor Injector Atmospheric pressure sensor EGR system (Built-in ECU) Fuel pressure regulating valve Air flow sensor (HFM) (IMV) Coolant temperature sensor Electrical fan control Fuel temperature sensor (Low/High-speed) Fuel pressure sensor A/C compressor relay...
Page 102 09-7 1491-01 2. STRUCTURE AND FUNCTION OF ECU 1) Function of ECU 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 103 09-8 1491-01 4. FUEL PRESSURE CONTROL 1) Fuel Pressure Control Elements Pressure control consists of 2 principle modules. 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. The aim is to adapt the injection pressure to the engine's requirements.
Page 104 09-9 1491-01 5. FUEL INJECTION CONTROL 1) 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 105 09-10 1491-01 ▶ 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 106 09-11 1491-01 6. FUEL FLOW CONTROL 1) Main Flow Control The main flow represents the amount of fuel injected into the cylinder during the main injection. The pilot flow represents the amount of fuel injected during the pilot injection. The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
Page 107 09-12 1491-01 A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the engine. Until the stating phase has finished, the system uses the supercharged fuel. Once the engine changes to normal operation, the system uses the total fuel. The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
Page 108 09-13 1491-01 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 109 09-14 1491-01 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 ·...
Page 110 09-15 1491-01 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 111 09-16 1491-01 7) Accelerometer Strategy ▶ 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 112 09-17 1491-01 ▶ Detection of leaks in the cylinders The accelerometer is also used to detect any injector which may have stuck open. The detection principle is based on monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-ignites as soon as the temperature and pressure conditions are favorable (high engine speed, high load and small leak).
Page 113 09-18 1491-01 7. INDIVIDUAL INJECTOR CALIBRATION (C2I) Injected fuel is proportional to square root of injection time and rail pressure. It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the following shape. Common rail injectors are very accurate components.
Page 114 09-19 1491-01 C2I is composed of models on these characteristics of injectors. C2I consists of 16-digit composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I, characteristics of each injector, to make the most optimal fuel injection. When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector's C2I value.
Page 115 09-20 1491-01 8. MINIMUM DRIVE PULSE (MDP) LEARNING When the pulse value that the injector starts injection is measured, it is called mininum drive pulse (MDP). Through MDP controls, can correct pilot injections effectively. Pilot injection volume is very small, 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors.
Page 116 10-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 117 10-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 118 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 119 10-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 120 10-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 121 10-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 122 10-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 123 10-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 124 01-3 1114-00 1114-00 ENGINE ASSEMBLY GENERAL 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The electronically controlled advanced D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
Page 125 01-4 1114-00 1) Engine Assembly Structure Front View Touch idler equipped (for A/T) Top View ENGINE ASSEMBLY undefined...
Page 126 01-5 1114-00 Right Side View Left Side View ENGINE ASSEMBLY undefined...
Page 127 01-6 1114-00 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY undefined...
Page 128 01-7 1114-00 2) Engine Performance Curve (1) Output and Torque General (2) Oil Temperature/Pressure and Boost Pressure General ENGINE ASSEMBLY undefined...
Page 129 01-8 1114-00 3. TIGHTENING TORQUE ENGINE ASSEMBLY undefined...
Page 130 01-9 1114-00 ENGINE ASSEMBLY undefined...
Page 131 01-10 1114-00 ENGINE ASSEMBLY undefined...
Page 132 01-11 1114-00 1) Engine Head Bolt Tightening Torque Head bolt wrench and tightening torque according to the cylinder head bolt changes of the DI engine (D20DT) Cylinder head bolt wrench W9912 003 0B I.D. of head bolt head: 14.5 mm O.D.
Page 133 01-12 1114-00 4. MAJOR CHANGES IN D20DT (EURO IV) ENGINE (COMPARED TO D20DT) 1) Engine Assembly D20DT (EURO 4) Engine D20DT Engine Front Side View Touch idler equipped (for A/T) Top Side View Right Side View Left Side View ENGINE ASSEMBLY undefined...
Page 134 01-13 1114-00 2) Major Changes and Summary D20DT (EURO 4) Engine D20DT Engine Remarks Injector * Injector label D20DT: Green (Cap) (16 digits: C2I value) D20DT (EURO 4): Red (Cap) (20 digits: C3I value) C3I Label C2I Label Fuel pipe * Diameter increased D20DT: ID (2.4 mm), OD (6.0 mm)
Page 135 01-14 1114-00 D20DT (EURO 4) Engine D20DT Engine Remarks * Version up HFM 6.0 HFM 5.0 D27DT: HFM5-CI (Analog signal) D27DTP: HFM6-ID (Digital signal added) Vacuum modulator * D20DT (EURO4) engine uses Vacuum modulator controlling turbo charger electric ally controlled E- actuator valve.
Page 136 01-15 1114-00 D20DT (EURO 4) Engine D20DT Engine Remarks Increase of Oil separator PCV oil separator capacity (approx. 10%) - D20DT (EURO 4): 160 /min - D20DT: 120 /min Blow-by gas Blow-by gas (To air duct (To air duct hose) hose) valve valve...
Page 137 02-3 1881-09 1881-09 ENGINE FUEL SYSTEM GENERAL 1. MAJOR CHANGES IN FUEL SYSTEM OF ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D20DT (EURO 4) engine. The major changes are as follows. Refer to the next pages for further details. 1) Injector Two nozzle holes are added (currently 7) to the tip of the injector to increase the...
Page 138 02-4 1881-09 3) Fuel Rail - Chrome Color The I.D and O.D of the fuel rail between Fuel pipe (Common rail → Injector) HP pump and common rail are increased according to the increased amount of fuel injection. Also, the engine ECU, HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely.
Page 140 02-6 1881-09 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF FUEL SYSTEM Injector (7-way Injection and C3I Coding) Fuel nozzle holes (7) Common Rail (Orifice for Preventing Fuel Pulsation Added) Orifice Orifice for HP pump fuel outlet Fuel Supply Rail (Increase in I.D) Fuel pipe Common rail Fuel rail...
Page 141 02-7 1881-09 Fuel filter Priming Pump Fuel filter Priming pump Connector Fuel from Fuel filter HP pump Fuel tank HP pump Fuel tank HP Pump Fuel temperature Fuel return Fuel return port sensor port IMV valve Venturi High pressure Low pressure fuel supply port fuel supply port (orifice included)
Page 142 02-8 1881-09 2. FUEL FLOW OF D20DT (EURO 4) ENGINE ENGINE FUEL SYSTEM undefined...
Page 143 03-3 2321-01 2321-01 ENGINE INTAKE SYSTEM OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The intake system for the D20DT (EURO 4) engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off. Therefore, the structure of the intake manifold has been changed.
Page 144 03-4 2321-01 2. INTAKE SYSTEM LAYOUT Uncompressed air Compressed air VGT Turbo Chargera Air cleaner Ambient air HFM Sensor (ver. 6.0) Temperature sensor Turbo coeaner charger Pretension graph ENGINE INTAKE SYSTEM undefined...
Page 145 03-5 2321-01 Booster Pressure Sensor Intake Manifold To corresponding Coolant Supply power cylinders Ground port Output voltage Compress ed air EGR gas Throttle body Normal: flap open Engine stopped: flap closed Intake duct Intake duct Intercooler Intake manifold Turbo charger (Throttle body) ENGINE INTAKE SYSTEM undefined...
Page 146 04-3 1792-01 1792-01 ENGINE EXHAUST SYSTEM OVERVIEW AND OPERATION PROCESS 1. COMPONENTS The components of the exhaust system for the D20DT (EURO4) engine have been changed as follows: ▶ E-EGR valve - Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) ▶...
Page 147 05-3 0000-00 1222 -01 LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1. OVERVIEW OIL SEPARATORS For the D20DT (EURO4) engine, the PCV oil separator's capacity has been increased by 10% compared to the conventional PCV oil separator for D20DT engine to separate the oil and the gas more efficiently.
Page 148 05-4 0000-00 Performance of PCV Separator and Oil/Carbon Accumulation in Intake Manifold It is not possible to separate the blowby gas (oil and unburned gas) completely from the crankcase. This problem is related to the engine control and the PCV oil separator is designed to recirculate approx.
Page 149 ENGINE COOLING SYSTEM 2112-00/1520-00 ENGINE COOLING SYSTEM COOLING SYSTEM 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE....... WATER PUMP 1. OVERVIEW..........
Page 150 06-2 0000-00 ENGINE COOLING SYSTEM undefined...
Page 151 06-3 0000-00 2112-00 COOLING SYSTEM 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT (EURO4) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
Page 152 06-4 0000-00 1520-00 WATER PUMP 1. OVERVIEW The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and, therefore, cannot be disassembled. The capacity of water pump has been increased due to the EGR cooler, increased engine power and additional coolant port in the cylinder block.
Page 153 06-5 0000-00 1) Structure of Water Pump for D20DT Engine ENGINE COOLING SYSTEM undefined...
Page 155 NO DATA...
Page 156 3) System Met with EURO IV Regulations The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December 2007 comply with the EURO IV regulations. Modified components from the old...
Page 157 08-4 1725-12 2. CDPF (EURO IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and Sensors Differential Pressure Sensor (ΔP sensor) Under air cleaner in right side of engine compartment As the soot is filtered in the CDPF, the pressure between the front side and the rear side of...
Page 158 08-5 1725-12 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
Page 159 08-6 1725-12 Overview and Operation Process 1. OVERVIEW As the solution for environmental regulations and PM (Particla 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 Oxydation Catalyst) is reduced.
Page 160 08-7 1725-12 2.CDPF (EURO IV) SYSTEM CONTROL 1) General Description As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
Page 161 08-8 1725-12 2) System Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
Page 162 08-9 1725-12 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type. CDPF undefined...
Page 163 08-10 1725-12 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
Page 164 08-11 1725-12 Front temperature sensor Rear temperature sensor (Measuring the temperature of (Measuring the temperature of exhaust exhaust gas passedthrough gas passed through DOC) exhaust manifold) Differrential pressure sensor Differrential pressure sensor (Front pressure port) (Rear pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects intoCDPF assembly after...
Page 165 08-12 1725-12 2) Fuel Injection During CDPF Regeneration 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 166 08-13 1725-12 ▶ Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration tem- perature due to low speed driving or other reason during the regeneration process, the soot is con- tinuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to in-form this situation to the driver.
Page 167 08-14 1725-12 4. COMPONENTS OF CDPF SYSTEM 1) Mounting Condition and Location Differential Pressure Sensor Rear exhaust gas temperature sensor Engine compartment (RH) Rear pressure port Differential Front pressure port pressure sensor CDPF assembly Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
Page 168 09-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 169 09-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 170 09-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 171 09-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 172 09-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 173 09-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 174 09-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 175 09-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 176 01-3 1113-01 1113-01 ENGINE ASSEMBLY GENERAL 1. DESCRIPTION AND OPERATION 1) Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation.
Page 177 01-4 1113-01 2) On-engine Service Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 178 01-5 1113-01 2. G23D ENGINE ASSEMBLY Front View Rear View ENGINE ASSEMBLY undefined...
Page 179 01-6 1113-01 LH Side View RH Side View ENGINE ASSEMBLY undefined...
Page 180 01-7 1113-01 3. G23D ENGINE STRUCTURE Front View Side View ENGINE ASSEMBLY undefined...
Page 181 01-8 1113-01 Front View ▶ FUNCTION FUNCTION HFM Sensor Intake Manifold Intake Air Duct Cylinder Head Cylinder Head Cover Exhaust Manifold Ignition Coi Dipstick Guide Tube and Gauge Spark Plug Connector Connecting Rod Fuel Distributor Crankshaft Injector Engine Mounting Bracket Exhaust Camshaft Starter Intake Camshaft...
Page 182 01-9 1113-01 4. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Oil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair.
Page 183 01-10 1113-01 ▶ Black Light and Dye Method A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit. Pour the specified amount of dye into the engine oil fill tube. Operate the vehicle normal operating conditions as directed in the kit. Direct the light toward the suspected area.
Page 184 01-11 1113-01 2) Compression Pressure Test ▶ Standard Service Data A9912 0012B (001 589 76 21 00) Compression Pressure Tester Measuring Procedure ▶ Warm the engine up to normal operating temperature. Remove the spark plugs using the spark plug wrench. Place the diagram sheet to compression pressure tester A9912 0012B (001 589 76 21 00).
Page 185 01-12 1113-01 3) Cylinder Pressure LeakageTest ▶ Permissible Pressure Leakage At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max. 20 % Cylinder Number ▶ 1, 4 OT (TDC) 2, 3 UT (BDC 180 °) ▶...
Page 186 01-13 1113-01 ▶ Leakage Test Warm the engine up to normal operating temperature. Disconnect the negative battery cable. Remove the spark plugs. Check the coolant level by opening the coolant reservoir cap and replenish if insufficient. Open the engine oil filler cap. Connect the tester to air pressure line and adjust the scale of tester.
Page 187 01-14 1113-01 5. GENERAL DIAGNOSIS ENGINE ASSEMBLY undefined...
Page 188 01-15 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 189 01-16 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 190 01-17 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 191 01-18 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 192 01-19 1113-01 6. SPECIFICATIONS 1) Engine Specifications MSE : Engine Control Module 3.53D : 4 Cylinder Version ENGINE ASSEMBLY undefined...
Page 193 01-20 1113-01 2) Fastener Tightening Specifications ENGINE ASSEMBLY undefined...
Page 194 01-21 1113-01 ▶ Fastener Tightening Specifications (Cont'd) ENGINE ASSEMBLY undefined...
Page 195 01-22 1113-01 2) Performance Curve ENGINE ASSEMBLY undefined...
Page 197 02-3 1713-08 0000-00 ENGINE INTAKE SYSTEM GENERAL 1. SPECIFICATIONS (1) Fastener Tightening Specifications ENGINE INTAKE SYSTEM undefined...
Page 198 03-3 2420-01 2420-01 ENGINE EXHAUST SYSTEM GENERAL 1. SPECIFICATION (1) Fastener Tightening Specifications ENGINE EXHAUST SYSTEM undefined...
Page 199 03-4 2420-01 OVERVIEW AND OPERATION PROCESS 1. DESCRIPTION AND OPERATION 1) Exhaust System When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials.
Page 200 03-5 2420-01 ▶ Catalytic Converter and Temperature Catalytic converter has the normal function of purification at a range of the temperature. Because it has a weak point of decreasing of the purification rate in the condition of continuous high temperature, it should keep the temperature range of 400 to 500°C normal condition.
Page 201 03-6 2420-01 ▶ Method for Reduction of NOx NOx is generated a great deal in case that combustion temperature and excess air factor are high. EGR valve can decrease NOx (30 to 35% decrease) by making temperature of combustion chamber fall by means of exhaust gas re-circulation. EGR valve is installed on the diesel engine of Musso, Korando, Istana and Rexton.
Page 202 04-3 2112-01 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM undefined...
Page 203 04-4 2112-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE COOLING SYSTEM undefined...
Page 204 04-5 2112-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENT LOCATOR 1. Reserver Tank 9. Radiator 2. Deaeration Tube 10. Lower Radiator Insulator 3. Inlet Hose 11. Plate 4. Outlet Hose 12. Clip 5. 3 way Hose 13. Upper Radiator Insulator 6. Clamp 14.
Page 205 04-6 2112-01 2. DESCRIPTION AND OPERATION 1) General Description The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly.
Page 206 04-7 2112-01 4) Water Pump The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and, therefore, cannot be disassembled. 5) Thermostat A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system.
Page 207 04-8 2112-01 The cooling fans are mounted behind the radiator in the engine compartment. The electric cooling fans increase the flow of air across the radiator fins and across the condenser on air conditioned (A/C)-equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds. All models have two fans.
Page 208 04-9 2112-01 3. PWM (PULSE WIDTH MODULATION) ELECTRIC FAN OPERATION 1) Function The PWM (Pulse Width Modulation) high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise. 2) Mounting Location Fan shroud PWM unit Electric fan...
Page 209 04-10 2112-01 3) PWM Electric Fan (1) Advantages and Disadvantages of the PWM Electric Fan ▶ Advantages Enhanced A/C performance: at low speed, at idling, driving in city Reduction of vibration/noise: fan activated by PWM only when necessary Reduction of engine consuming power (V/Fan driving force) by 4 Hp - Cost saving ▶...
Page 210 04-11 2112-01 5) Shutting-off Condition of the A/C Compressor Coolant temperature ▶ When coolant temperature is below 20°C or over 115°C, engine speed is below 650 rpm or over 4500 rpm for 4 seconds after engine starting, abrupt acceleration and A/C refrigerant pressure sensor detecting the followings A/C compressor is turned off when the refrigerant pressure is below 2.0 kg/cm2 and then is turned on when the refrigerant pressure is over 2.4 kg/cm2.
Page 211 05-3 1452-01 0000-00 ENGINE ELECTRIC DEVICES GENERAL 1. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Ignition System ENGINE ELECTRICAL SYSTEM undefined...
Page 212 05-4 1452-01 2) Ignition System (Cont'd) ENGINE ELECTRICAL SYSTEM undefined...
Page 213 05-5 1452-01 OVERVIEW AND OPERATION PROCESS 1. DESCRIPTION AND OPERATION 1) Battey The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed, except for two small vent holes in the sides. These vent holes allow the small amount of gas produced in the battery to escape.
Page 214 05-6 1452-01 (2) Cold Cranking Amperage The cold cranking amperage test is expressed at a battery temperature of -18°C(0°F). The current rating is the minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts.
Page 215 05-7 1452-01 4) Charging a Completely Discharged Battery (Off the Vehicle) Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced. The following procedure should be used to recharge a completely discharged battery: Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milliamperes.
Page 216 05-8 1452-01 5) Jump Starting Procedure Position the vehicle with the charged battery so that the jumper cables will reach from the charged battery to the battery that requires charging. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Leave the hazard flasher on if jump starting where there may be other traffic and any other lights needed for the work area.
Page 217 05-9 1452-01 6) Alternator Alternators are equipped with internal regulators. Unlike three-wire generators, the alternator may be used with only two connections: battery positive and an "D+" terminal to the charge indicator lamp. As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to RUN, and goes out when the engine is running.
Page 218 05-10 1452-01 9) Starting System The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular component, refer to that component section of the service manual. The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring.
Page 219 06-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 220 06-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 221 06-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 222 06-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 223 06-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 224 06-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 225 06-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 226 06-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 227 06-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 228 06-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 229 06-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 230 06-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 231 06-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 232 06-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 233 06-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 234 06-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 235 8210-01 8410-02 FUSE AND RELAY General information 1. GENERAL INFORMATION The ICM (Integrated Control Module) box installed to the new Actyon model is integrated with some relays of previous model and is installed to the back of the STICKS. As the ICM box is newly installed, the following relays are integrated into the ICM box. - Door lock relay (previously installed to STICKS bracket) - Windshield de-icer relay (previously installed next to floor on the driver side) - Turn signal lamp relay (previously installed to passenger side fuse &...
Page 236 8210-01 Overview and Operating Process 1. OVERVIEW The ICM (Integrated Control Module) mounted to the back of the STICS is integrated with the door lock relay, windshield de-icer relay and turn signal lamp relay. There are four fuse & relay units.
Page 237 8210-01 3. CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE COMPARTMENT The label attached on each fuse box indicates only major fuses and relays. Therefore, there are more fuses and relays than indicated. For details about the connection of fuses and relays, refer to the power distribution circuit diagram on the following pages.
Page 238 8210-01 4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY 1) Interior Fuse and Relay Box On the Driver Side FUSE AND RELAY undefined...
Page 239 8210-01 2) Interior Fuse and Relay Box On the Passenger Side FUSE AND RELAY undefined...
Page 240 8210-01 5. OPERATING PROCESS OF ICM BOX 1) Overview The ICM (Integrated Control Module) box installed to the new Actyon model is integrated with some relays of previous model and is installed to the back of the STICKS. As the ICM box is newly installed, the following relays are integrated into the ICM box. - Door lock relay (previously installed to STICKS bracket) - Windshield de-icer relay (previously installed next to floor on the driver side) - Turn signal lamp relay (previously installed to passenger side fuse &...
Page 241 8210-01 3) Operating Process by Power Supply of ICM Box (1) Door lock relay As the ICM box is supplied with power from the fuse (12-pin) and STICS (6-pin, 15-pin), it operates the door actuator (11-pin, 13-pin) through its door lock relay to lock/unlock the door. In order to check the operation of the relay, measure the voltage at the connector of the ICM box and check the output through the ICM box after operating the corresponding door.
Page 242 0-10 8210-01 (2) Turn signal lamp (hazard warning lamp operation) When the hazard warning lamp switch is pressed for approx. 0.1 to 0.59 seconds, the hazard warning lamp blinks 3 times at an interval of 0.35 seconds. When the hazard warning lamp switch is pressed for approx. 0.6 seconds or longer, the hazard warning lamp blinks 10 times at an interval of 0.35 seconds.
Page 243 0-11 8210-01 (3) Windshield de-icer operation Pressing the windshield de-icer switch activates the de-icer for 12 minutes and pressing the switch again deactivates the de-icer. At this time, pressing the switch again activates the de-icer for 12 minutes from the time the switch is pressed again. FUSE AND RELAY undefined...
Page 244 02-3 8710-01 8710-01 STICS GENERAL 1. OVERVIEW STICS of ACTYON SPORTS, called as RKSTICS (REKES + STICS (Super Time & Integrated Control System)), is almost the same as that of ACTYON in terms of its function and role. Due to the removal of tailgate opening switch and rear wiper and washer system, the circuit layout is slightly changed, compared to ACTYON.
Page 245 02-4 8710-01 3. SPECIFICATIONS 1) Electrical Performance ▶ Electrical Performance Characteristics of Radio Wave ▶ Transmitting frequency: 447.800 ± 0.0125 MHz Channel width: below 12.5 KHz Frequency bandwidth: below 8.5 KHz Modulation method: FSK (Frequency Shift Keying) Receiving distance: Approx. 10 ~ 15 m (In case there are not obstacles around the system) STICS undefined...
Page 246 02-5 8710-01 ▶ Rated Load STICS undefined...
Page 247 02-6 8710-01 ▶ Input Signals STICS undefined...
Page 248 02-7 8710-01 ▶ Chattering of Input Signals Vehicle speed input: The vehicle speed is the average value of 4 pulses among 6 pulse inputs regardless of the input for 1.0 second after IGI 1 ON. The time indicated in each function does not include the vehicle speed calculating time.
Page 249 02-8 8710-01 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW STICS of ACTYON SPORTS, called as RKSTICS (REKES + STICS (Super Time & Integrated Control System)), is almost the same as that of ACTYON in terms of its function and role. Due to the removal of tailgate opening switch and rear wiper and washer system, the circuit layout is slightly changed, compared to ACTYON.
Page 250 02-9 8710-01 2. FUNCTIONS AND SPECIFICATIONS 1) Wiper and Washer Operations Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position. Fast: Fast interval Slow: Slow interval Front wiper operation...
Page 251 02-10 8710-01 Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch "OFF", the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times, after then the washer fluid is sprayed and the wiper sweeps off 3 times again.
Page 252 02-11 8710-01 2) Wiper MIST and Front Washer Coupled Wiper The wiper relay is turned on at 0.3 seconds after from the time when the washer switch is turned on for 0.1 to 0.59 seconds (T2) with the ignition switch "ON". If the wiper parking terminal gets off, the wiper relay is turned off.
Page 253 02-12 8710-01 When the washer switch is turned on for more than 0.6 seconds during the wiper operation by INT switch, the operation in step (2) is performed. When it is turned on for a certain period of time (0.1 to 0.59 seconds), the operation in step (1) is performed. STICS undefined...
Page 254 02-13 8710-01 3) Rear Washer Motor Control When the rear washer switch is turned on with the ignition switch "ON", the rear washer motor relay output gets ON from the time when the rear washer switch is turned on. It gets OFF when the rear washer switch is turned off.
Page 255 02-14 8710-01 4) Auto Washer and Wiper Switch (AFW) When the auto washer switch is turned on with the ignition switch "ON" and the INT switch "OFF", the washer motor output gets ON for 1 second. If the system recognizes the output signal, the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second.
Page 256 02-15 8710-01 The auto washer switch output is overridden during the washer coupled wiper operation. The auto washer switch input is overridden during the auto washer coupled wiper operation. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation.
Page 257 02-16 8710-01 5) Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor, it has following operation system. ▶ System layout STICS undefined...
Page 258 02-17 8710-01 6) INT Switch Auto Position Reminder (Power-Up Reminder Wiper) When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of communication with rain sensor. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the wiper switch to "AUTO"...
Page 259 02-18 8710-01 7) Washer Coupled Wiper in Rain Sensing Mode The washer coupled wiper is operated when receiving the washer switch input with the ignition switch "ON" and the auto INT switch "ON" in the rain sensing mode. At this moment, the communication with the rain sensor is overridden.
Page 260 02-19 8710-01 8) Rain Sensing Sensitivity Control The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (while the ignition key is in the "ON" position, the wiper switch is in the "ON"...
Page 261 02-20 8710-01 9) When the Wiper Parking Signal is abnormal The wiper system continuously outputs the wiper parking signal when the wiper parking terminal is grounded (while the ignition key is in "ON" position and the wiper switch is in "ON" position). * The wiper motor runs only when the rain sensor requires the wiper operation.
Page 262 02-21 8710-01 10) Defective Rain Sensor The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the wiper switch is in "ON" position). The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON"...
Page 263 02-22 8710-01 (1) Trouble shooting Symptom 1. The wiper does not operate one cycle when turning the multifunction wiper switch to the "AUTO" from the "OFF" position or starting the engine while the wiper switch is in the "AUTO" position. When starting the engine with the multifunction wiper switch in the "AUTO"...
Page 264 02-23 8710-01 Symptom 5. The wiper does not operate at high speed even in heavy rain. Check if the wiper operates at high speed when grounding pin 1 and pin 2. Symptom 6. The wiper responses are too fast or slow. Check whether the variable resistance knob on the wiper switch is set in "FAST"...
Page 265 02-24 8710-01 11) Auto Light Control The tail lamps and headlamps can be controlled by the communication with the rain sensor only when the auto light switch is in "AUTO" position with the ignition switch "ON". Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically.
Page 266 02-25 8710-01 12) Speed Sensitive INT (Intermittent) Wiper For RKSTICS without the rain sensor, perform the following operation: ▶ Controls the wiper intermittent operation by the values from the vehicle speed and the volume. Calculates and converts the Intermittent interval automatically by using the INT VOLUME when the ignition switch is in the "ON"...
Page 267 02-26 8710-01 Pause time of vehicle speed sensitive INT wiper ▶ Speed sensitive INT (intermittent) wiper The wiper relay continues to output for remaining "ON" time even when the INT switch is turned off. IGN 2 switch "ON", INT switch "OFF": Resume the intermittent time when turning "ON" IGN 2 switch "OFF", INT switch "ON": Resume the intermittent time when turning "ON"...
Page 268 02-27 8710-01 13) Ignition Key Reminder Warning (The ignition key reminder warning has priority over the "TAILLAMP ON WARNING".) The chime buzzer sounds continuously when opening the driver's door while the ignition key is in ignition switch. When removing the ignition key or closing the driver's door during chime buzzer operation, the buzzer stops.
Page 269 02-28 8710-01 ▶Ignition Key Reminder The system outputs "UNLOCK" signal for 5 seconds after the driver's door is opened and the door lock switch is changed to "LOCK" (while the ignition key is in ignition switch). The system outputs "UNLOCK" signal for 5 seconds (T2) when the door lock switch is changed to "LOCK"...
Page 270 02-29 8710-01 14) All Door Lock Prevention Function when a Door is Open All doors, except the tailgate and hood, output "UNLOCK" signal for 5 seconds when the "LOCK" signal is inputted (while the ignition key is removed and one of any doors is open). When the door is closed during the UNLOCK output, the UNLOCK output stops immediately.
Page 271 02-30 8710-01 15) Tail Lamp Left on Warning The chime buzzer sounds with the interval of 0.8 second when opening the driver's door while the tail lamp is turned on and the ignition key is removed. The chime/buzzer output stops when turning off the tail lamp and closing the driver's door. The system outputs "UNLOCK"...
Page 272 02-31 8710-01 16) Door Ajar Warning The warning light in instrument panel comes on when opening any of doors including tailgate while the vehicle speed is below 10 km/h. The warning light goes off when closing the door under step 1. The warning light blinks when the vehicle speed is over 10 km/h while the warning light is turned on.
Page 273 02-32 8710-01 17) Seat Belt Warning The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to "ON" from "OFF". If the seat belt is fastened before turning the ignition key to the the "ON" position, the warning light in the instrument panel blinks, however, the chime buzzer does not sound.
Page 274 02-33 8710-01 18) Parking Brake Warning The parking brake warning light comes on for approx. 4 seconds when turning the ignition key from the "OFF" to the "ON" position regardless of the vehicle speed and the parking brake switch position. After this 4 seconds, the warning lamp comes on, goes off or blinks according to the vehicle speed and the parking brake switch position.
Page 275 02-34 8710-01 19) Front/Center Room Lamp Control The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the center room lamp switch is at the coupled operating position and the key reminder switch is "OFF". When the door (Driver's/Passenger's/Rear) is opened, the front and center room lamps come on and automatically go off after 30 seconds.
Page 276 02-35 8710-01 Front Room Lamp: 12V / 8W - 2EA Center Room Lamp: 12V / 8W - 1EA Driver's seat Tailgate Center Room Lamp (Lamp : ON) Center Room Lamp (Door coupled operation) Front room lamp (driver's or passenger's) is Center Room Lamp turned on and off when pressing the switch If the switch is at the door coupled position,...
Page 277 02-36 8710-01 20) Ignition Key Hole Illumination The ignition key hole illumination comes on when opening the driver's door or passenger's door while the ignition key is removed. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1. The output stops when the ignition key is turned to the "ON"...
Page 278 02-37 8710-01 21) Tail Lamp Auto Cut (Battery Saver) The tail lamp is turned on or off according to the operations of the tail lamp switch. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door after removing the ignition key without turning off the tail lamp.
Page 279 02-38 8710-01 23) Rear Defogger Timer The rear defogger output is "ON" when turning "ON" the rear defogger switch while the IGN 2 switch is "ON" (with engine running). The output is "OFF" when turning "ON" the rear defogger switch again during output. The output is "ON"...
Page 280 02-39 8710-01 24) Door Lock/Unlock Control by Door Lock Switch The door lock system outputs "LOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the lock position. The door lock system outputs "UNLOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the unlock position.
Page 281 02-40 8710-01 25) Tailgate Open Control When pressing and holding the tailgate open switch for more than 0.6 seconds while LOCK switches in all doors are in UNLOCK position and the vehicle speed is 0 Km/h, STICS operates the tailgate relay for 0.5 seconds to unlock the tailgate. If any LOCK switch is switched to LOCK position or vehicle speed exceeds 3 Km/h while operating the tailgate open relay, the output of the tailgate relay gets OFF.
Page 282 02-41 8710-01 26) Door Lock/Unlock Control by Door Lock Switch The door lock system outputs "LOCK/UNLOCK" signal for 0.5 seconds when operating the central door lock switch. (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) The "LOCK"...
Page 283 02-42 8710-01 27) Door LOCK/UNLOCK by Remote Control Key The door lock relay output is "ON" for 0.5 seconds when receiving the remote control lock signal. The door unlock relay output is "ON" for 0.5 seconds when receiving the remote control unlock signal.
Page 284 02-43 8710-01 28) Auto Door Lock The door lock system outputs "LOCK" when the vehicle speed maintains over 50 km/h. However, it doesn't output "LOCK" when all doors are locked or failed. If any of doors is unlocked after outputting "LOCK" in step 1, outputs "LOCK" up to 5 times (except step 1) at the interval of one second.
Page 285 02-44 8710-01 29) Auto Door Unlock (Crash Unlock) The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to "ON" position. After this period, the door lock system outputs "UNLOCK" for all doors for 5 seconds from 0.4 seconds after receiving the air bag collision signal.
Page 286 02-45 8710-01 30) Time Lag Power Window Control The power window relay output is "ON" when turning on the ignition switch. The power window relay output is "ON" for 30 seconds when turning off the ignition switch. The power window relay output is "OFF" when opening the driver's door or the passenger's door.
Page 287 02-46 8710-01 32) Description of Theft Deterrent Function Armed mode activation requirements The "LOCK" output is "ON" when the "LOCK" signal is received from transmitter while the ignition key is removed and all doors are closed. The armed mode is activated when the door lock switch is locked (hazard warning flasher blink twice).
Page 288 02-47 8710-01 Armed mode cancellation requirements 1) Receiving UNLOCK signal from the remote control key or starting the engine. Warning operation requirements 1) When opening the door in armed mode 2) When unlocking the door lock switch in armed mode by other than the remote control key 3) When closing and then opening the door after completion of warning (27 seconds) Warning operation 1) The theft deterrent horn and hazard warning flasher output is "ON"...
Page 289 02-48 8710-01 8. Operations when removing and installing the battery If the system is in armed mode while installing a battery, the horn sounds and the emergency warning lamp blinks (Same operations with warning in armed mode). RELOCK Operation It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key, the system outputs "LOCK"...
Page 290 02-49 8710-01 34) Remote Door Lock All doors are locked when briefly pressing the door LOCK switch on remote control key (less than 0.5 seconds). The system outputs LOCK signal immediately after receiving the door lock message from the remote control key. The system activates the theft deterrent mode when all doors are locked while they are fully closed (the hazard warning lamps blink twice.).
Page 291 02-50 8710-01 35) Door Unlock The door unlock operates when pressing the door switch on the remote control key for longer than 0.5 seconds. The door unlock relay is "ON" for 0.5 seconds when receiving the door unlock message from the remote control key. The hazard warning lamps blink once only when all the doors unlocked.
Page 292 02-51 8710-01 3. CIRCUIT DIAGRAM The circuit diagram below shows the input and output of STICS. 1) STICS Input Singnals and Others STICS undefined...
Page 293 02-52 8710-01 2) STICS Output Signals and Others STICS undefined...
Page 294 02-53 8710-01 3) Circuit Diagram of Wiper Rear wiper and washer system is not applied, the circuit related to rear wiper and washer is removed from the STICS circuit regarding wiper control. STICS undefined...
Page 295 02-54 8710-01 4) Wiring Circuit of STICS (Related to Ignition Key Reminder) STICS control related to the ignition key reminder is a convenience function to prevent the driver from leaving the vehicle with the tail lamps ON or without removing the key. As shown in the figure, STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions.
Page 296 02-55 8710-01 5) Wiring Circuit of STICS (Related to Seat Belt/Parking Brake Warning) STICS monitors the seat belt fastening status and the parking brake engagement status and warns the driver with the warning light on the instrument panel or chime buzzer.
Page 297 02-56 8710-01 6) Wiring Circuit of STICS (Related to Front/Center Room Lamp Control) The room lamp control of STICS is related to the door's opening and closing status and UNLOCK signal of the remote controller. The operating time control and dimming functions of room lamp have been introduced for user convenience.
Page 298 02-57 8710-01 7) Wiring Circuit of STICS (Related to Tail Lamp Auto Cut (Battery Saver)) STICS undefined...
Page 299 02-58 8710-01 8) Circuit Diagram of STICS (Related to Front/Rear Defogger Timer) The defogger system defrosts or demists the window glass with the heated wire integrated in glass. When operating the defogger switch, STICS controls the operating time only in IGN2 position.
Page 300 02-59 8710-01 9) Circuit Diagram of STICS (Related to Remote Controller and Door Lock/Unlock) STICS undefined...
Page 302 03-3 7010-06 7010-06 IMMOBILIZER SYSTEM OVERVIEW AND OPERATION PROCESS 1. OVERVIEW 1) What is the Immobilizer System? The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
Page 303 03-4 7010-06 2. BASIC FUNCTIONS OF IMMOBILIZER KEY (REKES FUNCTION) Door Unlock and Panic Function ▶ Briefly press (below 0.5 sec): Door unlock and theft LED flasher deterrent mode is deactivated Briefly press: blink once Press and hold (over 2 sec): Panic function Press and hold: blink twice 1.
Page 305 03-6 7010-06 3. OTHER FUNCTIONS IN SYSTEM 1) Immobilizer Function The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
Page 306 03-7 7010-06 Immobilizer and Warning Lamp ▶ This indicator comes on when the ignition key is communicating with the engine control unit (during engine starting) and goes out after starting the engine. Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: When turning the ignition key to ON...
Page 307 03-8 7010-06 4. REKES OPERATION LOGIC 1) Remote Door Lock When briefly pressing the door lock switch on the remote control key for less than 0.5 seconds, all doors are locked. The system outputs the "LOCK" signal immediately after receiving the door lock message from the remote control key.
Page 308 03-9 7010-06 2) Door Unlock When pressing and holding the door unlock switch on the remote control key for more than 0.5 seconds, all doors are unlocked. When receiving the DOOR UNLOCK message from the remote control key, the door unlock relay is turned on for 0.5 seconds.
Page 309 03-10 7010-06 5. CIRCUIT DIAGRAM IMMO undefined...
Page 310 05-2 8010-01 8010-01 CLUSTER OVERVEIW AND OPERATION PROCESS 1. DESCRIPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the signals to and from the relevant control units through CAN communication. The HDC warning light and the engine hood open warning light are newly introduced. CLUSTER undefined...
Page 311 05-3 8010-01 1. RPM gauge 16. Fog lamp indicator 2. Battery charge warning light 17. High beam indicator 3. Air bag warning light 18. Door open warning light 4. ESP warning light 19. Brake warning ligh 5. HDC warning light 20.
Page 312 05-4 8010-01 2. WARNING & INDICATOR PANEL CLUSTER undefined...
Page 313 05-5 8010-01 CLUSTER undefined...
Page 314 05-6 8010-01 3. CLUSTER OPERATION PROCESS 1) Warning Lights and Indicators (1) Engine Tachometer The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the current number of engine revolutions. Under the normal engine operating temperature, the proper idling speed is 700 ~ 800 rpm. The red zone (danger rpm range) starts from 4,500 rpm.
Page 315 05-7 8010-01 (2) Speedometer Gauge The speedometer indicates the vehicle speed by calculating the signals from the rear left and rear right wheel speed sensors through ABS or ESP unit. In this model, the wheel speed sensor is installed at the rear right tire area even though the ABS/ESP is not equipped. Its signal is used as a standard vehicle speed that is transmitted to instrument panel, TCU, TCCU, and engine ECU via CAN communication.
Page 316 05-8 8010-01 (3) Fuel Level Gauge The speedometer indicates the vehicle speed by calculating the signals from the rear left and rear right wheel speed sensors through ABS or ESP unit. In this model, the wheel speed sensor is installed at the rear right tire area even though the ABS/ESP is not equipped. Its signal is used as a standard vehicle speed that is transmitted to instrument panel, TCU, TCCU, and engine ECU via CAN communication.
Page 317 05-9 8010-01 (4) Coolant Temperature Gauge Using a needle, it displays the coolant temperature obtained from the engine coolant temperature sensor. The PTC resistance value of the coolant temperature sensor is transmitted to the engine ECU and then to the cluster as CAN signal. The angle of guage that can be varied by coolant temperature is as shown below.
Page 318 05-10 8010-01 2) TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter Odometer/Trip Odometer When pressing the TRIP/RESET switch on the center panel, the odometer/trip odometer is converted and the meter resets to 0.0 km in Trip A and Trip B. CLUSTER undefined...
Page 319 05-11 8010-01 (1) Operation of HDC Indicator Controller This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC switch is a push & self return type switch ? When you press it once, it starts to operate and when you press it again, it stops the operation.
Page 320 05-12 8010-01 (2) ESP Warning Lamp ▶ ESP Warning Lamp Blinking in Control ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to warn the driver. The ESP warning lamp goes off when ESP function is deactivated.
Page 321 05-13 8010-01 ▶ Resuming the ESP System by Using the ESP OFF Switch The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
Page 322 05-14 8010-01 ▶ ESP OFF Switch Monitoring When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds, the ESP unit determines it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 10 seconds.
Page 323 05-15 8010-01 ▶ ESP Warning Lamp Operation Depending on System Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is working. - When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate the vehicle stability (posture) during ESP operation.
Page 324 05-16 8010-01 4. CIRCUIT DIAGRAM CLUSTER undefined...
Page 325 05-17 8010-01 CLUSTER undefined...
Page 326 06-3 8310-01 8310-01 LAMP OVERVEIW AND OPERATION PROCESS 1. LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Headlamp Position lamp and Turn Signal Lamp Front Fog Light Side Repeater Push Push LAMP undefined...
Page 327 06-4 8310-01 Rear Combination Lamp Stop lamp/Tail lamp Turn signal lamp Back-up lamp Rear Fog Light High Mounted Stop Lamp License Plate Lamp LAMP undefined...
Page 328 06-5 8310-01 2. INTERIOR LAMPS Front Room Lamp: 12V/10W - (2 EA) Center Room Lamp: 12V/10W - (1 EA) Toward Toward tailgate dirver side Center room Center room lamp lamp (coupled operation (Lamp: ON) with door) The driver's room lamp and the passenger's Center Room Lamp room lamp are separately turned on when When this switch is pushed towards the rear of...
Page 329 06-6 8310-01 3. LAMP OPERATION LOGIC 1) Room Lamp Control The overhead console lamp (front room lamp) and the center room lamp come on when opening a door while the center/luggage room lamp switch is at coupled operating position and the key reminder switch is OFF.
Page 330 07-3 8510-31 8510-31 SWITCH GENERAL 1. SWITCH ARRANGEMENT Outside Rearview Mirror Folding Switch To fold the outside rearview mirrors, press the switch. To unfold the mirrors, press it again. Rear Fog Lamp Switch ESP OFF Switch If you press the ESP OFF switch, the ESP function stops indicator...
Page 331 07-4 8510-31 HDC Switch When this button is pressed once, HDC is ready for use. The green HDC indicator comes on the instrument panel. When the button is pressed again, HDC is deactivated and the indicator goes off. (Refer to ABS/ESP section.) Heated Tailgate Glass and Outside Rearview Mirror Glass Switch Press this switch to turn on the tailgate and...
Page 332 07-5 8510-31 Sun roof switch Main room lamp switch Front room lamp spot switch 4WD Control Switch Driver's Heated Seat Switch Passenger's Heated Seat Switch Head Lamp Leveling Switch Audio Remote Control Switch MUTER POWER ▲ MODER ▲ SEEK ▼ SEEK ▼...
Page 333 08-3 7810-01 & 7810-01 WIPER WASHER SYSTEM OVERVIEW AND OPERATION PROCESS 1. SYSTEM LAYOUT AND FUNCTION The wiper and washer system are controlled by STICS according to driver's wiper switch operation. And the detection of rain drops by rain sensor is transmitted to STICS as the signal for wiper system control.
Page 334 08-4 7810-01 3) Rear Washer Fluid Supply System There is no separate washer fluid reservoir for the rear washer system in this vehicle. The rear washer system uses the front washer fluid reservoir. Because of this, the washer hose is supposed to be long between front reservoir tank and rear washer nozzle.
Page 335 08-5 7810-01 4) Fluidic Washer Nozzle Fluidic Washer Nozzle is applied to the front washer spray system in this vehicle. The inside of nozzle is designed to utilize the fluidic movement. The water may be entered into the engine compartment if the curved area of the engine hood and the nozzle is not adhered closely.
Page 336 08-6 7810-01 2. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR) WIPER undefined...
Page 337 08-7 7810-01 WIPER undefined...
Page 338 08-8 7810-01 3. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION 1) Wiper and Washer Fluid Switch Operation WIPER undefined...
Page 339 08-9 7810-01 2) STICS Control Logic Related to Wiper and Washer (1) Wiper MIST and Front Washer Coupled Wiper The wiper relay is turned on 0.3 seconds after turning "ON" the washer switch for 0.1 ~ 0.59 seconds with the ignition key "ON", and it is turned off when the parking terminal is turned off.
Page 340 08-10 7810-01 When the washer switch is ON for more than 0.6 seconds during the wiper operation by the INT switch, the operation in step (2) is performed. When it is ON for a certain period of time (0.1 to 0.59 seconds), the operation in step (1) is performed. (2) Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch "ON", the rear washer motor relay output is activated from the time when the rear washer switch is turned on, and it is...
Page 341 08-11 7810-01 The auto washer switch output is overridden during the washer coupled wiper operation. The auto washer switch input is overridden during the auto washer coupled wiper operation. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation.
Page 342 08-12 7810-01 4. WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM WIPER undefined...
Page 343 09-3 8610-09 8610-09 RAIN SENSOR OVERVIEW AND OPERATION PROCESS 1. SYSTEM LAYOUT AND OVERVIEW The rain sensing wiper unit in this vehicle doesn't control the wiper directly. The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
Page 344 09-4 8610-09 Emitter lens The LED which is located bottom emits the infrared rays and the lens guides the infrared rays to target point. Auto light sensor (Vertical) Auto light sensor (Horizon) Enlarged auto light sensor section ▶ STICS The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
Page 345 09-5 8610-09 2. RAIN SENSING OPERATION The rain sensor is installed on the specific heat treated windshield that has minimum 13% of transmittance rate with specified intensity of radiation. It is installed on the glass with a adhesive of Sorepa. It communicates with STICS and makes the wipers to operate automatically under the rain sensing mode (multifunction switch wiper: AUTO mode).
Page 346 09-6 8610-09 3. RAIN SENSOR RELATED CIRCUIT The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram. However, in this vehicle, the terminal No. 1 and No. 2 are for communications between STICS and the rain sensor;...
Page 347 09-7 8610-09 4. FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING WIPER 1) Power-up Reminder Wiper When turning off and on the INT auto switch, the system drives the wiper motor for one cycle through LOW relay regardless of communication with rain sensor. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the INT auto switch to "ON"...
Page 348 09-8 8610-09 2) Washer Coupled Wiper in the Rain Sensing Mode The washer coupled wiper is operated when receiving the washer switch input with the ignition switch "ON" and the auto INT switch "ON" in rain sensing mode. At this moment, the communication with the rain sensor is overridden.
Page 349 09-9 8610-09 3) Rain Sensing Sensitivity Control The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to 1) (while the ignition key is in "ON" position, the wiper switch is in "AUTO"...
Page 350 09-10 8610-09 5) Wiper Operation When the Wiper Parking Terminal Is Grounded The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is grounded (while the ignition key is in "ON" position and the INT switch is in "ON"...
Page 351 09-11 8610-09 6) Defective Rain Sensor The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor (while the ignition key is in 'ON' position and the INT switch is in "ON" position). The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON"...
Page 352 09-12 8610-09 5. OPERATION MODE OF RAIN SENSING WIPER SYSTEM Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level.
Page 353 10-3 8790-03 8790-03 GENERAL 1. COMPONENT SPECIFICATIONS The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval and detects the reflected signals from obstacles while the gear selector lever is in "R" position. The alarm interval increases as the obstacle approaches. This supplementary system is to secure the safety distance for parking.
Page 354 10-4 8790-03 2. CAUTIONS ON PARKING AID SYSTEM Note that the display does not show everything in the rear area. Always check nobody, especially animals and children, is behind the vehicle when parking or reversing. If you can not properly check the vehicle behind, get out of the vehicle and then visually check it.
Page 355 10-5 8790-03 ▶ The parking aid system will not work or improperly work under following cases: 1. Certain obstacles that sensors can not detect Wires, ropes, chains. Cotton, sponge, clothes, snow that absorb ultrasonic waves. Obstacles lower than the bumper (ex. drain ditch or mud puddle) 2.
Page 356 10-6 8790-03 OVERVIEW AND OPERATION PROCESS 1. SYSTEM OVERVIEW The parking aid device is integrated in the rear bumper and it uses three Piezoelectric elements to measure vertical and horizontal distance to obstacles. When placing the gear selector lever to "R" position, the designated unit (PAS unit in the rear right quarter panel) activates the parking aid sensors to measure the distance to obstacles.
Page 357 10-7 8790-03 Left/Right/Center Sensor Location Center Sensor Side Sensor PAS Sensor Parking Aid Unit The PAS unit is installed in the rear right section of the rear quarter panel. undefined...
Page 358 10-8 8790-03 2. ALARM INTERVAL Alarm interval and display changes according to the distance as below: While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Page 359 10-9 8790-03 3. TROUBLESHOOTING OF SENSOR When the power is applied (gear selector lever is in "R" position), the sensor will be diagnosed once. If found any failure due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed sensor transmits to the instrument panel to light up the corresponding LED.
Page 360 10-10 8790-03 4. CIRCUIT DIAGRAM undefined...
Page 361 4610-00 8930-01 AUDIO SYSTEM OVERVIEW AND INSTALLATION 1. AUDIO SYSTEM OVERVIEW Audio System - 6 Speakers AUDIO SYSTEM undefined...
Page 362 02-3 3410-01 3640-01 ION 4-SPEED GENERAL 1. SPECIFICATIONS ION 4-SPEED ACTYON 2010.01...
Page 363 02-4 3410-01 2. FASTENER TIGHTENING SPECIFICATIONS ION 4-SPEED ACTYON 2010.01...
Page 364 Shift scheduling is highly flexible, and several independent schedules are programmed depending on the vehicle. Typically the NORMAL schedule is used to maximize fuel economy and driveability, and a POWER schedule is used to maximize performance. WINTER schedule is used to facilitate starting in second gear. ION 4-SPEED ACTYON 2010.01...
Page 365 02-6 3410-01 2. APPEARANCE 1) 4WD Automatic Transmission Torque converter Oil cooler return Oil cooler outlet Servo Adapter housing Inhibiter switch 2) 2WD Automatic Transmission ION 4-SPEED ACTYON 2010.01...
Page 366 02-7 3410-01 3. SHIFT PATTERN DIAGRAM 1) Normal Mode WINTER mode has same shift pattern with NORMAL mode except 2nd gear drive-off. 2) Power Mode ION 4-SPEED ACTYON 2010.01...
Page 367 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. ION 4-SPEED ACTYON 2010.01...
Page 368 Auto shift indicator light comes ON when the ignition switch ON and shows the gear shift control lever posi-tion. POWER mode indicator light comes ON when the POWER mode is selected and when the kickdown switch is depressed. WINTER mode indicator light comes ON when the WINTER mode is selected. ION 4-SPEED ACTYON 2010.01...
Page 369 Processing logic circuits which include a central microprocessor controller and a back-up memory system. Input circuits. Output circuits which control external devices such as the Variable Pressure Solenoid (VPS) driver, On/ Off solenoid drivers, a diagnostics output and the driving mode indicator light. ION 4-SPEED ACTYON 2010.01...
Page 370 The TCU is designed to operate at ambient temperatures between - 40 and 85°C (- 40 and 185°F). It is also protected against electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc welding or jump starting. ION 4-SPEED ACTYON 2010.01...
Page 371 This results in maximum oil flow through the external oil cooler and eliminates slippage in the torque converter. Both these actions combine to reduce the oil temperature in the transmission. ION 4-SPEED ACTYON 2010.01...
Page 372 02-13 3410-01 ION 4-SPEED ACTYON 2010.01...
Page 373 Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate reverse lamps when Reverse is selected Indicate to the TCU which lever position has been selected by way of a varying resistance. ION 4-SPEED ACTYON 2010.01...
Page 374 When system voltage recovers, the TCU will resume normal operation after a 30 seconds delay period. 7) TCU Outputs The outputs from the TCU are supplied to the components described below : Solenoids Mode Indicator Light ION 4-SPEED ACTYON 2010.01...
Page 375 Solenoid OFF gives high pressure. Solenoid 7: S7 is a normally open ON/OFF solenoid that controls the application of the converter clutch. Solenoid ON activates the clutch. Solenoid Logic for Static Gear States Gear Reverse Neutral Park ION 4-SPEED ACTYON 2010.01...
Page 376 02-17 3410-01 ▶ Solenoid Operation during Gearshifts ION 4-SPEED ACTYON 2010.01...
Page 377 1000 mA. Increasing current decreases output (S5) pressure. Decreasing current increases output (S5) pressure. Line 500 pressure, (approximately 440 to 560 kPa), is the reference pressure for the VPS, and the VPS output pressure is always below line 500 pressure. ION 4-SPEED ACTYON 2010.01...
Page 378 TCU design to be used over different vehicle mod-els. The particular code is sent to the microprocessor via the K-line and this results in the software selecting the correct shift and VPS ramp parameters. ION 4-SPEED ACTYON 2010.01...
Page 379 Torque converter lock-up is initiated by toggling the converter clutch control valve with an ON/OFF solenoid. The actual apply and release of the clutch is regulated by the VPS via the converter clutch regulator valve. The solenoid supply pressure regulator valve provides reference pressure for all the solenoids. ION 4-SPEED ACTYON 2010.01...
Page 380 02-21 3410-01 1) Hydraulic Control Circuit ION 4-SPEED ACTYON 2010.01...
Page 381 The 1-2 shift valve works in conjunction with the 3-4 shift valve to disengage the C4 clutch in first gear, and engage C4 in second gear. When Manual 1 is selected the C4 clutch and rear band (B2) are engaged. ION 4-SPEED ACTYON 2010.01...
Page 382 Note that the C4 clutch is applied in Manual 1 by virtue of the manual valve and the 1-2 hift valve. Refer to "1-2 Shift Valve" in this section. ION 4-SPEED ACTYON 2010.01...
Page 383 Heavy throttle application causes normally open S6 to open (switch Off) thus closing line 500 and opening S6 to exhaust. Removal of S6 pressure from the PRV results in HIGH line pressure. ION 4-SPEED ACTYON 2010.01...
Page 384 Band Apply Feed (BAF) pressure, of 1.4 times the S5 signal pressure when S4 is ON. When S4 is OFF the output pressure is 1.4 times the line 500 pressure. ION 4-SPEED ACTYON 2010.01...
Page 385 B2 at high speed, and by providing a reverse lockout function. Note that if the transmission is in failure mode, the rear band will be applied at all times in P, R and N. ION 4-SPEED ACTYON 2010.01...
Page 386 PRV moves to uncover the converter feed port thereby pressurizing the converter. If there is an excess of oil for the transmission's needs then the PRV moves further to allow oil to return to the suction port. ION 4-SPEED ACTYON 2010.01...
Page 387 To provide oil flow to the cooler the converter clutch control valve directs converter feed oil from the PRV directly to the cooler circuit. ION 4-SPEED ACTYON 2010.01...
Page 388 3-4 shift valve. The spring positions the valve to prevent oil entering the release area of the servo until circuit pressure reaches approximately 100 kPa. ION 4-SPEED ACTYON 2010.01...
Page 389 All the friction elements have been designed to provide low shift energies and high static capacities when used with the new low static co- efficient transmission fluids. Non-asbestos friction materials are used throughout. ION 4-SPEED ACTYON 2010.01...
Page 390 02-31 3410-01 ION 4-SPEED ACTYON 2010.01...
Page 391 Whenever lock-up occurs, improved fuel consumption is achieved. Torsional damper springs are provided in the damper and piston assembly to absorb any engine torque fluctuations during lock-up. ION 4-SPEED ACTYON 2010.01...
Page 392 B1 prevents the reverse sun gear from rotating by holding the C3 clutch assembly stationary. In second gear only the outer area of the apply piston is utilized. In fourth gear both areas are utilized for greater clamping force. ION 4-SPEED ACTYON 2010.01...
Page 393 In Park, Reverse and Neutral, both areas are utilized for greater clamping force. ▶ Planetary gear set The planetary gear set used in the transmission is a conventional six pinion Ravigneaux compound gear set. ION 4-SPEED ACTYON 2010.01...
Page 394 Power Flow - Drive 3 Power Flow - Drive 3 Lock Up Power Flow - Drive 4 (Overdrive) Power Flow - Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections. ION 4-SPEED ACTYON 2010.01...
Page 395 02-36 3410-01 1) Park and Neutral ION 4-SPEED ACTYON 2010.01...
Page 396 The line 500 circuit is charged by the solenoid supply pressure regulator valve. The S5 circuit is charged by the variable pressure solenoid (S5). Line pressure is prevented from entering the drive circuit by the manual valve. The B1 circuit and all clutch circuits are open to exhaust. ION 4-SPEED ACTYON 2010.01...
Page 397 02-38 3410-01 2) Reverse ION 4-SPEED ACTYON 2010.01...
Page 398 Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value. All other clutch and band apply circuits are open to exhaust. ION 4-SPEED ACTYON 2010.01...
Page 399 02-40 3410-01 3) Manual 1 ION 4-SPEED ACTYON 2010.01...
Page 400 Drive (line pressure) oil from the manual valve engages the C2 clutch. Lo-1st (line pressure) oil is routed through the 1-2 shift valve to the C4 clutch, and to the inner apply area of the rear servo piston for B2 band application. ION 4-SPEED ACTYON 2010.01...
Page 401 02-42 3410-01 4) Drive 1 ION 4-SPEED ACTYON 2010.01...
Page 402 Solenoids S1 and S2 are switched ON. The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure. Drive (line pressure) oil from the manual valve engages the C2 clutch. ION 4-SPEED ACTYON 2010.01...
Page 403 02-44 3410-01 5) Drive 2 and Manual 2 ION 4-SPEED ACTYON 2010.01...
Page 404 Solenoids S1 and S2 are switched ON. The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure. Drive (line pressure) oil from the manual valve engages the C2 clutch. ION 4-SPEED ACTYON 2010.01...
Page 405 02-46 3410-01 6) Drive 3 and Manual 3 ION 4-SPEED ACTYON 2010.01...
Page 406 3-4 shift valve to the spring end of the 4-3 sequence valve, and to the release side of the front servo piston to hold band 1 OFF. Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch. ION 4-SPEED ACTYON 2010.01...
Page 407 02-48 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 3 and Manual 3 ION 4-SPEED ACTYON 2010.01...
Page 408 02-49 3410-01 7) Drive 3 Lock Up and Manual 3 Lock Up ION 4-SPEED ACTYON 2010.01...
Page 409 Converter clutch release oil is exhausted at the converter clutch control valve. Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit. ELEMENTS ENGAGED Gear State CLUTCH Drive 3 Lock Up and Manual 3 Lock Up ION 4-SPEED ACTYON 2010.01...
Page 410 02-51 3410-01 8) Drive 4 (Overdrive) ION 4-SPEED ACTYON 2010.01...
Page 411 Clutch Apply Feed (CAF) circuit. The CAF oil is directed to The C1clutch · The 4-3 sequence valve · Drive oil (line pressure) from the manual valve engages the C2 clutch. ION 4-SPEED ACTYON 2010.01...
Page 412 02-53 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED ACTYON 2010.01...
Page 413 02-54 3410-01 9) Drive 4 Lock Up ION 4-SPEED ACTYON 2010.01...
Page 414 Converter clutch release oil is exhausted at the converter clutch control valve. Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit. ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED ACTYON 2010.01...
Page 415 Using all of these input signals, the TCU can determine when the time and conditions are right for a shift, or when to apply or release the torque converter clutch. It will also determine the pressure needed to optimise shift feel. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 416 Shift schedule points are optimised for fuel to depress the brake pedal with efficiency and general driving conditions. the ignition switch "ON". DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 417 3650-01 2. STRUCTURE CHARACTERISTICS AND SPECIFICATIONS 1) Specifications DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 418 3650-01 2) Appearance ▶ 4WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Inhibiter switch Adapter housing ▶ 2WD Automatic Transmission DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 419 3650-01 3) Internal Assembly Figure DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 420 3650-01 4) Shift Pattern DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 421 3650-01 3. TIGHTENING TORQUE DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 422 The automatic transmission is electronically controlled. The control system is comprised of the following elements: External transmission control unit (TCU) Internal embedded memory module (EMM) Input and output speed sensors Valve body unit comprised of four on/off solenoid valves and six variable bleed solenoids Torque converter DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 423 Upon installation, the TCU will download the data from the EMM and utilise this data in the operation of the transmission. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 424 Torque demand downshifts occur (automatically) when the driver demand for torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 425 P : Parking R : Reverse N : Neutral D : Driving (5) Tip Switch (Manual Gear Adjustment) The shiftable gear can be adjusted by this switch when the gear selector lever is in "M" position. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 426 5th gear has engine braking available. ▶ 6st Gear State The 6th gear state will display on the instrument cluster. 6-5, 6-4 automatic kick-down shifts are available. 6th gear has engine braking availabl DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 427 The best way to transport the vehicle is to load it to a truck and transport it, especially if the vehicle is 4WD. - If towing the vehicle with the propeller shaft connected, the transmission or oil pump of transfer case may malfunction, resulting in internal damage due to poor lubrication. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 428 Ambient air temperature Barometric pressure 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 transmission gear changes. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 429 This function is used for: - Increasing the transmission service life by shortening the slipping time - Improving the shift comfort by reducing the step change in torque caused by the gearshift DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 430 When winter mode is selected, starting in second gear is facilitated and the WINTER mode indicator light is switched ON. To prevent wheel spin on slippery surfaces, the transmission will not allow first gear unless manually overridden. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 431 The fluid temperature must be below 105캜 to exit all hot modes. ▶ Cruise When cruise control is activated the engine ECU may request the transmission to downshift under trailing throttle conditions to increase engine braking. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 432 The EMM data contains transmission specific characterisation information. Upon installation, the TCU will upload the data from the EMM and utilise this data in the operation of the transmission. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 433 Power train - D 3rd gear Power train - D 4th gear - D 4th gear - limp home mode Power train - D 5th gear Power train - D 6th gear ▶ Gear States Summary DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 434 0-21 3650-01 ▶ Overall Hydraulic Circui DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 435 S5 regulates pressure supplied to the C1 Clutch S6 regulates pressure supplied to the C2 Clutch S7 regulates pressure supplied to the C3 Clutch & B2 Band S8 regulates pressure supplied to the B1 Band ▶ Gear States Summary DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 436 Drive oil that engages C2 Clutch is regulated by VBS S6. ▶ Connecting Components Manual 1st is not achieved by moving the Manual Valve into a certain position. This gear state is obtained electronically by solenoids S1 & S7. ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 437 0-24 3650-01 ▶ Manual 1st - C2 & B2 ON (3.536) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 438 S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch. C2 Shift Valve (S2 OFF) is open allowing drive oil to engage C2 Clutch. Drive oil that engages C2 Clutch is regulated by VBS S6. Connecting Components ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 439 0-26 3650-01 ▶ Auto 1st - C2 & OWC ON (3.536) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 440 Drive oil that engages C2 Clutch is regulated by VBS S6. S4 ON moves B1 Shift Valve to its left-end position allowing engagement of B1 Band. Drive oil that engages B1 Band is regulated by VBS S8. ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 441 0-28 3650-01 ▶ Auto 2nd - C2 & B1 ON (2.143) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 442 0-29 3650-01 4) Power Train - "D" (Drive) 2nd - Lockup ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 443 0-30 3650-01 ▶ 2nd Lockup - C2, B1 & TCC ON DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 444 S3 & S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch. ▶ Connecting Components C3 Clutch cannot be engaged without S7 being ON and supplying pressure to the C3 Regulator Valve. ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 445 0-32 3650-01 ▶ 3rd Gear - C2 & C3 ON (1.478) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 446 C2 Shift Valve is OPEN (S2 OFF) allowing drive oil to engage C2 Clutch. Drive oil that engages C1 & C2 Clutches is regulated by S5 & S6 VBS, respectively for each clutch. Connecting Components ▶ 4th GEAR is used as a LHM state. ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 447 0-34 3650-01 ▶ 4th & 4th LHM - C1 & C2 ON (1.156) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 448 C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch S3 ON and with S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutc. Connecting Components ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 449 0-36 3650-01 ▶ 5th Gear - C1 & C3 ON (0.866) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 450 S2 ON moves C2 Shift Valve to its left-end position not allowing the application of the C2 Clutch. C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch S4 ON moves B1 Shift Valve to its left-end position allowing the engagement of B1 Band. Connecting Components ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 451 0-38 3650-01 ▶ 6th Gear - C1 & B1 ON (0.677) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 452 Line pressure is directed via Manual Valve to apply B2 Band directly. S3 ON allows ramping and regulating pressure supplied to the C3. S1 & S2 are ON not allowing engagement either C1 or C2 Clutch at any circumstances. Connecting Components ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 453 0-40 3650-01 ▶ Reverse - C3 & B2 ON (-3.094) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 454 0-41 3650-01 10) Power Train - Reverse (Limp Home Mode) ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 455 0-42 3650-01 ▶ Reverse at LHM - C3 & B2 ON DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 456 0-43 3650-01 11) Power Train - Parking ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 457 0-44 3650-01 ▶ Park DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 458 0-45 3650-01 12) Power Train - Neutral ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 459 0-46 3650-01 ▶ Neutral DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 460 0-95 3110-01 DIAGNOSIS AND TESTING 1. WIRING DIAGRAM DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 461 0-96 3110-01 2. WIRE HARNESS CONNECTOR CHART Connector Front View 3. UNIT CONNECTOR DESCRIPTION 1) Transmission Control Unit ▶ Connector J1 (A) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 462 0-97 3110-01 ▶ Connector J2 (B) Connector J3 (C) ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 463 0-98 3110-01 2) Transmission Connector Front View ▶ Connector J4 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 464 0-99 3110-01 3) Inhibitor Switch Connector J5 ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 465 0-100 3110-00 TROUBLE CODE DIAGNOSIS 1. DIAGNOSTIC TROUBLE CODE LIST DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 466 0-101 3110-00 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 467 If a transmission component degrades to a point whereby the TCU is unable to adapt its shift data to maintain shift quality, the TCU will set a DTC. ▶ Connector J5 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 468 0-103 3110-00 ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 469 0-104 3110-00 ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 470 There is a different resistance value for each position of the TGS lever. ▶ DTC Description ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 471 0-106 3110-00 ▶ Resistance Values Gear Lever Position Sensor Specifications ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 472 0-107 3110-00 DTC Clearing ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 473 The TCU also monitors the rate of temperature change according to current operating conditions (performance). If the temperature sensor performance is outside a pre-determined set of values, DTC P0711 will set. DTC Description ▶ ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 474 When the transmission fluid is cold, the sensor resistance is high, with the sensor resistance decreasing as the fluid temperature increases. ▶ DTC Description ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 475 0-110 3110-00 ▶ Resistance Values DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 476 0-111 3110-00 ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 477 The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 36 times per revolution of the C2 cylinder. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 478 0-113 3110-00 ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 479 0-114 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 480 0-115 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 481 6) Transmission Gear Select Lever The transmission gear select lever contains the mode switch, manual mode active switch and up/down switches. These switches are connected directly to the TCU. ▶ DTC Description ▶ Schematic DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 482 0-117 3110-00 ▶ Connector Details ▶ Resistance Values Transmission Gear Select Lever ▶ Resistance Values DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 483 0-118 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 484 The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 22 times per revolution of the transmission output shaft. ▶ DTC Description ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 485 0-120 3110-00 ▶ DTC Details DTC Details ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 486 Transmission gear change is controlled by the TCU. The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch (TCC) operation at each gear change. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 487 0-122 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 488 0-123 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 489 (VBS). During operation, the TCU evaluates torque converter slip speed and compares this against what is expected. If torque converter slip is not within predefined parameters, a DTC will set to indicate a torque converter lock-up problem. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 490 0-125 3110-00 ▶ DTC Details DTC Clearing ▶ DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 491 The steering wheel contains transmission gear select (TGS) up/down switches and are directly connected to the TCU. These switches operate in parallel with the TGS lever switches directly to the TCU. ▶ DTC Description ▶ Schematic DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 492 0-127 3110-00 ▶ Connector Details ▶ Resistance Values ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 493 0-128 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 494 During operation, the TCU evaluates the actual current delivered to the solenoid and compares this against what is expected. If the current is not within predefined parameters, a DTC will be set to indicate the load on the TCU is abnormal. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 495 0-130 3110-00 ▶ DTC Description Schematic ▶ ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 496 0-131 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 497 0-132 3110-00 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 498 0-133 3110-00 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 499 0-134 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 500 During operation, the TCU evaluates the actual current delivered to the on/off solenoid and compares this against what is expected. If the current is not within predefined parameters, a DTC will be set to indicate the load on the TCU is abnormal. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 501 0-136 3110-00 ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 502 0-137 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 503 0-138 3110-00 DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 504 0-139 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 505 The TCU obtains the majority if its information via this network. If the TCU does not receive information at regular intervals from the electronic control units connected to the bus, the TCU will set a communication DTC. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 506 0-141 3110-00 ▶ Schematic ▶ Connector Details ▶ DTC Details DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 507 0-142 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 508 TCU software or calibration may be upgraded at service. These DTC뭩 protect the TCU against corrupted files being loaded into the TCU. They also ensure only the correct calibration parameters are used with the software version currently loaded into the TCU. ▶ DTC Description DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 509 0-144 3110-00 ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 510 Raise up the vehicle with a proper lift. Clean up the surroundings of the filler plug before removing the plug. After removing the plug, clean up the plug thoroughly and inspect the O-ring for any damage. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 511 Replace the filler plug with a new one. Wipe off oil on the transmission or other parts of the vehicle. Apply the specified torque to tighten up the filler plug (30 ~ 35 Nm). DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 512 Press Accelerator Pedal to 100 % for 6 seconds Observe Engine speed Release Accelerator Pedal Shift To Reverse Press Accelerator Pedal to 100 % for 6 seconds Observe Engine speed If engine speed is observed > 3000 rpm; transmission hardware failure DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 513 (engine not running). Set the parameter Set Km Travelled to 0 Km. Run the task Reset Adaptive Data. Turn the ignition key to the OFF position. Start the vehicle and check for normal operation. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 514 Allow transmission fluid to drain from the fluid level hole for 50 seconds. Reinstall the fluid level plug and tighten the plug to the correct torque specification. Lower the vehicle to the ground and road test the vehicle to check vehicle operation and for fluid leaks. DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 515 Whist the engine is running, have an assistant pump transmission fluid into the transmission fluid level hole. Connect the rear transmission cooler line to the transmission. Check the transmission fluid level; refer to Fluid Level Inspection on page 69. 6. LUBRICATION Automatic transmission fluid....Caltex PED 1712 ATF DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 516 0-151 3680-01 7. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE(NEW TRANSMISSION) DSI M78 6-SPEED A/T ACTYON 2010.01...
Page 517 This system is only activated when the TGS lever is engaged in the “M” position. When the lever is pushed to the “D” position, the tip switches will not change gears. 1) Components TGS LEVER ACTYON 2010.01...
Page 518 When maximum engine rpm is reached the transmission will upshift automatically regardless of the driver selected limit. 4WD models with low range will not automatically upshift when low range is selected. TGS LEVER ACTYON 2010.01...
Page 519 2nd gear has engine braking available. (11) 1: 1 gears (only available in the “M” position) 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. TGS LEVER ACTYON 2010.01...
Page 520 When the selector lever is pushed to the D position from the M mode, the M position sensor detects the change and sends another signal to the TCU. Then, the TCU enables the transmission to choose from all available gears including the highest one (the D position). TGS LEVER ACTYON 2010.01...
Page 521 In case of 4WD-models (inapplicable to 2WD- or AWD-models), when the full throttle is attempted at 25 Km/h or slower speed, the Mode switch sends out a control signal from the Selector Lever unit to the TCU through hard wires. TGS LEVER ACTYON 2010.01...
Page 522 3722-01 2) Electric Circuit TGS LEVER ACTYON 2010.01...
Page 523 1. Selector Lever 2. Shift Pattern Display 3. Selector Lever Handle 4. Parking Lock Release Flap 5. Selector Lever Control Unit (Internally Installed) 6. Mode Switch 2) Electric Circuit TGS LEVER ACTYON 2010.01...
Page 524 0-10 3722-01 3) Shift Lock Solenoid Function TGS LEVER ACTYON 2010.01...
Page 525 In this situation, the lock lever (4) is engaged to the P Lock position and the Locking Lever Tap (3) holds the Lock Lever (2). Therefore, the Selector Lever cannot be shifted to other positions. TGS LEVER ACTYON 2010.01...
Page 526 Then, shift the lever to other positions. Shift lever lock release Do not push down the shift lock release lever excessively. The internal parts could be damaged. TGS LEVER ACTYON 2010.01...
Page 527 The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock devices are installed. The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model. ACTYON 2010.01...
Page 528 03-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications ACTYON 2010.01...
Page 529 03-5 3170-01 2) Tightening Torque ACTYON 2010.01...
Page 530 03-6 3170-01 OVERVIEW AND OPERATION PROCESS 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch 0.5 mm N (Neutral) Switch 0.5 mm Outside N Switch Inside N Switch ACTYON 2010.01...
Page 531 RPM. In case of Actyon, the N switch signal is transmitted to the instrument panel, and then the instrument panel transmits it to the engine ECU through the CAN communication. Vehicle Made After 04.09.15 Actyon ACTYON 2010.01...
Page 532 Neutral Signal Input None / Wire / Wire / Actyon & Kyron models with manual transmission New Rexton model with manual transmission Manufactured after 04.09.15 BODY IN: after 154600 Automatic transmission & Rodius model with automatic transmission before 2006 ACTYON 2010.01...
Page 534 04-3 3010-01 3020-01 CLUTCH GENERAL 1. CLUTCH SPECIFICATIONS 2. TIGHTENING TORQUE CLUTCH ACTYON 2010.01...
Page 535 Disc wear (Free play) → Diaphragm spring (1) → Adjusting equipment (2, 3) → Pressure plate (4) CLUTCH ACTYON 2010.01...
Page 536 This system provides higher efficiency than conventional clutch system, and its durability is superior. Clutch master cylinder (mounted on clutch pedal) Concentric slave cylinder pipe (mounted inside of transmission) CLUTCH ACTYON 2010.01...
Page 537 04-6 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH ACTYON 2010.01...
Page 538 04-7 3010-01 Cross Sectional View of Clutch Assembly Transmission housing Bolt Clutch disc assembly Washer Clutch disc cover assembly Bolt CLUTCH ACTYON 2010.01...
Page 539 05-3 4120-01 4120-01 AXLE GENERAL 1. SPECIFICATIONS OF AXLE 1) Front View 2) Rear View 3) Specifications AXLE ACTYON 2010.01...
Page 540 The specification below is for front and rear axles equipped in Actyon, including gear ratio and specific specifications. For details, refer to each section. → ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← AXLE ACTYON 2010.01...
Page 541 05-5 4120-01 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW OF AXLE 1) Front Axle 2) Rear Axle AXLE ACTYON 2010.01...
Page 542 In non-ABS vehicle, the vehicle speed sensor is installed on the rear drive axle. The engine ECU sends the speed signal to the instrument panel, and then the instrument panel provides the information to TCCU and other devices. 2. SPECIFICATIONS TRANSFER CASE ACTYON 2010.01...
Page 543 3240-01 OVERVIEW AND OPERATION PROCESS 1. STRUCTURE Front axle Front locking hub system (IWE) Power steering assembly Front propeller shaft ION 4th gear automatic transmission Part time transfer case TCCU Rear propeller shaft Rear axle TRANSFER CASE ACTYON 2010.01...
Page 544 Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly T/C motor Oil drain plug (Tightening torque: 19 ~ 30 Nm) Damper Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm) TRANSFER CASE ACTYON 2010.01...
Page 545 3240-01 2. SYSTEM LAYOUT AND OPERATION 1) System Layout TRANSFER CASE ACTYON 2010.01...
Page 546 Operating Process Booster TCCU Vacuum pump Atmosphere Vacuum modulator Atmosphere Electrical (for engine) signal Vacuum solenoid valve for IWE Locking hub actuator Locking hub actuator Vacuum generation process in front hub actuator: TRANSFER CASE ACTYON 2010.01...
Page 547 The vacuum pressure is released from hub actuator so that it will the hub actuator. At this time, the front not be engaged with the hub end gear is engaged. front end hub gear. TRANSFER CASE ACTYON 2010.01...
Page 548 3240-01 4. POWER FLOW 1) Components of Power Flow Part time transfer case Transfer case Engine Rear (2WD) Rear wheel side Front (4WD) Front wheel side TRANSFER CASE ACTYON 2010.01...
Page 549 0-10 3240-01 2) Flow Layout TRANSFER CASE ACTYON 2010.01...
Page 550 0-11 3240-01 3) 2H Mode (Rear Wheel Drive) (1) Layout ↓ TRANSFER CASE ACTYON 2010.01...
Page 551 0-12 3240-01 4) 4H Mode (4 Wheel Drive - High speed) (1) Layout ↓ TRANSFER CASE ACTYON 2010.01...
Page 552 0-13 3240-01 4) 4L Mode (4 Wheel Drive - Low speed) (1) Layout TRANSFER CASE ACTYON 2010.01...
Page 553 07-3 4411-01 4510-01 SUSPENSION GENERAL 1. SPECIFICATIONS OF SUSPENSION 2. WHEEL ALIGNMENT SUSPENSION ACTYON 2010.01...
Page 554 (thickness: approx. 10.4 mm) is installed on ABS/ESP equipped vehicle. Rear Disc and Caliper (1 Internal Cylinder) 3) Parking Brake For the parking brake system, the hand operated type parking brake is installed regardless of the models. ACTYON 2010.01...
Page 555 08-4 4892-01 2. SECTIONAL DRAWING 1) Front Disc Brake 2) Rear Disc Brake ACTYON 2010.01...
Page 556 ECU (terminal 36), where its signal is processed, and is connected to other related systems through CAN communication. (1) Location of the wheel speed sensor (rear right wheel) Location of the Sensor Connector Connector Appearance In vehicle without In vehicle with ABS/ESP ACTYON 2010.01...
Page 557 08-6 4892-01 3. SPECIFICATIONS Description Item NON-ABS ABS/ESP Brake pedal Brake master cylinder Brake booster Front brake Rear brake Parking brake Brake fluid ACTYON 2010.01...
Page 558 It is also a physical phenomenon and has no relation with the brake performance. ACTYON 2010.01...
Page 559 During the ARP operation, vehicle safety (rollover prevention) takes the first priority and thus, stronger engine control is in effect. Consequently, the vehicle speed decreases rapidly, so the driver must take caution for the vehicle may drift away from the lane. ACTYON 2010.01...
Page 560 2. EBD (Electronic Brake-Force Distribution) 3. ABD (Automatic Braking Differential) 4. ASR (Acceleration Slip Regulation) 5. AYC (Active Yaw Control, Understeer Oversteer control) 6. HBA (Hydraulic Brake Assist System) 7. ARP (Active Rollover Protection) 8. HDC (Hill Descent Control) ACTYON 2010.01...
Page 561 (ESP warning lamp goes off) again (Green HDC indicator goes off) Steering Angle Sensor Sensor cluster (Steering Wheel) Detects Detects the angle of the steering Detects lateral acceleration, longitudinal wheel and sends it to HECU. acceleration and yaw rate. ACTYON 2010.01...
Page 562 08-11 4892-01 Receives the signals from wheel speed HECU sensor, steering wheel angle sensor, sensor cluster and pressure sensor and perform the vehicle stability control function. Rear Wheel Speed Sensor (LH/RH) Wheel Speed Sensor(FOR 4WD) ACTYON 2010.01...
Page 563 As the centrifugal force increases, the tires can easily lose the traction and the vehicle tends to slip outward when the curve angle gets bigger and the speed increases. ACTYON 2010.01...
Page 564 When compared with under steering vehicles, the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases. ACTYON 2010.01...
Page 565 In order to compensate to this problem, the ESP system sets the priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be changed depending on the vehicle driving situations and driving conditions. ACTYON 2010.01...
Page 566 08-15 4892-01 The following figure shows the operating range according to driving conditions. Operating range Turning Turning ACTYON 2010.01...
Page 567 (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operating during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating. ACTYON 2010.01...
Page 568 When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels. ACTYON 2010.01...
Page 569 If the drive depresses the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake system with booster is activated. Operating conditions: Pressure: over 20 bar Pressure changes: over 1500 bar/sec Vehicle speed: over 7 Km/h ACTYON 2010.01...
Page 570 The vehicle driving condition is controlled by the internally programmed logic according to the input signals from wheel speed sensor, steering angle sensor and lateral sensor. ACTYON 2010.01...
Page 571 The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off (however, the ARP function is also deactivated when the ESP function is not operatable due to system malfunction). ACTYON 2010.01...
Page 572 Green letters The G sensor in sensor cluster measures the actual road steepness. However, it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10%, and the HDC may operate. ACTYON 2010.01...
Page 573 7 km/ h, but is converted to the stand-by mode. When the vehicle speed increases again as a result of the increase of the road steepness, etc., the HDC goes into operation.) Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission) ACTYON 2010.01...
Page 574 When depressing the brake pedal, HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation. ACTYON 2010.01...
Page 575 The red HDC warning lamp blinks when the internal temperature goes over 350°C. When reaches 450°C, the HDC warning lamp stays on. The HDC can be operated in this range even where the HDC warning lamp blinks. When the slope level is below 10% ACTYON 2010.01...
Page 576 08-25 4892-01 4) Input/Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function. ACTYON 2010.01...
Page 577 Basically, the brake system's basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: Initial ignition ON HDC system error occurs Brake system overheat ACTYON 2010.01...
Page 578 During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and the brake system, but this is a normal condition during the HDC operation. ACTYON 2010.01...
Page 579 There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system. However, the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied. Master cylinder pressure sensor Active Wheel Speed Sensor Valve body Motor pump ACTYON 2010.01...
Page 580 08-29 4892-01 (1) Comparison with ABS System ESP OFF Switch HDC Indicator ABS / ESP Indicator Steering Wheel Sensor Cluster (Yaw Rate + Lateral Sensor HDC Switch Angle Sensor + Longitudinal Sensor) ACTYON 2010.01...
Page 581 08-30 4892-01 7. INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input/Output of ESP System ▶ ACTYON 2010.01...
Page 582 08-31 4892-01 8. HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ACTYON 2010.01...
Page 583 Then, the inlet and outlet valves will be closed or open depending on the braking pressure increase, decrease or unchanged conditions. For details, refer to "Hydraulic Pressure for each ESP Operating Range". ACTYON 2010.01...
Page 584 The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied. Then the pump operates to allow fast oil drainage. The shuttle valve and the separation valve do not operate while decompression. ACTYON 2010.01...
Page 585 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. ACTYON 2010.01...
Page 586 Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps rotating and the outlet valve and the separation valve will stay closed. When the wheel starts to lock, the BAS function cancels and switches to ABS operation. ACTYON 2010.01...
Page 587 HECU (valve body and ECU integrated type), front wheel speed sensor and rear wheel speed sensor. Front Wheel Speed Rear Wheel Speed Sensor (for 4WD) Sensor HECU (Valve Body and ECU Integrated Type) Valve body ABS warning lamp B: Plunger C: Cam bushing Motor pump ACTYON 2010.01...
Page 588 08-37 4892-01 1) Input and Output Diagram Of ABS System ACTYON 2010.01...
Page 589 The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one from the previous model. ACTYON 2010.01...
Page 590 The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the brake pedal vibration and some noise. ACTYON 2010.01...
Page 591 This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at the brake pedal. ACTYON 2010.01...
Page 592 In this case, the operating force of the steering wheel is conveyed to the pinion, and the movement of the pinion moves the rack through the pinion gear combined to the rack gear. 2. SPECIFICATIONS POWER STEERING ACTYON 2010.01...
Page 593 09-4 4610-01 OVERVIEW AND OPERATION 1. SYSTEM LAYOUT POWER STEERING ACTYON 2010.01...
Page 594 09-5 4610-01 POWER STEERING ACTYON 2010.01...
Page 595 09-6 4610-01 2. COMPONENTS POWER STEERING ACTYON 2010.01...
Page 596 09-7 4610-01 POWER STEERING ACTYON 2010.01...
Page 597 Replacement parts when a curtain air bag deploys: the new curtain air bag for the deployed side, the air bag unit and its connection wires (connectors included), the collision G sensor assembly for the curtain air bag, and the trims and roof headlining for the broken parts. AIR BAG ACTYON 2010.01...
Page 598 Air bag cable Driver side STICS Curtain air bag collision G sensor BPT: Belt Pretensioner after receiving deployment signal at the vehicle speed 3 km/h or higher, it sends out the door UNLOCK signal for 5 seconds. AIR BAG ACTYON 2010.01...
Page 599 (driver's and passenger's air bags) and (or) the driver's and passenger's seat belt retensioners. When the front collision G sensor sends out only the air bag deployment signal, the signal deploys the two front air bags and ctivates their seat belt pretensioners. AIR BAG ACTYON 2010.01...
Page 600 The overall air bag operation process and its functions and roles are broadly explained in this block diagram. This diagram summarizes and highlights the functions adopted by Ssangyoung Motors. 1) Air Bag System Block Diagram (Functions and Roles Included) AIR BAG ACTYON 2010.01...
Page 601 02-7 8810-03 AIR BAG ACTYON 2010.01...
Page 602 Air bag housing Air bag cushion (approx. 50 liters) Inflator* (approx. 190 Kpa) Retainer ring Horn switch Inflator* The inflator is composed of the detonator, explosives, and the gas generator. It inflates air bag when vehicle collides. AIR BAG ACTYON 2010.01...
Page 603 (curtain air bags independently operate in case of the side collisions). Rear View Front View (1) Components Passenger's air bag module housing Inflator Air bag cushion Retainer AIR BAG ACTYON 2010.01...
Page 604 B-pillar. The signal is transmitted to the air bag unit. The air bag unit instantly inflates the necessary air bag necessary by sending a high current. When the Curtain Air Bag is Installed Terms of the Curtain Air Bag When the Curtain Air Bag Deploys AIR BAG ACTYON 2010.01...
Page 605 02-11 8810-03 (1) Components AIR BAG ACTYON 2010.01...
Page 606 This holds the occupant more securely in the seat. Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side) 35 ~ 55 Nm Curtain air bag G sensor Belt pretensioner (LH) Belt pretensioner (RH) AIR BAG ACTYON 2010.01...
Page 607 Belt Pretensioner Pretensioner reel assembly Reel bracket Ring upper stay D-ring Bending tongue Tongue stopper Mini anchor D-bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D-bolt Label D-bolt Spacer Bush Mini anchor cover AIR BAG ACTYON 2010.01...
Page 608 02-14 8810-03 5) Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel. The sensor that detects collision is integrated into the air bag unit. Air Bag Unit Connector AIR BAG ACTYON 2010.01...
Page 609 But incorrect tightening torque may break the sensor or make it insecure. As a result, the sensor may have inaccurate judgment and have the air bag deployed inaccurately. Driver's Side Passenger's Side 9 Nm ± 1 Nm Connector Signal Ground terminal AIR BAG ACTYON 2010.01...
Page 610 Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance. The detonator may explode due to a sudden extra power supplied by the tester. Before removing or installing any air bag related components, disconnect the negative battery cable. AIR BAG ACTYON 2010.01...
Page 611 But, if an unlock request is made by the air bag signal or the remote control key, the request will be accepted. When the lock and unlock functions are simultaneously requested, the lock function will be performed and the unlock function will be ignored. AIR BAG ACTYON 2010.01...
Page 612 Other Systems When, due to an error from outside the system, the intermittent failure signal is received 5 times or less, the air bag warning lamp comes on for about 6 seconds and then, goes off. AIR BAG ACTYON 2010.01...
Page 613 02-19 8810-03 10) Electrical Wiring Diagram AIR BAG ACTYON 2010.01...
Page 614 Reclining Motor Lumbar Support Lever Seat cushion (rear area) up/ down bar Sliding rail Sliding rail Seat cushion (front area) up/ down bar Seat Cushion (Rear Area) Seat Cushion (Front Area) Sliding motor Up/Down Motor Up/Down Motor SEAT ACTYON 2010.01...
Page 615 03-4 7410-01 (2) Passenger Seat Reclining Motor Sliding rail Sliding rail Power Seat Switch Reclining Switch Sliding lever (No seat height control function) Sliding motor SEAT ACTYON 2010.01...
Page 616 Seatback Reclining Adjustment When moving the upper side of the reclining switch forward rearward, the seatback moves forward or rearward by the motor. * Driver and passenger seats SEAT ACTYON 2010.01...
Page 617 Seatback Reclining Adjustment Full Flatting the Seat Seatback Seatback Reclining Lever Reclining Lever To change the seatback angle, push the lever rearward. Then, release the lever at the desired position. The seat is locked at the position SEAT ACTYON 2010.01...
Page 618 Seat belt D-ring Seat Belt in Rear Seat (2 & 3Point Type) (Center) Buckle of 3-point type seat belt Buckle of 3-point type seat belt 2-point type seat belt Buckle of 2-point 3-point type type seat belt seat belt SEAT ACTYON 2010.01...
Page 619 04-3 7340-01 7340-01 SUNROOF OVERVIEW AND OPERATION PROCESS 1. COMPONENTS AND LOCATIONS Sunroof Control Unit (SCU) Sunroof Switch Sunroof Motor Sunroof Assembly Front Drain Hose Rear Drain Hose SUNROOF ACTYON 2010.01...
Page 620 2) Sunroof Tilting Operation (1) Tilt-up To tilt-up the sunroof, rotate the sunroof switch counterclockwise (CLOSE direction) with the sunroof fully closed. (2) Tilt-down To tilt-down the sunroof, rotate the sunroof switch clockwise (OPEN direction) with the sunroof tilted-up. SUNROOF ACTYON 2010.01...
Page 621 4) Hazard (Manual) Operation The sunroof can be operated by rotating the screw in motor operating hole on the sunroof motor with a proper tool. 5) Circuit Diagram of Sunrrof Motor and SCU SUNROOF ACTYON 2010.01...
Page 622 04-6 7340-01 6) Circuit Diagram of Sunroof SUNROOF ACTYON 2010.01...
Page 623 Instrument Panel Glove Box and Instrument Sun Visor Instrument Lower Panel (Driver Side) Lower Panel (Passenger Side) A Pillar B Pillar C Pillar/D Pillar and Rear Quarter Panel Center Console Assembly C Pillar D Pillar Quarter Panel BODY INTERIOR ACTYON 2010.01...
Page 624 05-3 7610-01 Door Trim (Front Door) Rear Door Trim Headlining Assembly Interior Room Lamp Sun Visor A Pillar Front Room Lamp Roof Wiring B Pillar Rear Washer Hose BODY INTERIOR ACTYON 2010.01...
Page 625 1. COMPOSITION OF BODY EXTERIOR Hood Assembly Sunroof Assembly Front Door Assembly Front Fender Assembly Front Bumper Assembly Cover - Front end member, lower Energy absorber - Front bumper Front bumper fascia assembly Headlamp Front extension cover BODY EXTERIOR ACTYON 2010.01...
Page 626 Rear Door Assembly Tailgate Assembly Side sill garnish Rear Bumper Assembly Rear upper bracket Rear bumper beam Energy absorber - Rear bumper Rear bumper garnish Rear bumper fascia assembly Dummy type Fog light type Fog light type BODY EXTERIOR ACTYON 2010.01...
Page 627 07-3 4110-01 4110-01 BODY REPAIR GENERAL 1. DIMENSIONS BODY REPAIR ACTYON 2010.01...
Page 628 07-4 4110-01 2. JACK-UP POINTS BODY REPAIR ACTYON 2010.01...
Page 629 Blocks the noise from engine and transmission and improves the reinforcement of vehicle body. Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility engine retreat when collision. BODY REPAIR ACTYON 2010.01...
Page 630 BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise. Door impact beam BPR sealer reinforcement to reinforce the body to reinforce the door panel and reduce the impact beam noise Door impact beam to protect the passengers in case of side collision BODY REPAIR ACTYON 2010.01...
Page 631 07-7 4110-01 4) Applied BPR (Body Panel Reinforcement) Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise. BODY REPAIR ACTYON 2010.01...
Page 632 07-8 4110-01 5) Applied the Asphalt to the Body Panel (Improved Anti-Vibration) BODY REPAIR ACTYON 2010.01...
Page 634 FATC controller. This sensor is installed at the front bottom of Ambient Temperature Sensor engine compartment. This changes the air source mode by detecting the air pollution and the ambient temperature. Ambient temperature sensor AIR CONDITIONER ACTYON 2010.01...
Page 635 Detects A/C switch position, A sensor that detects the refrigerant and coolant temperature, engine coolant temperature and reserves refrigerant to condition and driving condition to transmits it to engine supply smoothly. control the air conditioner. ECU. AIR CONDITIONER ACTYON 2010.01...
Page 636 01-4 6810-20 2. VENTILATION SYSTEM 1) Locations of Vents 2) Air Duct AIR CONDITIONER ACTYON 2010.01...
Page 637 Coolant temperature detection sensor Mode door actuator Air source door actuator Power transistor Air mix door Main wire actuator connector Thermo AMP Active incar sensor Blower motor (interior temperature sensor) and humidity sensor Air conditioner controller unit AIR CONDITIONER ACTYON 2010.01...
Page 638 Air Source Door Air Conditioner Filter Sensor Actuator Air mix door actuator Mode Door Actuator Thermo AMP Active Incar Sensor Power Transistor/ Blower A/C Controller Unit (Humidity Sensor) Motor Power transistor Active incar and humidity sensor Blower motor AIR CONDITIONER ACTYON 2010.01...
Page 639 01-7 6810-20 2) Components AIR CONDITIONER ACTYON 2010.01...
Page 640 01-8 6810-20 3) PTC Heater and FFH Heater Layout (1) PTC Heater Assembly Layout (2) FFH Heater Assembly Layout AIR CONDITIONER ACTYON 2010.01...
Page 641 Coolant temperature: over 115°C For approx. 4 seconds after starting the engine When engine speed is below 650 rpm When engine speed is over 4,500 rpm During abrupt acceleration for the vehicle equipped with manual transmission AIR CONDITIONER ACTYON 2010.01...
Page 643 ECU-GASOLINE 0000-00 ECU-GASOLINE 1. ECU-GASOLINE........
Page 645 0000-00 0000-00 ECU-GASOLINE 1. ECU-GASOLINE ECU-GASOLINE ACTYON 2010.01...
Page 646 0000-00 ECU-GASOLINE ACTYON 2010.01...
Page 647 0000-00 ECU-GASOLINE ACTYON 2010.01...
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Page 689 0-47 0000-00 ECU-GASOLINE ACTYON 2010.01...
Page 691 ECU-DIESEL 0000-00 ECU-DIESEL DIAGNOSIS 1. ECU-DIESEL..........
Page 693 0000-00 0000-00 ECU-DIESEL 1. ECU-DIESEL ECU-DIESEL ACTYON 2010.01...
Page 694 0000-00 ECU-DIESEL ACTYON 2010.01...
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Page 767 0-77 0000-00 ECU-DIESEL ACTYON 2010.01...
Page 768 0-78 0000-00 ECU-DIESEL ACTYON 2010.01...
Page 769 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
Page 771 0000-00 0000-00 BRAKE 1. BRAKE BRAKE ACTYON 2010.01...
Page 772 0000-00 BRAKE ACTYON 2010.01...
Page 773 0000-00 BRAKE ACTYON 2010.01...
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Page 777 0000-00 BRAKE ACTYON 2010.01...
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Page 779 0-11 0000-00 BRAKE ACTYON 2010.01...
Page 780 0-12 0000-00 BRAKE ACTYON 2010.01...
Page 781 AIR-BAG 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG..........
Page 783 0000-00 0000-00 AIR-BAG 1. AIR-BAG AIR-BAG ACTYON 2010.01...
Page 784 0000-00 AIR-BAG ACTYON 2010.01...
Page 785 0000-00 AIR-BAG ACTYON 2010.01...
Page 786 0000-00 AIR-BAG ACTYON 2010.01...
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Page 788 0000-00 AIR-BAG ACTYON 2010.01...
Page 789 0000-00 AIR-BAG ACTYON 2010.01...
Page 790 0-10 0000-00 AIR-BAG ACTYON 2010.01...
Page 791 CCCS 0000-00 CCCS DIAGNOSIS 1. CCCS.............
Page 793 0000-00 0000-00 CCCS 1. CCCS CCCS ACTYON 2010.01...
Page 794 0000-00 CCCS ACTYON 2010.01...
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Page 817 0-27 0000-00 CCCS ACTYON 2010.01...
Page 819 FATC 0000-00 FATC DIAGNOSIS 1. SELF DIAGNOSIS........
Page 821 1) Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds. Check LED segments on the vacuum fluorescent display (VFD). Press OFF switch more than 5 seconds. FATC ACTYON 2010.01...
Page 822 If any failure exists, the appropriate trouble code is displayed as below. The symbol "-" in front of step number "2" means a short circuit of the blinking sensor. Short-circuit in the ambient air temperature sensor Trouble Code FATC ACTYON 2010.01...
Page 823 Slightly turn the TEMP switch in step 3 until "41" is displayed on the display window. When pressing DEF switch , mode changes as shown below in turns to check each function. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4 FATC ACTYON 2010.01...
Page 824 (other than TEMP switch) in step 5. Starts the trouble Compensates the diagnosis step 6 temperature turning turning TEMP speed dial. dial. Min. temperature Max. temperature Step 6 compensation value compensation value FATC ACTYON 2010.01...
Page 825 0000-00 DIAGNOSIS 1. FFH............
Page 827 0000-00 0000-00 1. FFH ACTYON 2010.01...
Page 828 0000-00 ACTYON 2010.01...
Page 829 0000-00 ACTYON 2010.01...
Page 830 0000-00 ACTYON 2010.01...
Page 831 P/TRUNK 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK..........
Page 833 0000-00 0000-00 P/TRUNK 1. P/TRUNK P/TRUNK ACTYON 2010.01...
Page 834 0000-00 P/TRUNK ACTYON 2010.01...
Page 835 RAIN SENSOR 0000-00 RAIN SENSOR DIAGNOSIS 1. TROUBLE SHOOTING......
Page 837 Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity. RAIN SENSOR ACTYON 2010.01...
Page 838 The wiper responses are too fast or slow. Check whether the variable resistance knob on the wiper switch is set in "FAST" or "SLOW". Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage. RAIN SENSOR ACTYON 2010.01...
Page 839 STICS 0000-00 STICS DIAGNOSIS 1. STICS............
Page 841 0000-00 0000-00 STICS 1. STICS STICS ACTYON 2010.01...
Page 842 0000-00 STICS ACTYON 2010.01...
Page 843 0000-00 DIAGNOSIS 1. TC............
Page 845 0000-00 0000-00 1. TC ACTYON 2010.01...
Page 846 0000-00 ACTYON 2010.01...
Page 847 0000-00 ACTYON 2010.01...
Page 848 0000-00 ACTYON 2010.01...
Page 849 0000-00 DIAGNOSIS 1. TCU............
Page 851 0000-00 0000-00 1. TCU ACTYON 2010.01...
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Page 867 0-19 0000-00 ACTYON 2010.01...
Page 869 TGS LEVER 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER...........
Page 871 0000-00 0000-00 TGS LEVER 1. TGS LEVER TGS LEVER ACTYON 2010.01...
Page 872 0000-00 TGS LEVER ACTYON 2010.01...
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