1. Manuals
  2. Brands
  3. SSANGYONG Manuals
  4. Automobile
  5. ACTYON 2006.03
  6. Manual

SSANGYONG ACTYON 2006.03 Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

GENERAL
1. DIMENSIONS........................................
2. SPECIFICATIONS.................................
3. VEHICLE IDENTIFICATION...................
4. MAINTENANCE INTERVAL...................
LUBRICANTS........................................
CONNECTOR........................................
LAYOUT................................................
3
4
6
7
9
10
11
12
14
GENERAL
0000-00
GENERAL

Advertisement

Table of Contents
loading

Related Manuals for SSANGYONG ACTYON 2006.03

Summary of Contents for SSANGYONG ACTYON 2006.03

  • Page 1: Table Of Contents

    GENERAL 0000-00 GENERAL GENERAL 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.
  • Page 2 0000-00 GENERAL ACTYON 2006.03...

  • Page 3: Dimensions

    0000-00 4110-01 GENERAL 1. DIMENSIONS GENERAL ACTYON 2006.03...

  • Page 4: Specifications

    0000-00 2. SPECIFICATIONS GENERAL ACTYON 2006.03...
  • Page 5 0000-00 GENERAL ACTYON 2006.03...

  • Page 6: Vehicle Identification

    The chassis number is stamped on The certification label is located on the frame behind the front right tire. the driver's door sill. Engine Number The engine number is stamped on the lower area of cylinder block in the intake manifold side. GENERAL ACTYON 2006.03...

  • Page 7: Maintenance Interval

    0000-00 4. MAINTENANCE INTERVAL * 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 In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or In hilly or moutainous terrain. Severe Conditions in Air Conditioner Filter - Pollutant area or off-road driving, extended air conditioner or heater operation GENERAL ACTYON 2006.03...

  • Page 9: Recommended Fluids And Lubricants

    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. GENERAL...

  • Page 10: Jack-Up Points (Dotted Circles)

    0-10 0000-00 6. JACK-UP POINTS GENERAL ACTYON 2006.03...

  • Page 11: Pin Arrangement Of Diagnostic Connector

    0-11 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 ACTYON 2006.03...

  • Page 12: Electric Components And Layout

    0-12 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement GENERAL ACTYON 2006.03...
  • Page 13 0-13 0000-00 2) Components Locator GENERAL ACTYON 2006.03...

  • Page 14: Standard Bolts Specifications

    0-14 0000-00 9. STANDARD BOLTS SPECIFICATIONS GENERAL ACTYON 2006.03...
  • Page 15 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. GENERAL ACTYON 2006.03...
  • Page 17 GENERAL 0000-00 GENERAL GENERAL 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.
  • Page 18 0000-00 GENERAL ACTYON 2006.03...

  • Page 19: Dimensions

    0000-00 4110-01 GENERAL 1. DIMENSIONS GENERAL ACTYON 2006.03...

  • Page 20: Specifications

    0000-00 2. SPECIFICATIONS GENERAL ACTYON 2006.03...
  • Page 21 0000-00 GENERAL ACTYON 2006.03...

  • Page 22: Vehicle Identification

    The chassis number is stamped on The certification label is located on the frame behind the front right tire. the driver's door sill. Engine Number The engine number is stamped on the lower area of cylinder block in the intake manifold side. GENERAL ACTYON 2006.03...

  • Page 23: Maintenance Interval

    0000-00 4. MAINTENANCE INTERVAL * 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 24 In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or In hilly or moutainous terrain. Severe Conditions in Air Conditioner Filter - Pollutant area or off-road driving, extended air conditioner or heater operation GENERAL ACTYON 2006.03...

  • Page 25: Recommended Fluids And Lubricants

    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. GENERAL...

  • Page 26: Jack-Up Points (Dotted Circles)

    0-10 0000-00 6. JACK-UP POINTS GENERAL ACTYON 2006.03...

  • Page 27: Pin Arrangement Of Diagnostic Connector

    0-11 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 ACTYON 2006.03...

  • Page 28: Electric Components And Layout

    0-12 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement GENERAL ACTYON 2006.03...
  • Page 29 0-13 0000-00 2) Components Locator GENERAL ACTYON 2006.03...

  • Page 30: Standard Bolts Specifications

    0-14 0000-00 9. STANDARD BOLTS SPECIFICATIONS GENERAL ACTYON 2006.03...
  • Page 31 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. GENERAL ACTYON 2006.03...
  • Page 33 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 35: Engine Assembly Layout

    01-3 0000-00 0000-00 ENGINE GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL ACTYON 2006.03...
  • Page 36 01-4 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL ACTYON 2006.03...

  • Page 37: Engine Controls Layout

    Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter & priming pump Brake fluid reservoir Battery ABS/ESP modulator Fuse box Air cleaner assembly Washer fluid reservoir ENGINE GENERAL ACTYON 2006.03...
  • Page 38 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 ACTYON 2006.03...
  • Page 39 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 ACTYON 2006.03...
  • Page 40 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 ACTYON 2006.03...
  • Page 41 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) ENGINE GENERAL ACTYON 2006.03...

  • Page 42: 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 ACTYON 2006.03...
  • Page 43 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 ACTYON 2006.03...

  • Page 44: 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 ACTYON 2006.03...
  • Page 45 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 ACTYON 2006.03...

  • Page 46: 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 ACTYON 2006.03...
  • Page 47 IP interior fuse air duct hose via PCV valve that Engine ECU box (RH) opens/closes due to pressure differences (No. 95) No.63(7.5A) between the intake side and crankcase. ENGINE GENERAL ACTYON 2006.03...

  • Page 48: 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 ACTYON 2006.03...
  • Page 49 Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/closes due to pressure differences between the intake side and crankcase. ENGINE GENERAL ACTYON 2006.03...

  • Page 50: Cooling System Layout

    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 ACTYON 2006.03...
  • Page 51 01-19 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL ACTYON 2006.03...

  • Page 52: Fuel System Layout

    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 ACTYON 2006.03...
  • Page 53 01-21 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL ACTYON 2006.03...

  • Page 54: Fuel Supply System

    Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE GENERAL ACTYON 2006.03...

  • Page 55: Cleanness

    The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. ENGINE GENERAL ACTYON 2006.03...
  • Page 56 At this point, thoroughly clean the related area in engine compartment. Clean the engine compartment before starting service works. Tool kit for Took kit for low Removal tool box and high pressure line pressure line cap kits ENGINE GENERAL ACTYON 2006.03...
  • Page 57 If not, the injection point may be deviated from correct position, and it may cause engine disorder. Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components. ENGINE GENERAL ACTYON 2006.03...
  • Page 58 Priming pump filled pump. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. With SCAN-100, check if there are curr- ent faults and erase the history faults. ENGINE GENERAL ACTYON 2006.03...
  • Page 59 Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.) ENGINE GENERAL ACTYON 2006.03...

  • Page 60: Maintenance And Repair

    Using oils of any viscosity other than those viscosities recommended could result in engine damage. ▷ Cooling System Service Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section. ENGINE GENERAL ACTYON 2006.03...
  • Page 61 Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type) ENGINE GENERAL ACTYON 2006.03...
  • Page 62 Notice means precautions on tool/device or part damages or personal injuries that can occur during service works. However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses. ENGINE GENERAL ACTYON 2006.03...
  • Page 63 LOCK position before work. · Be careful not to touch hot components like catalytic converter, muffler and exhaust pipe when the engine is running or just stopped. They may burn you badly. ENGINE GENERAL ACTYON 2006.03...
  • Page 64 While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. During service work of removal/installation, be sure to check each connected portions to engine not to make interference. ENGINE GENERAL ACTYON 2006.03...
  • Page 65 When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury. ENGINE GENERAL ACTYON 2006.03...

  • Page 66: During Service Work For Inspection

    Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work. Use recommended and specified tools to increase efficiency of service work. Use only genuine spare parts. ENGINE GENERAL ACTYON 2006.03...
  • Page 67 (Refer to cleanness.) If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new. ENGINE GENERAL ACTYON 2006.03...

  • Page 68: During Service Work For Electric Devices

    If lift up the vehicle with safety jack and stand, should be more careful during works. Never be under the vehicle if supported with only jack. If have to be under the vehicle, · be sure to use safety block. Use wheel block in front and rear of every wheel. · ENGINE GENERAL ACTYON 2006.03...

  • Page 69: Owner Inspections And Services

    ▶ Headlamp Aim Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed. ENGINE GENERAL ACTYON 2006.03...
  • Page 70 Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once. ENGINE GENERAL ACTYON 2006.03...
  • Page 71 ▶ Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly. ENGINE GENERAL ACTYON 2006.03...
  • Page 72 Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation. ENGINE GENERAL ACTYON 2006.03...

  • Page 73: Standard Bolts Specifications

    01-41 0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL ACTYON 2006.03...
  • Page 74 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. ENGINE GENERAL ACTYON 2006.03...

  • Page 75: Guidelines For Service Work Safety

    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 77: Engine Assembly Layout

    01-3 0000-00 0000-00 ENGINE GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL ACTYON 2006.03...
  • Page 78 01-4 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL ACTYON 2006.03...

  • Page 79: Engine Controls Layout

    Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter & priming pump Brake fluid reservoir Battery ABS/ESP modulator Fuse box Air cleaner assembly Washer fluid reservoir ENGINE GENERAL ACTYON 2006.03...
  • Page 80 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 ACTYON 2006.03...
  • Page 81 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 ACTYON 2006.03...
  • Page 82 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 ACTYON 2006.03...
  • Page 83 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) ENGINE GENERAL ACTYON 2006.03...

  • Page 84: 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 ACTYON 2006.03...
  • Page 85 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 ACTYON 2006.03...

  • Page 86: 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 ACTYON 2006.03...
  • Page 87 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 ACTYON 2006.03...

  • Page 88: 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 ACTYON 2006.03...
  • Page 89 IP interior fuse air duct hose via PCV valve that Engine ECU box (RH) opens/closes due to pressure differences (No. 95) No.63(7.5A) between the intake side and crankcase. ENGINE GENERAL ACTYON 2006.03...

  • Page 90: 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 ACTYON 2006.03...
  • Page 91 Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/closes due to pressure differences between the intake side and crankcase. ENGINE GENERAL ACTYON 2006.03...

  • Page 92: Cooling System Layout

    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 ACTYON 2006.03...
  • Page 93 01-19 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL ACTYON 2006.03...

  • Page 94: Fuel System Layout

    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 ACTYON 2006.03...
  • Page 95 01-21 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL ACTYON 2006.03...

  • Page 96: Fuel Supply System

    Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE GENERAL ACTYON 2006.03...

  • Page 97: Cleanness

    The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. ENGINE GENERAL ACTYON 2006.03...
  • Page 98 At this point, thoroughly clean the related area in engine compartment. Clean the engine compartment before starting service works. Tool kit for Took kit for low Removal tool box and high pressure line pressure line cap kits ENGINE GENERAL ACTYON 2006.03...
  • Page 99 If not, the injection point may be deviated from correct position, and it may cause engine disorder. Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components. ENGINE GENERAL ACTYON 2006.03...
  • Page 100 Priming pump filled pump. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. With SCAN-100, check if there are curr- ent faults and erase the history faults. ENGINE GENERAL ACTYON 2006.03...
  • Page 101 Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.) ENGINE GENERAL ACTYON 2006.03...

  • Page 102: Maintenance And Repair

    Using oils of any viscosity other than those viscosities recommended could result in engine damage. ▷ Cooling System Service Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section. ENGINE GENERAL ACTYON 2006.03...
  • Page 103 Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type) ENGINE GENERAL ACTYON 2006.03...

  • Page 104: Guidelines For Service Work Safety

    Notice means precautions on tool/device or part damages or personal injuries that can occur during service works. However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses. ENGINE GENERAL ACTYON 2006.03...
  • Page 105 LOCK position before work. · Be careful not to touch hot components like catalytic converter, muffler and exhaust pipe when the engine is running or just stopped. They may burn you badly. ENGINE GENERAL ACTYON 2006.03...
  • Page 106 While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. During service work of removal/installation, be sure to check each connected portions to engine not to make interference. ENGINE GENERAL ACTYON 2006.03...
  • Page 107 When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury. ENGINE GENERAL ACTYON 2006.03...

  • Page 108: During Service Work For Inspection

    Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work. Use recommended and specified tools to increase efficiency of service work. Use only genuine spare parts. ENGINE GENERAL ACTYON 2006.03...
  • Page 109 (Refer to cleanness.) If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new. ENGINE GENERAL ACTYON 2006.03...

  • Page 110: During Service Work For Electric Devices

    If lift up the vehicle with safety jack and stand, should be more careful during works. Never be under the vehicle if supported with only jack. If have to be under the vehicle, · be sure to use safety block. Use wheel block in front and rear of every wheel. · ENGINE GENERAL ACTYON 2006.03...

  • Page 111: Owner Inspections And Services

    ▶ Headlamp Aim Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed. ENGINE GENERAL ACTYON 2006.03...
  • Page 112 Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once. ENGINE GENERAL ACTYON 2006.03...
  • Page 113 ▶ Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly. ENGINE GENERAL ACTYON 2006.03...
  • Page 114 Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation. ENGINE GENERAL ACTYON 2006.03...

  • Page 115: Standard Bolts Specifications

    01-41 0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL ACTYON 2006.03...
  • Page 116 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. ENGINE GENERAL ACTYON 2006.03...
  • Page 117 It satisfies the strict emission regulation and provides improved output and maximum torque. Oil separator Coolant (PCV valve) reservoir Engine oil Vacuum dipstick pump Air cleaner assembly Engine oil filler cap VGT Turbo sensor charger Engine ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 118 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 ACTYON 2006.03...
  • Page 119 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 Idle pulley Viscos clutch pulley ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 120 Fuel pressure sensor Water outlet port EGR valve Oil filler Booster pressure sensor Common rail (25 ± 2.5 Nm) Vacuum pump (10 ± 1.0 Nm) Glow plug (15 ± 3 Nm) Cylinder head cover VGT Turbo charger ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 121 Air conditioner compressor Engine mounting bracket Vacuum modulator for VGT turbocharger actuator Flywheel Crank position sensor Gap: 0.7 ~ 1.5 mm Vacuum modulator for EGR valve Oil filter & oil cooler Vacuum pump Booster pressure sensor Intake manifold ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 122 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 ACTYON 2006.03...
  • Page 123 02-8 1212-01 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 124 02-9 1212-01 2) Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 125 02-10 1212-01 3. TIGHTENING TORQUE ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 126 02-11 1212-01 ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 127 02-12 1212-01 ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 128 It satisfies the strict emission regulation and provides improved output and maximum torque. Oil separator Coolant (PCV valve) reservoir Engine oil Vacuum dipstick pump Air cleaner assembly Engine oil filler cap VGT Turbo sensor charger Engine ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 129 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 ACTYON 2006.03...
  • Page 130 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 Idle pulley Viscos clutch pulley ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 131 Fuel pressure sensor Water outlet port EGR valve Oil filler Booster pressure sensor Common rail (25 ± 2.5 Nm) Vacuum pump (10 ± 1.0 Nm) Glow plug (15 ± 3 Nm) Cylinder head cover VGT Turbo charger ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 132 Air conditioner compressor Engine mounting bracket Vacuum modulator for VGT turbocharger actuator Flywheel Crank position sensor Gap: 0.7 ~ 1.5 mm Vacuum modulator for EGR valve Oil filter & oil cooler Vacuum pump Booster pressure sensor Intake manifold ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 133 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 ACTYON 2006.03...
  • Page 134 02-8 1212-01 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 135 02-9 1212-01 2) Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 136 02-10 1212-01 3. TIGHTENING TORQUE ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 137 02-11 1212-01 ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 138 02-12 1212-01 ENGINE ASSEMBLY ACTYON 2006.03...
  • Page 139 5) Conditions for Using Priming Pump After run out of fuel After draining the water from fuel separator After replacing the fuel filter ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 140 When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes rigid before starting the engine. The water drain from fuel filter should be performed whenever changing the engine oil. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 141 Start the engine and check the conditions. If the priming pump is not properly operated, air may get into the fuel line. It may cause starting problem or fuel system problem. Make sure to perform the job in step 4. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 142 Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 143 ECU control section. Fuel Line System common rail High pressure pipe Common rail Fuel pressure sensor Injector D20DT: 4 EA D27DT: 5 EA Priming pump Fuel filter Fuel pump (High pressure pump, transfer pump) Fuel route ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 144 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) High pressure supply line Transfer pressure supply line Return line ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 145 After run out of fuel After draining the water from fuel separator After replacing the fuel filter Press the priming pump until it becomes rigid before starting the engine. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 146 Fuel filter purifies fuel before it reaches to high pressure pump help proper operations in high pressure pump. And more, it separates water from fuel to prevent water from getting into FIE system (high pressure line). ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 147 Fuel pressure is measured by rail pressure sensor. And the fuel pressure regulating valve (IMV, Inlet Metering Valve) included in high pressure pump housing keeps pressure to a desired level. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 148 6) Fuel filter replacement Fuel filter change interval: every 30,000 km Water separation interval: every 10,000 km (same with engine oil change interval) Never reuse the removed fuel filter ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 149 03-13 1881-01 6. CIRCUIT DIAGRAM ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 150 03-14 1881-01 ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 151 03-15 1881-01 ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 153 5) Conditions for Using Priming Pump After run out of fuel After draining the water from fuel separator After replacing the fuel filter ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 154 When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes rigid before starting the engine. The water drain from fuel filter should be performed whenever changing the engine oil. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 155 Start the engine and check the conditions. If the priming pump is not properly operated, air may get into the fuel line. It may cause starting problem or fuel system problem. Make sure to perform the job in step 4. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 156 Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 157 ECU control section. Fuel Line System common rail High pressure pipe Common rail Fuel pressure sensor Injector D20DT: 4 EA D27DT: 5 EA Priming pump Fuel filter Fuel pump (High pressure pump, transfer pump) Fuel route ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 158 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) High pressure supply line Transfer pressure supply line Return line ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 159 After run out of fuel After draining the water from fuel separator After replacing the fuel filter Press the priming pump until it becomes rigid before starting the engine. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 160 Fuel filter purifies fuel before it reaches to high pressure pump help proper operations in high pressure pump. And more, it separates water from fuel to prevent water from getting into FIE system (high pressure line). ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 161 Fuel pressure is measured by rail pressure sensor. And the fuel pressure regulating valve (IMV, Inlet Metering Valve) included in high pressure pump housing keeps pressure to a desired level. ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 162 6) Fuel filter replacement Fuel filter change interval: every 30,000 km Water separation interval: every 10,000 km (same with engine oil change interval) Never reuse the removed fuel filter ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 163 03-13 1881-01 6. CIRCUIT DIAGRAM ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 164 03-14 1881-01 ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 165 03-15 1881-01 ENGINE FUEL SYSTEM ACTYON 2006.03...
  • Page 167 ­ 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. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 168 1. Plug-in sensor 2. Cylinder housing 3. Protection grid Plug-in sensor 4. Hybrid cover 5. Measuring duct cover 6. Housing 7. Hybrid 8. Sensor 9. Mounting plate Temperature 10. O-ring Protection grid sensor 11. Temperature sensor ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 169 Turbocharger Intercooler The charging efficiency may be lowered or the knocking may happen as the intake air is heated and the density of air is lowered. The intercooler is the device which cools the supercharged air. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 170 04-6 0000-00 2) Layout ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 171 The inlet port and coolant outlet port is integrated together. Therefore, be careful not to let the residual coolant in the manifold enter the inlet port when removing the intake manifold. Also, replace the gasket with a new one and tighten it to the specified torque (25 2.5 Nm). ± ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 172 Intake air Intake air Exhaust gas 1. EGR pipe (RH) 5. Exhaust gas 2. EGR pipe (center) 6. EGR pipe (LH) 3. Coolant emission port 7. Vacuum modulator to the EGR valve 4. Intake air (intercooler) ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 173 Thus, more air is entered the cylinder than the engine only with the turbocharger to give more power. Intercooler For removal and installation procedures, refer to the "Cooling system" section in DI engine service manual. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 174 04-10 0000-00 2. AIR FLOWS 1) Work Flow of Intake System ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 175 ­ 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. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 176 1. Plug-in sensor 2. Cylinder housing 3. Protection grid Plug-in sensor 4. Hybrid cover 5. Measuring duct cover 6. Housing 7. Hybrid 8. Sensor 9. Mounting plate Temperature 10. O-ring Protection grid sensor 11. Temperature sensor ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 177 Turbocharger Intercooler The charging efficiency may be lowered or the knocking may happen as the intake air is heated and the density of air is lowered. The intercooler is the device which cools the supercharged air. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 178 04-6 0000-00 2) Layout ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 179 The inlet port and coolant outlet port is integrated together. Therefore, be careful not to let the residual coolant in the manifold enter the inlet port when removing the intake manifold. Also, replace the gasket with a new one and tighten it to the specified torque (25 2.5 Nm). ± ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 180 Intake air Intake air Exhaust gas 1. EGR pipe (RH) 5. Exhaust gas 2. EGR pipe (center) 6. EGR pipe (LH) 3. Coolant emission port 7. Vacuum modulator to the EGR valve 4. Intake air (intercooler) ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 181 Thus, more air is entered the cylinder than the engine only with the turbocharger to give more power. Intercooler For removal and installation procedures, refer to the "Cooling system" section in DI engine service manual. ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 182 04-10 0000-00 2. AIR FLOWS 1) Work Flow of Intake System ENGINE INTAKE SYSTEM ACTYON 2006.03...
  • Page 183 The DI engine ECU receives feedback signal of change in amount of air being passed through the HFM sensor according to the opening amount of the EGR valve. ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 184 Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is used to control the booster pressure valve in turbo charger. ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 185 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 → Muffler ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 186 05-6 1913-01 2) Exhaust Gas Flows ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 187 The DI engine ECU receives feedback signal of change in amount of air being passed through the HFM sensor according to the opening amount of the EGR valve. ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 188 Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is used to control the booster pressure valve in turbo charger. ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 189 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 → Muffler ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 190 05-6 1913-01 2) Exhaust Gas Flows ENGINE EXHAUST SYSTEM ACTYON 2006.03...
  • Page 191 When operating in dusty, sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing 2. OIL PRESSURE SWITCH Operating temperature: -40 ~ 140°C Operating pressure: 0.3 ~ 0.55 bar Permissible pressure: 10 bar LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 192 Blow-by gas again after entering the combustion chamber (air duct hose) through air duct hose via PCV valve that Inlet port opens/closes due to pressure differences between the intake side and crankcase. Oil (oil gauge pipe) LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 193 06-5 1533-01 Oil pressure Cylinder Head Cover Warning Lamp (Cluster) Oil Pan and Baffle Plate Oil Strainer Oil Filter & Oil Cooler (Integrated Type) cooler filter LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 194 Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 φ 14 Return hole: φ 1 Chain nozzle: φ 6 HP pump bearing: Cylinder Block LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 195 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 ACTYON 2006.03...
  • Page 196 When operating in dusty, sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing 2. OIL PRESSURE SWITCH Operating temperature: -40 ~ 140°C Operating pressure: 0.3 ~ 0.55 bar Permissible pressure: 10 bar LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 197 Blow-by gas again after entering the combustion chamber (air duct hose) through air duct hose via PCV valve that Inlet port opens/closes due to pressure differences between the intake side and crankcase. Oil (oil gauge pipe) LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 198 06-5 1533-01 Oil pressure Cylinder Head Cover Warning Lamp (Cluster) Oil Pan and Baffle Plate Oil Strainer Oil Filter & Oil Cooler (Integrated Type) cooler filter LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 199 Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 φ 14 Return hole: φ 1 Chain nozzle: φ 6 HP pump bearing: Cylinder Block LUBRICATION SYSTEM ACTYON 2006.03...
  • Page 200 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 ACTYON 2006.03...
  • Page 201 07-3 2112-01 9210-05 ENGINE COOLING SYSTEM 1. ENGINE COOLING SPECIFICATIONS COOLING SYSTEM ACTYON 2006.03...
  • Page 202 07-4 2112-01 1. COMPONENTS ENGINE COOLING Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor COOLING SYSTEM ACTYON 2006.03...
  • Page 203 Cylinder block side · Block 5 # → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side Cylinder head Coolant outlet port (intake Radiator Water pump · → → → COOLING SYSTEM ACTYON 2006.03...
  • Page 204 It prevents cooling efficiency from decreasing due to coolant separation between · cylinder #4 and #5. In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to water pump with an additional pulley. COOLING SYSTEM ACTYON 2006.03...
  • Page 205 07-3 2112-01 9210-05 ENGINE COOLING SYSTEM 1. ENGINE COOLING SPECIFICATIONS COOLING SYSTEM ACTYON 2006.03...
  • Page 206 07-4 2112-01 1. COMPONENTS ENGINE COOLING Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor COOLING SYSTEM ACTYON 2006.03...
  • Page 207 Cylinder block side · Block 5 # → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side Cylinder head Coolant outlet port (intake Radiator Water pump · → → → COOLING SYSTEM ACTYON 2006.03...
  • Page 208 It prevents cooling efficiency from decreasing due to coolant separation between · cylinder #4 and #5. In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to water pump with an additional pulley. COOLING SYSTEM ACTYON 2006.03...
  • Page 209 08-3 1451-01 1461-01 ENGINE ELECTRICAL SYSTEM 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 210 08-4 1451-01 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 ACTYON 2006.03...
  • Page 211 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 ACTYON 2006.03...
  • Page 212 08-6 1451-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1) Preheating ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 213 08-7 1451-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1) Starting & Charging ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 214 08-3 1451-01 1461-01 ENGINE ELECTRICAL SYSTEM 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 215 08-4 1451-01 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 ACTYON 2006.03...
  • Page 216 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 ACTYON 2006.03...
  • Page 217 08-6 1451-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1) Preheating ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 218 08-7 1451-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1) Starting & Charging ENGINE ELECTRIC DEVICES ACTYON 2006.03...
  • Page 219 Water Pump and Pipe Coolant Port Cylinder block Thermostat (inside) Coolant outlet Radiator port Reservior (coolant inlet hose) Engine Oil Filter and Cooler Oil Filter cap Oil cooler Oil cooler Oil filter Oil pressure switch ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 220 09-4 1491-01 2. TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 221 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 ACTYON 2006.03...
  • Page 222 (Water warning light, glow Accelerator sensor plug Vehicle speed sensor indicator light, engine warning Switch input signal light) (IG, brake, clutch, A/C signal, Preheater (auxiliary heater) A/C compressor) K - line CAN communication Self-diagnosis ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 223 Driving mode control If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm and the drive map will be used to match the drivers inputs with optimum engine power. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 224 If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is increased. If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is reduced. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 225 To do this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the water temperature. This requirement only concerns the starting phase, since once the engine has started the system must re-use the mapping and the corrections described previously. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 226 This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude. During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant temperature. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 227 This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined before each injection as a function of the instantaneous engine speed. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 228 A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 229 The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver demand is then corrected according to the coolant temperature. This correction is added to the driver demand. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 230 A correction depending on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 231 The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 232 The first MDP value is provided by the C2I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 233 The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 234 The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of the injector. So, the pulse should be corrected according to characteristics of each injector. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 235 When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when the accelerator pedal is depressed. C2I Number value (16 digits) For coding of C2I, refer to "Diagnosis" section ※ ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 236 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors. 1) Learning Conditions 2) Trouble Codes ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 237 Water Pump and Pipe Coolant Port Cylinder block Thermostat (inside) Coolant outlet Radiator port Reservior (coolant inlet hose) Engine Oil Filter and Cooler Oil Filter cap Oil cooler Oil cooler Oil filter Oil pressure switch ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 238 09-4 1491-01 2. TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 239 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 ACTYON 2006.03...
  • Page 240 (Water warning light, glow Accelerator sensor plug Vehicle speed sensor indicator light, engine warning Switch input signal light) (IG, brake, clutch, A/C signal, Preheater (auxiliary heater) A/C compressor) K - line CAN communication Self-diagnosis ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 241 Driving mode control If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm and the drive map will be used to match the drivers inputs with optimum engine power. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 242 If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is increased. If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is reduced. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 243 To do this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the water temperature. This requirement only concerns the starting phase, since once the engine has started the system must re-use the mapping and the corrections described previously. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 244 This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude. During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant temperature. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 245 This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined before each injection as a function of the instantaneous engine speed. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 246 A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 247 The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver demand is then corrected according to the coolant temperature. This correction is added to the driver demand. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 248 A correction depending on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 249 The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 250 The first MDP value is provided by the C2I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 251 The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 252 The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of the injector. So, the pulse should be corrected according to characteristics of each injector. ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 253 When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when the accelerator pedal is depressed. C2I Number value (16 digits) For coding of C2I, refer to "Diagnosis" section ※ ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 254 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors. 1) Learning Conditions 2) Trouble Codes ENGINE CONTROL SYSTEM ACTYON 2006.03...
  • Page 255 The cruise control system is a supplementary system, which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle-to-vehicle distance meets the legal requirement. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 256 Use the cruise control system only when driving on motorways or highways. Do not use the cruise control system where the road conditions are as follows: - When there is strong wind or cross wind. - Heavy traffic. - Slippery roads or steep decline. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 257 10-5 8510-23 2. CIRCUIT DIAGRAM 1) CONFIGURATION CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 258 Refer to the following pages for details of operation. Never use the cruise control system until you get used to it. Improper use or not fully aware of this function could result in collision and/or personal injuries. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 259 (0.81 mph). For example, if you want to increase the speed 13 km/h (81 mph) more than the previous set speed, tap up the switch lever to ACCEL side ten times without using the accelerator pedal. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 260 (0.62 mph). For example, if you want to decrease the speed 10 km/h (62 mph) lower than the previous set speed, tap down the switch lever to DECEL side ten times without using the brake pedal. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 261 But the driver should know the previous set speed to react to the changed vehicle speed properly. If the vehicle speed increases abruptly, depress the brake pedal to adjust the vehicle speed properly. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 262 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 263 The cruise control system is a supplementary system, which helps the driver to drive the vehicle at a desired speed without using the accelerator pedal under the traffic condition where the vehicle-to-vehicle distance meets the legal requirement. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 264 Use the cruise control system only when driving on motorways or highways. Do not use the cruise control system where the road conditions are as follows: - When there is strong wind or cross wind. - Heavy traffic. - Slippery roads or steep decline. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 265 10-5 8510-23 2. CIRCUIT DIAGRAM 1) CONFIGURATION CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 266 Refer to the following pages for details of operation. Never use the cruise control system until you get used to it. Improper use or not fully aware of this function could result in collision and/or personal injuries. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 267 (0.81 mph). For example, if you want to increase the speed 13 km/h (81 mph) more than the previous set speed, tap up the switch lever to ACCEL side ten times without using the accelerator pedal. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 268 (0.62 mph). For example, if you want to decrease the speed 10 km/h (62 mph) lower than the previous set speed, tap down the switch lever to DECEL side ten times without using the brake pedal. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 269 But the driver should know the previous set speed to react to the changed vehicle speed properly. If the vehicle speed increases abruptly, depress the brake pedal to adjust the vehicle speed properly. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 270 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM ACTYON 2006.03...
  • Page 271 There are three fuse and relay boxes in this vehicle (one at each side of instrument panel and one in engine compartment). The designation and capacity of relays and fuses is shown on the fuse and relay box cover. 1) FUSE AND RELAY BOX IN ENGINE COMPARTMENT Fuses and Relays Connector Arrangement FUSES AND REALYS ACTYON 2006.03...
  • Page 272 8410-02 2) INTERIOR FUSES AND RELAYS Fuse and Relay Box (LH) Fuse and Relay Box (RH) FUSES AND REALYS ACTYON 2006.03...
  • Page 273 8410-02 2. DESIGNATION AND CAPACITY OF FUSES AND RELAY 1) Fuses and Relays in Engine FUSES AND REALYS ACTYON 2006.03...
  • Page 274 8410-02 2) Designation and Capacity (1) Driver Side FUSES AND REALYS ACTYON 2006.03...
  • Page 275 EGR vacuum modulator and HFM. No. 64 fuse (7.5A) ▶ This supplies the power to the HP pump IMV. If this is blown out, IMV opens fully, so too many fuel is delivered. FUSES AND REALYS ACTYON 2006.03...
  • Page 276 8410-02 3. POWER DISTRIBUTION For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 277 8410-02 For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 278 0-10 8410-02 4. POWER DISTRIBUTION OF INTERIOR FUSE 1) IP - Interior Fuse (Driver Side) For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 279 0-11 8410-02 2) IP - Interior Fuse (Passenger Side) For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 280 There are three fuse and relay boxes in this vehicle (one at each side of instrument panel and one in engine compartment). The designation and capacity of relays and fuses is shown on the fuse and relay box cover. 1) FUSE AND RELAY BOX IN ENGINE COMPARTMENT Fuses and Relays Connector Arrangement FUSES AND REALYS ACTYON 2006.03...
  • Page 281 8410-02 2) INTERIOR FUSES AND RELAYS Fuse and Relay Box (LH) Fuse and Relay Box (RH) FUSES AND REALYS ACTYON 2006.03...
  • Page 282 8410-02 2. DESIGNATION AND CAPACITY OF FUSES AND RELAY 1) Fuses and Relays in Engine FUSES AND REALYS ACTYON 2006.03...
  • Page 283 8410-02 2) Designation and Capacity (1) Driver Side FUSES AND REALYS ACTYON 2006.03...
  • Page 284 EGR vacuum modulator and HFM. No. 64 fuse (7.5A) ▶ This supplies the power to the HP pump IMV. If this is blown out, IMV opens fully, so too many fuel is delivered. FUSES AND REALYS ACTYON 2006.03...
  • Page 285 8410-02 3. POWER DISTRIBUTION For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 286 8410-02 For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 287 0-10 8410-02 4. POWER DISTRIBUTION OF INTERIOR FUSE 1) IP - Interior Fuse (Driver Side) For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 288 0-11 8410-02 2) IP - Interior Fuse (Passenger Side) For details, refer to the electric circuit diagram. FUSES AND REALYS ACTYON 2006.03...
  • Page 289 4 times, and then the washer fluid is sprayed and the wiper sweeps off 3 times again. ▶Auto Light Sensor and Rain Sensor The auto light sensor integrated rain sensor communicates with STICS. ▶Tailgate Open Relay Control Tailgate unlock switch (Installed on the tailgate) RK STICS Tailgate unlock relay STICS ACTYON 2006.03...
  • Page 290 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 ACTYON 2006.03...
  • Page 291 02-5 8710-01 ▶ Rated Load STICS ACTYON 2006.03...
  • Page 292 02-6 8710-01 ▶ Input Signals STICS ACTYON 2006.03...
  • Page 293 If not indicated, time tolerance will be 10%. ± However, if less than 500 ms, time tolerance will be ± 100 ms. The time indicated in each function does not include chattering processing time from switch input changing point. STICS ACTYON 2006.03...
  • Page 294 The following function has been a dded to the RK STICS (REKES + STICS (Super Time & Integrated Control System): The tailgate open switch is installed on the tailgate. It activates the tailgate relay when operating the tailgate open switch. Door Lock Relay RK STICS Chime Buzzer PAS Buzzer Tailgate Open Switch STICS ACTYON 2006.03...
  • Page 295 When pulling up the lever, the wiper operates once and the wiper lever returns to the "OFF" position. Stop the operation. AUTO Operates automatically according to the vehicle speed or the amount of rain. Continuous wipe, Continuous wipe, fast operation slow operation. STICS ACTYON 2006.03...
  • Page 296 Pull and hold the lever for more than 0.6 seconds: Rear Wiper Stops Three wiping cycles with washer spray Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch. When releasing the switch, it returns to "OFF" position. STICS ACTYON 2006.03...
  • Page 297 The wiper relay is turned on at 0.3 seconds (T1) after from the time when the washer switch is turned on for more than 0.6 seconds (T2) with the ignition switch "ON". The wiper relay gets on 3 times immediately after turning off the washer switch. STICS ACTYON 2006.03...
  • Page 298 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 ACTYON 2006.03...
  • Page 299 ON from the time when the rear washer switch is turned on. It gets OFF when the rear washer switch is turned off. This control is not available while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. STICS ACTYON 2006.03...
  • Page 300 "OFF", the washer motor output gets ON for 1 second. If the system recognizes the output signal, the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second. Then, the wiper relay output gets OFF after 3 cycles. STICS ACTYON 2006.03...
  • Page 301 The auto washer switch input is overridden during the rear washer operation. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. The auto washer switch input is overridden during the front washer operation. STICS ACTYON 2006.03...
  • Page 302 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 ACTYON 2006.03...
  • Page 303 FAST ↔ SLOW: Auto delay/Auto speed section (rain sensor mounting section on the control. A position that can control sensitivity windshield) with photodiode (auto light sensor against rains in the windshield and transmits integrated type) wiping demand signal accordingly STICS ACTYON 2006.03...
  • Page 304 "ON" and the auto INT switch "ON" in the rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during the continuous operation. The operation data is sent to the rain sensor even during the washer coupled wiper's operation. STICS ACTYON 2006.03...
  • Page 305 "ON" position, and the wiper motor is in "Parked" position). However, the wiper motor can be operated only when the rain sensor detects the "Rain Detected" signal. * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle. STICS ACTYON 2006.03...
  • Page 306 When the parking terminal is fixed to IGN, the wiper system outputs the wiper operating signal for 2 seconds, then continuously outputs the wiper parking signal. * The wiper motor runs only when the rain sensor requires the wiper operation. STICS ACTYON 2006.03...
  • Page 307 The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the wiper switch is in "ON" position). STICS ACTYON 2006.03...
  • Page 308 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. STICS ACTYON 2006.03...
  • Page 309 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. STICS ACTYON 2006.03...
  • Page 310 (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) Emitter lense Auto light sensor (Vertical) Auto light sensor (Horizon) STICS ACTYON 2006.03...
  • Page 311 The pause time is calculated by the vehicle speed and the VOLUME. · If the pause time is below 1.0 second, the wipers operate without pause. If the pause time is over 1.5 seconds, the wipers operate intermittently · STICS ACTYON 2006.03...
  • Page 312 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is "ON" (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch) (The output stops immediately after turning OFF the switch.) STICS ACTYON 2006.03...
  • Page 313 When removing the ignition key or closing the driver's door during chime buzzer operation, the buzzer stops. This function is not available when the ignition switch is in "ON" position. PAS buzzer Chime buzzer STICS ACTYON 2006.03...
  • Page 314 If the "UNLOCK" conditions are met, the system outputs "UNLOCK" signal unconditionally. However, if the ignition key is removed after the door lock switch is changed from "UNLOCK" to "LOCK", the system does not output "UNLOCK" signal. STICS ACTYON 2006.03...
  • Page 315 If the ignition switch is in the "ON" position or the ignition switch is removed, the above steps are performed. If the key is in the key cylinder, the ignition key reminder function is activated. This function does not work if the vehicle speed is over 10 km/h. STICS ACTYON 2006.03...
  • Page 316 The system outputs "UNLOCK" signal for 5 seconds when the driver's and passenger's door lock switch is locked (while the tail lamp is turned on and the driver's door is open). This function is not available when the ignition key is in the "ON" position. STICS ACTYON 2006.03...
  • Page 317 The warning light blinks when a door is open while the vehicle speed is over 10 km/h. The warning light goes off when closing the door under step 3. The warning light comes on when the vehicle speed goes below 10 km/h under step 3. STICS ACTYON 2006.03...
  • Page 318 Chime Buzzer Chime buzzer The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to "ON" from "OFF". After fastening the seat belt, the chime buzzer stops. STICS ACTYON 2006.03...
  • Page 319 6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 10 km/h under step 4. 7. This function is not available when the ignition key is turned to the "OFF" position. STICS ACTYON 2006.03...
  • Page 320 LOCK button on the remote control key. The luggage room lamp does not have a door coupled operating function. It shoulde be turned on and off by hand. STICS ACTYON 2006.03...
  • Page 321 The lamp always comes on while closed. The front and center room lamps the switch is at the other position. come on when pressing the room lamp main switch (3). STICS ACTYON 2006.03...
  • Page 322 Key cylinder with key hole illumination For diesel and gasoline For diesel engine equipped For gasoline engine engine equipped vehicle vehicle equipped vehicle Without immobilizer With immobilizer → With key hole illumination → With key hole illumination STICS ACTYON 2006.03...
  • Page 323 The output is "ON" only for 6 minutes when turning "ON" the front defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. The output is "OFF" when the ignition switch is "OFF". STICS ACTYON 2006.03...
  • Page 324 The output is "ON" only for 6 minutes when turning "ON" the rear defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. The output is "OFF" when the IGN 2 switch is "OFF". STICS ACTYON 2006.03...
  • Page 325 "UNLOCK" signal by other functions. All door lock signals are "UNLOCK" for 0.5 seconds just for once when receiving the "LOCK" signal within 0.5 seconds after closing the driver's or passenger's door while the ignition key is removed. STICS ACTYON 2006.03...
  • Page 326 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. STICS ACTYON 2006.03...
  • Page 327 (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) The "LOCK" or "UNLOCK" inputs from the central door lock switch in anti-theft mode are ignored. STICS ACTYON 2006.03...
  • Page 328 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. STICS ACTYON 2006.03...
  • Page 329 UNLOCK signal unconditionally when turning the ignition switch to OFF position.) However, when the ignition key is turned to "OFF" position, the lock output conditions will be cancelled. The "FAIL" condition of the door will be erased when the ignition key is turned to "OFF" position. STICS ACTYON 2006.03...
  • Page 330 "LOCK" (or "UNLOCK") output is ignored if "LOCK" (or "UNLOCK") output is required while performing the output of "LOCK" (or "UNLOCK"). If the door lock system outputs "LOCK" and "UNLOCK" simultaneously, only the "LOCK" output can be activated. STICS ACTYON 2006.03...
  • Page 331 DOOR LOCK: Indicates that all door lock switches (including tailgate) are in LOCK positions. DOOR UNLOCK: Indicates that any of all door lock switches (including tailgate) is in UNLOCK position. Engine hood open warning lamp The warning lamp comes on when the engine hood is open. STICS ACTYON 2006.03...
  • Page 332 (RELOCK operation). Also, at this moment, the system outputs hazard warning flasher twice. The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key. STICS ACTYON 2006.03...
  • Page 333 If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is canceled immediately and the warning buzzer stops after 27 seconds (remaining time). Operation when warning is cancelled a. The theft deterrent horn and hazard warning flasher outputs are "OFF". STICS ACTYON 2006.03...
  • Page 334 The front room lamp comes on for 30 seconds when receiving door unlock signal by the remote control key while the front room lamp coupled switch is pressed. It is turned off when receiving the LOCK signal from the remote control key. STICS ACTYON 2006.03...
  • Page 335 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.). STICS ACTYON 2006.03...
  • Page 336 36) Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock, the doors are automatically locked and the armed mode of anti-theft system is activated again. STICS ACTYON 2006.03...
  • Page 337 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 ACTYON 2006.03...
  • Page 338 02-52 8710-01 2) STICS Output Signals and Others STICS ACTYON 2006.03...
  • Page 339 When the washer motor output is detected, the wiper relay output gets ON for 4 cycles. Then, the washer motor output gets ON for 1 second, the wiper relay output gets ON for 3 cycles and gets OFF. STICS ACTYON 2006.03...
  • Page 340 ON or without removing the key. As shown in the figure, STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions. For details, refer to following information. STICS ACTYON 2006.03...
  • Page 341 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. STICS ACTYON 2006.03...
  • Page 342 The operating time control and dimming functions of room lamp have been introduced for user convenience. The ignition key reminder warning signal in the circuit is related to the dimming function. Refer to the detailed information in this manual for the control logic. STICS ACTYON 2006.03...
  • Page 343 02-57 8710-01 7) Wiring Circuit of STICS (Related to Tail Lamp Auto Cut (Battery Saver)) STICS ACTYON 2006.03...
  • Page 344 The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch. Windshield heated glass switch The windshield heated glass is turned on for 12 minutes when pressing this switch. STICS ACTYON 2006.03...
  • Page 345 02-59 8710-01 9) Circuit Diagram of STICS (Related to Remote Controller and Door Lock/Unlock) STICS ACTYON 2006.03...
  • Page 347 4 times, and then the washer fluid is sprayed and the wiper sweeps off 3 times again. ▶Auto Light Sensor and Rain Sensor The auto light sensor integrated rain sensor communicates with STICS. ▶Tailgate Open Relay Control Tailgate unlock switch (Installed on the tailgate) RK STICS Tailgate unlock relay STICS ACTYON 2006.03...
  • Page 348 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 ACTYON 2006.03...
  • Page 349 02-5 8710-01 ▶ Rated Load STICS ACTYON 2006.03...
  • Page 350 02-6 8710-01 ▶ Input Signals STICS ACTYON 2006.03...
  • Page 351 If not indicated, time tolerance will be 10%. ± However, if less than 500 ms, time tolerance will be ± 100 ms. The time indicated in each function does not include chattering processing time from switch input changing point. STICS ACTYON 2006.03...
  • Page 352 The following function has been a dded to the RK STICS (REKES + STICS (Super Time & Integrated Control System): The tailgate open switch is installed on the tailgate. It activates the tailgate relay when operating the tailgate open switch. Door Lock Relay RK STICS Chime Buzzer PAS Buzzer Tailgate Open Switch STICS ACTYON 2006.03...
  • Page 353 When pulling up the lever, the wiper operates once and the wiper lever returns to the "OFF" position. Stop the operation. AUTO Operates automatically according to the vehicle speed or the amount of rain. Continuous wipe, Continuous wipe, fast operation slow operation. STICS ACTYON 2006.03...
  • Page 354 Pull and hold the lever for more than 0.6 seconds: Rear Wiper Stops Three wiping cycles with washer spray Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch. When releasing the switch, it returns to "OFF" position. STICS ACTYON 2006.03...
  • Page 355 The wiper relay is turned on at 0.3 seconds (T1) after from the time when the washer switch is turned on for more than 0.6 seconds (T2) with the ignition switch "ON". The wiper relay gets on 3 times immediately after turning off the washer switch. STICS ACTYON 2006.03...
  • Page 356 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 ACTYON 2006.03...
  • Page 357 ON from the time when the rear washer switch is turned on. It gets OFF when the rear washer switch is turned off. This control is not available while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. STICS ACTYON 2006.03...
  • Page 358 "OFF", the washer motor output gets ON for 1 second. If the system recognizes the output signal, the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second. Then, the wiper relay output gets OFF after 3 cycles. STICS ACTYON 2006.03...
  • Page 359 The auto washer switch input is overridden during the rear washer operation. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. The auto washer switch input is overridden during the front washer operation. STICS ACTYON 2006.03...
  • Page 360 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 ACTYON 2006.03...
  • Page 361 FAST ↔ SLOW: Auto delay/Auto speed section (rain sensor mounting section on the control. A position that can control sensitivity windshield) with photodiode (auto light sensor against rains in the windshield and transmits integrated type) wiping demand signal accordingly STICS ACTYON 2006.03...
  • Page 362 "ON" and the auto INT switch "ON" in the rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during the continuous operation. The operation data is sent to the rain sensor even during the washer coupled wiper's operation. STICS ACTYON 2006.03...
  • Page 363 "ON" position, and the wiper motor is in "Parked" position). However, the wiper motor can be operated only when the rain sensor detects the "Rain Detected" signal. * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle. STICS ACTYON 2006.03...
  • Page 364 When the parking terminal is fixed to IGN, the wiper system outputs the wiper operating signal for 2 seconds, then continuously outputs the wiper parking signal. * The wiper motor runs only when the rain sensor requires the wiper operation. STICS ACTYON 2006.03...
  • Page 365 The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the wiper switch is in "ON" position). STICS ACTYON 2006.03...
  • Page 366 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. STICS ACTYON 2006.03...
  • Page 367 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. STICS ACTYON 2006.03...
  • Page 368 (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) Emitter lense Auto light sensor (Vertical) Auto light sensor (Horizon) STICS ACTYON 2006.03...
  • Page 369 The pause time is calculated by the vehicle speed and the VOLUME. · If the pause time is below 1.0 second, the wipers operate without pause. If the pause time is over 1.5 seconds, the wipers operate intermittently · STICS ACTYON 2006.03...
  • Page 370 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is "ON" (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch) (The output stops immediately after turning OFF the switch.) STICS ACTYON 2006.03...
  • Page 371 When removing the ignition key or closing the driver's door during chime buzzer operation, the buzzer stops. This function is not available when the ignition switch is in "ON" position. PAS buzzer Chime buzzer STICS ACTYON 2006.03...
  • Page 372 If the "UNLOCK" conditions are met, the system outputs "UNLOCK" signal unconditionally. However, if the ignition key is removed after the door lock switch is changed from "UNLOCK" to "LOCK", the system does not output "UNLOCK" signal. STICS ACTYON 2006.03...
  • Page 373 If the ignition switch is in the "ON" position or the ignition switch is removed, the above steps are performed. If the key is in the key cylinder, the ignition key reminder function is activated. This function does not work if the vehicle speed is over 10 km/h. STICS ACTYON 2006.03...
  • Page 374 The system outputs "UNLOCK" signal for 5 seconds when the driver's and passenger's door lock switch is locked (while the tail lamp is turned on and the driver's door is open). This function is not available when the ignition key is in the "ON" position. STICS ACTYON 2006.03...
  • Page 375 The warning light blinks when a door is open while the vehicle speed is over 10 km/h. The warning light goes off when closing the door under step 3. The warning light comes on when the vehicle speed goes below 10 km/h under step 3. STICS ACTYON 2006.03...
  • Page 376 Chime Buzzer Chime buzzer The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to "ON" from "OFF". After fastening the seat belt, the chime buzzer stops. STICS ACTYON 2006.03...
  • Page 377 6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 10 km/h under step 4. 7. This function is not available when the ignition key is turned to the "OFF" position. STICS ACTYON 2006.03...
  • Page 378 LOCK button on the remote control key. The luggage room lamp does not have a door coupled operating function. It shoulde be turned on and off by hand. STICS ACTYON 2006.03...
  • Page 379 The lamp always comes on while closed. The front and center room lamps the switch is at the other position. come on when pressing the room lamp main switch (3). STICS ACTYON 2006.03...
  • Page 380 Key cylinder with key hole illumination For diesel and gasoline For diesel engine equipped For gasoline engine engine equipped vehicle vehicle equipped vehicle Without immobilizer With immobilizer → With key hole illumination → With key hole illumination STICS ACTYON 2006.03...
  • Page 381 The output is "ON" only for 6 minutes when turning "ON" the front defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. The output is "OFF" when the ignition switch is "OFF". STICS ACTYON 2006.03...
  • Page 382 The output is "ON" only for 6 minutes when turning "ON" the rear defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. The output is "OFF" when the IGN 2 switch is "OFF". STICS ACTYON 2006.03...
  • Page 383 "UNLOCK" signal by other functions. All door lock signals are "UNLOCK" for 0.5 seconds just for once when receiving the "LOCK" signal within 0.5 seconds after closing the driver's or passenger's door while the ignition key is removed. STICS ACTYON 2006.03...
  • Page 384 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. STICS ACTYON 2006.03...
  • Page 385 (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) The "LOCK" or "UNLOCK" inputs from the central door lock switch in anti-theft mode are ignored. STICS ACTYON 2006.03...
  • Page 386 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. STICS ACTYON 2006.03...
  • Page 387 UNLOCK signal unconditionally when turning the ignition switch to OFF position.) However, when the ignition key is turned to "OFF" position, the lock output conditions will be cancelled. The "FAIL" condition of the door will be erased when the ignition key is turned to "OFF" position. STICS ACTYON 2006.03...
  • Page 388 "LOCK" (or "UNLOCK") output is ignored if "LOCK" (or "UNLOCK") output is required while performing the output of "LOCK" (or "UNLOCK"). If the door lock system outputs "LOCK" and "UNLOCK" simultaneously, only the "LOCK" output can be activated. STICS ACTYON 2006.03...
  • Page 389 DOOR LOCK: Indicates that all door lock switches (including tailgate) are in LOCK positions. DOOR UNLOCK: Indicates that any of all door lock switches (including tailgate) is in UNLOCK position. Engine hood open warning lamp The warning lamp comes on when the engine hood is open. STICS ACTYON 2006.03...
  • Page 390 (RELOCK operation). Also, at this moment, the system outputs hazard warning flasher twice. The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key. STICS ACTYON 2006.03...
  • Page 391 If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is canceled immediately and the warning buzzer stops after 27 seconds (remaining time). Operation when warning is cancelled a. The theft deterrent horn and hazard warning flasher outputs are "OFF". STICS ACTYON 2006.03...
  • Page 392 The front room lamp comes on for 30 seconds when receiving door unlock signal by the remote control key while the front room lamp coupled switch is pressed. It is turned off when receiving the LOCK signal from the remote control key. STICS ACTYON 2006.03...
  • Page 393 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.). STICS ACTYON 2006.03...
  • Page 394 36) Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock, the doors are automatically locked and the armed mode of anti-theft system is activated again. STICS ACTYON 2006.03...
  • Page 395 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 ACTYON 2006.03...
  • Page 396 02-52 8710-01 2) STICS Output Signals and Others STICS ACTYON 2006.03...
  • Page 397 When the washer motor output is detected, the wiper relay output gets ON for 4 cycles. Then, the washer motor output gets ON for 1 second, the wiper relay output gets ON for 3 cycles and gets OFF. STICS ACTYON 2006.03...
  • Page 398 ON or without removing the key. As shown in the figure, STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions. For details, refer to following information. STICS ACTYON 2006.03...
  • Page 399 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. STICS ACTYON 2006.03...
  • Page 400 The operating time control and dimming functions of room lamp have been introduced for user convenience. The ignition key reminder warning signal in the circuit is related to the dimming function. Refer to the detailed information in this manual for the control logic. STICS ACTYON 2006.03...
  • Page 401 02-57 8710-01 7) Wiring Circuit of STICS (Related to Tail Lamp Auto Cut (Battery Saver)) STICS ACTYON 2006.03...
  • Page 402 The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch. Windshield heated glass switch The windshield heated glass is turned on for 12 minutes when pressing this switch. STICS ACTYON 2006.03...
  • Page 403 02-59 8710-01 9) Circuit Diagram of STICS (Related to Remote Controller and Door Lock/Unlock) STICS ACTYON 2006.03...
  • Page 405 The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU. Refer to the information that follows for specific functions and their descriptions. Immobilizer Transponder Battery IMMO ACTYON 2006.03...
  • Page 406 The lamps go off immediately when the LOCK signal is sent from the remote control key (room lamp coupled unction). Door button Key plate 1. Engine start 2. Door lock/unlock Battery Replacement ▶ Specification CR 2032 Quantity IMMO ACTYON 2006.03...
  • Page 408 When the key is close to any device sending or receiving electromagnetic fields or waves. When the key is close to any electronic or electric devices such as lightening equipment, security keys or security cards. When the key is close to a magnetic or metal object or a battery. IMMO ACTYON 2006.03...
  • Page 409 In any case, the immobilizer system can not be removed from the vehicle. If you attempt to remove it and damage the system, starting will be impossible, so never attempt to remove, damage or modify it. The remote engine starter cannot be installed on the vehicle equipped with the immobilizer system. IMMO ACTYON 2006.03...
  • Page 410 The system outputs the "LOCK" signal immediately after receiving the door lock message from the remote control key. If the vehicle is locked while all doors including tailgate and engine hood are closed, the theft deterrent mode is activated (hazard warning lamps are blinking twice). IMMO ACTYON 2006.03...
  • Page 411 0.5 seconds, all doors are unlocked. When receiving the DOOR UNLOCK message from the remote control key, the door unlock relay is turned on for 0.5 seconds. The hazard warning lamps blink once only when the doors are successfully unlocked. IMMO ACTYON 2006.03...
  • Page 412 03-10 7010-06 5. CIRCUIT DIAGRAM IMMO ACTYON 2006.03...
  • Page 413 The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU. Refer to the information that follows for specific functions and their descriptions. Immobilizer Transponder Battery IMMO ACTYON 2006.03...
  • Page 414 The lamps go off immediately when the LOCK signal is sent from the remote control key (room lamp coupled unction). Door button Key plate 1. Engine start 2. Door lock/unlock Battery Replacement ▶ Specification CR 2032 Quantity IMMO ACTYON 2006.03...
  • Page 416 When the key is close to any device sending or receiving electromagnetic fields or waves. When the key is close to any electronic or electric devices such as lightening equipment, security keys or security cards. When the key is close to a magnetic or metal object or a battery. IMMO ACTYON 2006.03...
  • Page 417 In any case, the immobilizer system can not be removed from the vehicle. If you attempt to remove it and damage the system, starting will be impossible, so never attempt to remove, damage or modify it. The remote engine starter cannot be installed on the vehicle equipped with the immobilizer system. IMMO ACTYON 2006.03...
  • Page 418 The system outputs the "LOCK" signal immediately after receiving the door lock message from the remote control key. If the vehicle is locked while all doors including tailgate and engine hood are closed, the theft deterrent mode is activated (hazard warning lamps are blinking twice). IMMO ACTYON 2006.03...
  • Page 419 0.5 seconds, all doors are unlocked. When receiving the DOOR UNLOCK message from the remote control key, the door unlock relay is turned on for 0.5 seconds. The hazard warning lamps blink once only when the doors are successfully unlocked. IMMO ACTYON 2006.03...
  • Page 420 03-10 7010-06 5. CIRCUIT DIAGRAM IMMO ACTYON 2006.03...
  • Page 421 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 ACTYON 2006.03...
  • Page 422 24. Low fuel level warning light 11. Speedometer 25. Engine hood open warning light 12. ODOmeter/Trip odometer 26. Over temperature warning light 13. Coolant temperature gauge 27. Power mode indicator 14. Fuel level gauge 28. Winter mode indicator CLUSTER ACTYON 2006.03...
  • Page 423 05-4 8010-01 2. WARNING & INDICATOR PANEL CLUSTER ACTYON 2006.03...
  • Page 424 05-5 8010-01 CLUSTER ACTYON 2006.03...
  • Page 425 If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner and then compare the value on tachometer with the reading from scanner. CLUSTER ACTYON 2006.03...
  • Page 426 2. Check if the speedometer gauge is shaking and the abnormal noise sounds. 3. Eliminate the hysteresis by tapping the speedometer. - The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range. CLUSTER ACTYON 2006.03...
  • Page 427 Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored. CLUSTER ACTYON 2006.03...
  • Page 428 When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection (engine ECU, No. 101 and 102). CLUSTER ACTYON 2006.03...
  • Page 429 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 ACTYON 2006.03...
  • Page 430 - 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 CLUSTER ACTYON 2006.03...
  • Page 431 ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the basic ABS system will operate. CLUSTER ACTYON 2006.03...
  • Page 432 150 ms, the ESP OFF mode and the ESP warning lamp will not be changed. - When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be turned on. CLUSTER ACTYON 2006.03...
  • Page 433 ESP OFF switch is pushed (for over 150 ms) and then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP OFF switch for approx. 3.5 seconds. CLUSTER ACTYON 2006.03...
  • Page 434 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. CLUSTER ACTYON 2006.03...
  • Page 435 05-16 8010-01 4. CIRCUIT DIAGRAM CLUSTER ACTYON 2006.03...
  • Page 436 05-17 8010-01 CLUSTER ACTYON 2006.03...
  • Page 437 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 ACTYON 2006.03...
  • Page 438 24. Low fuel level warning light 11. Speedometer 25. Engine hood open warning light 12. ODOmeter/Trip odometer 26. Over temperature warning light 13. Coolant temperature gauge 27. Power mode indicator 14. Fuel level gauge 28. Winter mode indicator CLUSTER ACTYON 2006.03...
  • Page 439 05-4 8010-01 2. WARNING & INDICATOR PANEL CLUSTER ACTYON 2006.03...
  • Page 440 05-5 8010-01 CLUSTER ACTYON 2006.03...
  • Page 441 If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner and then compare the value on tachometer with the reading from scanner. CLUSTER ACTYON 2006.03...
  • Page 442 2. Check if the speedometer gauge is shaking and the abnormal noise sounds. 3. Eliminate the hysteresis by tapping the speedometer. - The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range. CLUSTER ACTYON 2006.03...
  • Page 443 Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored. CLUSTER ACTYON 2006.03...
  • Page 444 When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection (engine ECU, No. 101 and 102). CLUSTER ACTYON 2006.03...
  • Page 445 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 ACTYON 2006.03...
  • Page 446 - 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 CLUSTER ACTYON 2006.03...
  • Page 447 ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the basic ABS system will operate. CLUSTER ACTYON 2006.03...
  • Page 448 150 ms, the ESP OFF mode and the ESP warning lamp will not be changed. - When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be turned on. CLUSTER ACTYON 2006.03...
  • Page 449 ESP OFF switch is pushed (for over 150 ms) and then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP OFF switch for approx. 3.5 seconds. CLUSTER ACTYON 2006.03...
  • Page 450 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. CLUSTER ACTYON 2006.03...
  • Page 451 05-16 8010-01 4. CIRCUIT DIAGRAM CLUSTER ACTYON 2006.03...
  • Page 452 05-17 8010-01 CLUSTER ACTYON 2006.03...
  • Page 453 06-3 8310-01 8310-01 LAMP 1. LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Headlamp Position lamp and Turn Signal Lamp Front Fog Light Side Repeater Push Push LAMP ACTYON 2006.03...
  • Page 454 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 ACTYON 2006.03...
  • Page 455 The front room lamps and center lamp are lamp stays on. turned on when pressing the room lamp main switch (3). Glove Box: 12V/10W Luggage Room Lamp: Door Courtesy Lamp: 12V/5W 12V/10W (on front doors) LAMP ACTYON 2006.03...
  • Page 456 The room lamp output stops immediately and the theft deterrent system is activated after receiving the lock signal from driver's door, passenger's door and rear doors lock switch while the driver's door, passenger's door and rear doors are closed. The luggage room lamp comes on when the switch is pressed. LAMP ACTYON 2006.03...
  • Page 457 06-3 8310-01 8310-01 LAMP 1. LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Headlamp Position lamp and Turn Signal Lamp Front Fog Light Side Repeater Push Push LAMP ACTYON 2006.03...
  • Page 458 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 ACTYON 2006.03...
  • Page 459 The front room lamps and center lamp are lamp stays on. turned on when pressing the room lamp main switch (3). Glove Box: 12V/10W Luggage Room Lamp: Door Courtesy Lamp: 12V/5W 12V/10W (on front doors) LAMP ACTYON 2006.03...
  • Page 460 The room lamp output stops immediately and the theft deterrent system is activated after receiving the lock signal from driver's door, passenger's door and rear doors lock switch while the driver's door, passenger's door and rear doors are closed. The luggage room lamp comes on when the switch is pressed. LAMP ACTYON 2006.03...
  • Page 461 Press this switch again to resume the ESP function. At this time, the indicator lamp goes out. Driver's Power Window Switch Driver can controls all door windows (Open/Close/Lock/Unlock) and doors (Lock/Unlock) with this switch unit. SWITCH ACTYON 2006.03...
  • Page 462 Pull the lever briefly (below 0.6 seconds): One wiping cycle Pull and hold the lever for more than 0.6 seconds: Three wiping cycles with washer spray Washer fluid will be sprayed onto the rear window glass and the wiper will also operate once. SWITCH ACTYON 2006.03...
  • Page 463 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 ▼ SWITCH ACTYON 2006.03...
  • Page 464 Press this switch again to resume the ESP function. At this time, the indicator lamp goes out. Driver's Power Window Switch Driver can controls all door windows (Open/Close/Lock/Unlock) and doors (Lock/Unlock) with this switch unit. SWITCH ACTYON 2006.03...
  • Page 465 Pull the lever briefly (below 0.6 seconds): One wiping cycle Pull and hold the lever for more than 0.6 seconds: Three wiping cycles with washer spray Washer fluid will be sprayed onto the rear window glass and the wiper will also operate once. SWITCH ACTYON 2006.03...
  • Page 466 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 ▼ SWITCH ACTYON 2006.03...
  • Page 467 The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity. To control the system, the sensed values of rain sensor and auto light sensor are sent to pin no. 63 in STICS unit. WIPER ACTYON 2006.03...
  • Page 468 To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone. Rear washer hose and roof wiring harness are fixed at the headlining section with silicone. WIPER ACTYON 2006.03...
  • Page 469 (fan-shape). The figure below shows the changes of spraying direction according to the spraying time. It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle. WIPER ACTYON 2006.03...
  • Page 470 08-6 7810-01 2. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR) WIPER ACTYON 2006.03...
  • Page 471 08-7 7810-01 WIPER ACTYON 2006.03...
  • Page 472 08-8 7810-01 3. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION 1) Wiper and Washer Fluid Switch Operation WIPER ACTYON 2006.03...
  • Page 473 The wiper relay is turned on 0.3 seconds after turning "ON" the washer switch over 0.6 seconds with the ignition key "ON", and it is turned on three times immediately after turning off the washer switch. WIPER ACTYON 2006.03...
  • Page 474 It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. WIPER ACTYON 2006.03...
  • Page 475 The auto washer switch input is overridden during the rear washer operation. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. The auto washer switch input is overridden during the front washer operation. WIPER ACTYON 2006.03...
  • Page 476 08-12 7810-01 4. WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM WIPER ACTYON 2006.03...
  • Page 477 The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity. To control the system, the sensed values of rain sensor and auto light sensor are sent to pin no. 63 in STICS unit. WIPER ACTYON 2006.03...
  • Page 478 To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone. Rear washer hose and roof wiring harness are fixed at the headlining section with silicone. WIPER ACTYON 2006.03...
  • Page 479 (fan-shape). The figure below shows the changes of spraying direction according to the spraying time. It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle. WIPER ACTYON 2006.03...
  • Page 480 08-6 7810-01 2. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR) WIPER ACTYON 2006.03...
  • Page 481 08-7 7810-01 WIPER ACTYON 2006.03...
  • Page 482 08-8 7810-01 3. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION 1) Wiper and Washer Fluid Switch Operation WIPER ACTYON 2006.03...
  • Page 483 The wiper relay is turned on 0.3 seconds after turning "ON" the washer switch over 0.6 seconds with the ignition key "ON", and it is turned on three times immediately after turning off the washer switch. WIPER ACTYON 2006.03...
  • Page 484 It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. WIPER ACTYON 2006.03...
  • Page 485 The auto washer switch input is overridden during the rear washer operation. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. The auto washer switch input is overridden during the front washer operation. WIPER ACTYON 2006.03...
  • Page 486 08-12 7810-01 4. WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM WIPER ACTYON 2006.03...
  • Page 487 A position that controls sensitivity against The auto light sensor is Integrated into the rains on the windshield and transmits rain sensor (refer to the below picture). wiping demand signal accordingly. RAIN SENSOR ACTYON 2006.03...
  • Page 488 Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (For example, the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR ACTYON 2006.03...
  • Page 489 The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor. Followings are the components and functions of the rain sensor unit 1) Rain Sensor Unit (Including Cover) RAIN SENSOR ACTYON 2006.03...
  • Page 490 No. 2 terminal sends the wiper and washer operation information such as washer operation mode, wiper relay, or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode. RAIN SENSOR ACTYON 2006.03...
  • Page 491 "ON" position). When the wiper switch is turned to "ON" position again from "OFF" position, the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the "Rain Detected" signal. RAIN SENSOR ACTYON 2006.03...
  • Page 492 "ON" and the auto INT switch "ON" in rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during continuous operation. The operation data is sent to the rain sensor even during the washer coupled wiper operation. RAIN SENSOR ACTYON 2006.03...
  • Page 493 4) Auto Light Control Only when the auto light switch is in "AUTO" position, it controls the tail lamp and headlamp by communicating with the rain sensor (while the ignition key is in "ON" position). RAIN SENSOR ACTYON 2006.03...
  • Page 494 2 seconds, then continuously outputs the parking signal of current sensitivity (while the ignition key is in "ON" position and the INT switch is in "ON" position). ※ The wiper motor runs only when the rain sensor requires. RAIN SENSOR ACTYON 2006.03...
  • Page 495 The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the INT switch is in "ON" position). RAIN SENSOR ACTYON 2006.03...
  • Page 496 Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR ACTYON 2006.03...
  • Page 497 A position that controls sensitivity against The auto light sensor is Integrated into the rains on the windshield and transmits rain sensor (refer to the below picture). wiping demand signal accordingly. RAIN SENSOR ACTYON 2006.03...
  • Page 498 Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (For example, the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR ACTYON 2006.03...
  • Page 499 The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor. Followings are the components and functions of the rain sensor unit 1) Rain Sensor Unit (Including Cover) RAIN SENSOR ACTYON 2006.03...
  • Page 500 No. 2 terminal sends the wiper and washer operation information such as washer operation mode, wiper relay, or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode. RAIN SENSOR ACTYON 2006.03...
  • Page 501 "ON" position). When the wiper switch is turned to "ON" position again from "OFF" position, the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the "Rain Detected" signal. RAIN SENSOR ACTYON 2006.03...
  • Page 502 "ON" and the auto INT switch "ON" in rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during continuous operation. The operation data is sent to the rain sensor even during the washer coupled wiper operation. RAIN SENSOR ACTYON 2006.03...
  • Page 503 4) Auto Light Control Only when the auto light switch is in "AUTO" position, it controls the tail lamp and headlamp by communicating with the rain sensor (while the ignition key is in "ON" position). RAIN SENSOR ACTYON 2006.03...
  • Page 504 2 seconds, then continuously outputs the parking signal of current sensitivity (while the ignition key is in "ON" position and the INT switch is in "ON" position). ※ The wiper motor runs only when the rain sensor requires. RAIN SENSOR ACTYON 2006.03...
  • Page 505 The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the INT switch is in "ON" position). RAIN SENSOR ACTYON 2006.03...
  • Page 506 Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR ACTYON 2006.03...
  • Page 507 Min. 20° 110 ± 5 100° 50 ± 5 Vertical: Min. 20° 110 ± 5 cm Min. 60° 50 ± 5 There is no upper mounting cover and spring in the PAS sensor installed in this vehicle. ACTYON 2006.03...
  • Page 508 If the system is in abnormal operating condition, a beep sounds for 3 seconds when the gear selector lever is moved into "R" position with the ignition key "ON" or engine running. However, it is also occurred when the obstacle is within 50 cm from the rear bumper. ACTYON 2006.03...
  • Page 509 When the sensing portion is covered by rain, water drops, snow or mud When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles) When a high-power radio is turned on When some accessories are attached in detecting ranges ACTYON 2006.03...
  • Page 510 When placing the gear selector lever to "R" position, the designated unit (PAS unit in the rear right quarter panel) activates the parking aid sensors to measure the distance to obstacles. ▶ PAS Related Devices Gear Selector Lever (R Position) Location of PAS Buzzer Unit PAS buzzer STICS PAS piezoelectric buzzer ACTYON 2006.03...
  • Page 511 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. ACTYON 2006.03...
  • Page 512 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. ACTYON 2006.03...
  • Page 513 Sensor failure conditions (conditions for warning beep Open in sending circuit Open in receiving circuit Open in power circuit (+, -) Back sonar (RH) Back sonar (LH) Back sonar (center) ▶ Warning Beeps ACTYON 2006.03...
  • Page 514 10-10 8790-03 4. CIRCUIT DIAGRAM ACTYON 2006.03...
  • Page 515 Min. 20° 110 ± 5 100° 50 ± 5 Vertical: Min. 20° 110 ± 5 cm Min. 60° 50 ± 5 There is no upper mounting cover and spring in the PAS sensor installed in this vehicle. ACTYON 2006.03...
  • Page 516 If the system is in abnormal operating condition, a beep sounds for 3 seconds when the gear selector lever is moved into "R" position with the ignition key "ON" or engine running. However, it is also occurred when the obstacle is within 50 cm from the rear bumper. ACTYON 2006.03...
  • Page 517 When the sensing portion is covered by rain, water drops, snow or mud When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles) When a high-power radio is turned on When some accessories are attached in detecting ranges ACTYON 2006.03...
  • Page 518 When placing the gear selector lever to "R" position, the designated unit (PAS unit in the rear right quarter panel) activates the parking aid sensors to measure the distance to obstacles. ▶ PAS Related Devices Gear Selector Lever (R Position) Location of PAS Buzzer Unit PAS buzzer STICS PAS piezoelectric buzzer ACTYON 2006.03...
  • Page 519 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. ACTYON 2006.03...
  • Page 520 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. ACTYON 2006.03...
  • Page 521 Sensor failure conditions (conditions for warning beep Open in sending circuit Open in receiving circuit Open in power circuit (+, -) Back sonar (RH) Back sonar (LH) Back sonar (center) ▶ Warning Beeps ACTYON 2006.03...
  • Page 522 10-10 8790-03 4. CIRCUIT DIAGRAM ACTYON 2006.03...
  • Page 523 8610-26 8930-01 AUDIO SYSTEM 1. AUDIO SYSTEM OVERVIEW Audio System - 6 Speakers AUDIO SYSTEM ACTYON 2006.03...
  • Page 524 8610-26 2. CIRCUIT DIAGRAM OF AUDIO SYSTEM AUDIO SYSTEM ACTYON 2006.03...
  • Page 525 8610-26 8930-01 AUDIO SYSTEM 1. AUDIO SYSTEM OVERVIEW Audio System - 6 Speakers AUDIO SYSTEM ACTYON 2006.03...
  • Page 526 8610-26 2. CIRCUIT DIAGRAM OF AUDIO SYSTEM AUDIO SYSTEM ACTYON 2006.03...
  • Page 527 02-3 3410-01 3640-01 ION 4-SPEED 1. SPECIFICATIONS ION 4-SPEED ACTYON 2006.03...
  • Page 528 02-4 3410-01 2. FASTENER TIGHTENING SPECIFICATIONS ION 4-SPEED ACTYON 2006.03...
  • Page 529 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 2006.03...
  • Page 530 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 2006.03...
  • Page 531 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 2006.03...
  • Page 532 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. ION 4-SPEED ACTYON 2006.03...
  • Page 533 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 2006.03...
  • Page 534 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 2006.03...
  • Page 535 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 2006.03...
  • Page 536 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 2006.03...
  • Page 537 02-13 3410-01 ION 4-SPEED ACTYON 2006.03...
  • Page 538 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 2006.03...
  • Page 539 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 2006.03...
  • Page 540 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 2006.03...
  • Page 541 02-17 3410-01 ▶ Solenoid Operation during Gearshifts ION 4-SPEED ACTYON 2006.03...
  • Page 542 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 2006.03...
  • Page 543 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 2006.03...
  • Page 544 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 2006.03...
  • Page 545 02-21 3410-01 1) Hydraulic Control Circuit ION 4-SPEED ACTYON 2006.03...
  • Page 546 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 2006.03...
  • Page 547 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 2006.03...
  • Page 548 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 2006.03...
  • Page 549 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 2006.03...
  • Page 550 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 2006.03...
  • Page 551 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 2006.03...
  • Page 552 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 2006.03...
  • Page 553 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 2006.03...
  • Page 554 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 2006.03...
  • Page 555 02-31 3410-01 ION 4-SPEED ACTYON 2006.03...
  • Page 556 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 2006.03...
  • Page 557 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 2006.03...
  • Page 558 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 2006.03...
  • Page 559 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 2006.03...
  • Page 560 02-36 3410-01 1) Park And Neutral ION 4-SPEED ACTYON 2006.03...
  • Page 561 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 2006.03...
  • Page 562 02-38 3410-01 2) Reverse ION 4-SPEED ACTYON 2006.03...
  • Page 563 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 2006.03...
  • Page 564 02-40 3410-01 3) Manual 1 ION 4-SPEED ACTYON 2006.03...
  • Page 565 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 2006.03...
  • Page 566 02-42 3410-01 4) DRIVE 1 ION 4-SPEED ACTYON 2006.03...
  • Page 567 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 2006.03...
  • Page 568 02-44 3410-01 5) DRIVE 2 AND MANUAL 2 ION 4-SPEED ACTYON 2006.03...
  • Page 569 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 2006.03...
  • Page 570 02-46 3410-01 6) DRIVE 3 AND MANUAL 3 ION 4-SPEED ACTYON 2006.03...
  • Page 571 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 2006.03...
  • Page 572 02-48 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 3 and Manual 3 ION 4-SPEED ACTYON 2006.03...
  • Page 573 02-49 3410-01 7) DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP ION 4-SPEED ACTYON 2006.03...
  • Page 574 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 2006.03...
  • Page 575 02-51 3410-01 8) DRIVE 4 (OVERDRIVE) ION 4-SPEED ACTYON 2006.03...
  • Page 576 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 2006.03...
  • Page 577 02-53 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED ACTYON 2006.03...
  • Page 578 02-54 3410-01 9) DRIVE 4 LOCK UP ION 4-SPEED ACTYON 2006.03...
  • Page 579 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 2006.03...
  • Page 580 02-3 3410-01 3640-01 ION 4-SPEED 1. SPECIFICATIONS ION 4-SPEED ACTYON 2006.03...
  • Page 581 02-4 3410-01 2. FASTENER TIGHTENING SPECIFICATIONS ION 4-SPEED ACTYON 2006.03...
  • Page 582 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 2006.03...
  • Page 583 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 2006.03...
  • Page 584 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 2006.03...
  • Page 585 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. ION 4-SPEED ACTYON 2006.03...
  • Page 586 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 2006.03...
  • Page 587 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 2006.03...
  • Page 588 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 2006.03...
  • Page 589 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 2006.03...
  • Page 590 02-13 3410-01 ION 4-SPEED ACTYON 2006.03...
  • Page 591 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 2006.03...
  • Page 592 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 2006.03...
  • Page 593 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 2006.03...
  • Page 594 02-17 3410-01 ▶ Solenoid Operation during Gearshifts ION 4-SPEED ACTYON 2006.03...
  • Page 595 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 2006.03...
  • Page 596 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 2006.03...
  • Page 597 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 2006.03...
  • Page 598 02-21 3410-01 1) Hydraulic Control Circuit ION 4-SPEED ACTYON 2006.03...
  • Page 599 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 2006.03...
  • Page 600 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 2006.03...
  • Page 601 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 2006.03...
  • Page 602 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 2006.03...
  • Page 603 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 2006.03...
  • Page 604 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 2006.03...
  • Page 605 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 2006.03...
  • Page 606 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 2006.03...
  • Page 607 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 2006.03...
  • Page 608 02-31 3410-01 ION 4-SPEED ACTYON 2006.03...
  • Page 609 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 2006.03...
  • Page 610 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 2006.03...
  • Page 611 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 2006.03...
  • Page 612 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 2006.03...
  • Page 613 02-36 3410-01 1) Park And Neutral ION 4-SPEED ACTYON 2006.03...
  • Page 614 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 2006.03...
  • Page 615 02-38 3410-01 2) Reverse ION 4-SPEED ACTYON 2006.03...
  • Page 616 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 2006.03...
  • Page 617 02-40 3410-01 3) Manual 1 ION 4-SPEED ACTYON 2006.03...
  • Page 618 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 2006.03...
  • Page 619 02-42 3410-01 4) DRIVE 1 ION 4-SPEED ACTYON 2006.03...
  • Page 620 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 2006.03...
  • Page 621 02-44 3410-01 5) DRIVE 2 AND MANUAL 2 ION 4-SPEED ACTYON 2006.03...
  • Page 622 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 2006.03...
  • Page 623 02-46 3410-01 6) DRIVE 3 AND MANUAL 3 ION 4-SPEED ACTYON 2006.03...
  • Page 624 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 2006.03...
  • Page 625 02-48 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 3 and Manual 3 ION 4-SPEED ACTYON 2006.03...
  • Page 626 02-49 3410-01 7) DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP ION 4-SPEED ACTYON 2006.03...
  • Page 627 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 2006.03...
  • Page 628 02-51 3410-01 8) DRIVE 4 (OVERDRIVE) ION 4-SPEED ACTYON 2006.03...
  • Page 629 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 2006.03...
  • Page 630 02-53 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED ACTYON 2006.03...
  • Page 631 02-54 3410-01 9) DRIVE 4 LOCK UP ION 4-SPEED ACTYON 2006.03...
  • Page 632 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 2006.03...
  • Page 633 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 2006.03...
  • Page 634 03-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications ACTYON 2006.03...
  • Page 635 03-5 3170-01 2) Tightening Torque ACTYON 2006.03...
  • Page 636 03-6 3170-01 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch 0.5 mm N (Neutral) Switch 0.5 mm Outside N Switch Inside N Switch ACTYON 2006.03...
  • Page 637 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 2006.03...
  • Page 638 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 2006.03...
  • Page 640 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 2006.03...
  • Page 641 03-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications ACTYON 2006.03...
  • Page 642 03-5 3170-01 2) Tightening Torque ACTYON 2006.03...
  • Page 643 03-6 3170-01 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch 0.5 mm N (Neutral) Switch 0.5 mm Outside N Switch Inside N Switch ACTYON 2006.03...
  • Page 644 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 2006.03...
  • Page 645 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 2006.03...
  • Page 647 04-3 3010-01 3020-01 CLUTCH 1. CLUTCH SPECIFICATIONS 2. TIGHTENING TORQUE CLUTCH ACTYON 2006.03...
  • Page 648 Disc wear (Free play) → Diaphragm spring ( 1 ) → Adjusting equipment 2 , 3 ) → Pressure plate ( 4 ) CLUTCH ACTYON 2006.03...
  • Page 649 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 2006.03...
  • Page 650 04-6 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH ACTYON 2006.03...
  • Page 651 04-7 3010-01 Cross Sectional View of Clutch Assembly Transmission housing Bolt Clutch disc assembly Washer Clutch disc cover assembly Bolt CLUTCH ACTYON 2006.03...
  • Page 652 04-3 3010-01 3020-01 CLUTCH 1. CLUTCH SPECIFICATIONS 2. TIGHTENING TORQUE CLUTCH ACTYON 2006.03...
  • Page 653 Disc wear (Free play) → Diaphragm spring ( 1 ) → Adjusting equipment 2 , 3 ) → Pressure plate ( 4 ) CLUTCH ACTYON 2006.03...
  • Page 654 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 2006.03...
  • Page 655 04-6 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH ACTYON 2006.03...
  • Page 656 04-7 3010-01 Cross Sectional View of Clutch Assembly Transmission housing Bolt Clutch disc assembly Washer Clutch disc cover assembly Bolt CLUTCH ACTYON 2006.03...
  • Page 657 05-3 4120-01 4120-01 AXLE 1. SPECIFICATIONS OF AXLE 1) Front View 2) Rear View 3) Specifications AXLE ACTYON 2006.03...
  • Page 658 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 2006.03...
  • Page 659 05-5 4120-01 1. OVERVIEW OF AXLE 1) Front Axle 2) Rear Axle AXLE ACTYON 2006.03...
  • Page 660 05-3 4120-01 4120-01 AXLE 1. SPECIFICATIONS OF AXLE 1) Front View 2) Rear View 3) Specifications AXLE ACTYON 2006.03...
  • Page 661 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 2006.03...
  • Page 662 05-5 4120-01 1. OVERVIEW OF AXLE 1) Front Axle 2) Rear Axle AXLE ACTYON 2006.03...
  • Page 663 Instrument panel(Note 1) : 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 2006.03...
  • Page 664 3240-01 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 2006.03...
  • Page 665 Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly T/C motor Oil drain plug (Tightening torque: 19 ~ 30 Damper Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm) TRANSFER CASE ACTYON 2006.03...
  • Page 666 Shifting to 4H mode (to 4H direction) (4WD HIGH comes on) Shifting to 2H mode Shifting to 2H mode (to 2H direction) (4WD HIGH goes off) System defective (4WD CHECK comes TCCU Solenoid valve Magnetic clutch TRANSFER CASE ACTYON 2006.03...
  • Page 667 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 2006.03...
  • Page 668 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 2006.03...
  • Page 669 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 2006.03...
  • Page 670 0-10 3240-01 2) Flow Layout TRANSFER CASE ACTYON 2006.03...
  • Page 671 0-11 3240-01 3) 2H Mode (Rear Wheel Drive) (1) Layout ↓ TRANSFER CASE ACTYON 2006.03...
  • Page 672 0-12 3240-01 4) 4H Mode (4 Wheel Drive - High speed) (1) Layout ↓ TRANSFER CASE ACTYON 2006.03...
  • Page 673 Instrument panel(Note 1) : 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 2006.03...
  • Page 674 3240-01 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 2006.03...
  • Page 675 Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly T/C motor Oil drain plug (Tightening torque: 19 ~ 30 Damper Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm) TRANSFER CASE ACTYON 2006.03...
  • Page 676 Shifting to 4H mode (to 4H direction) (4WD HIGH comes on) Shifting to 2H mode Shifting to 2H mode (to 2H direction) (4WD HIGH goes off) System defective (4WD CHECK comes TCCU Solenoid valve Magnetic clutch TRANSFER CASE ACTYON 2006.03...
  • Page 677 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 2006.03...
  • Page 678 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 2006.03...
  • Page 679 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 2006.03...
  • Page 680 0-10 3240-01 2) Flow Layout TRANSFER CASE ACTYON 2006.03...
  • Page 681 0-11 3240-01 3) 2H Mode (Rear Wheel Drive) (1) Layout ↓ TRANSFER CASE ACTYON 2006.03...
  • Page 682 0-12 3240-01 4) 4H Mode (4 Wheel Drive - High speed) (1) Layout ↓ TRANSFER CASE ACTYON 2006.03...
  • Page 683 07-3 4411-01 4510-01 SUSPENSION 1. SPECIFICATIONS OF SUSPENSION 2. WHEEL ALIGNMENT SUSPENSION ACTYON 2006.03...
  • Page 684 07-3 4411-01 4510-01 SUSPENSION 1. SPECIFICATIONS OF SUSPENSION 2. WHEEL ALIGNMENT SUSPENSION ACTYON 2006.03...
  • Page 685 (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 2006.03...
  • Page 686 08-4 4892-01 2. SECTIONAL DRAWING 1) Front Disc Brake 2) Rear Disc Brake ACTYON 2006.03...
  • Page 687 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 2006.03...
  • Page 688 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 2006.03...
  • Page 689 It is also a physical phenomenon and has no relation with the brake performance. ACTYON 2006.03...
  • Page 690 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 2006.03...
  • Page 691 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 2006.03...
  • Page 692 (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 2006.03...
  • Page 693 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 2006.03...
  • Page 694 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 2006.03...
  • Page 695 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 2006.03...
  • Page 696 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 2006.03...
  • Page 697 08-15 4892-01 The following figure shows the operating range according to driving conditions. Operating range Turning Turning ACTYON 2006.03...
  • Page 698 (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 2006.03...
  • Page 699 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 2006.03...
  • Page 700 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 2006.03...
  • Page 701 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 2006.03...
  • Page 702 · 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 2006.03...
  • Page 703 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 2006.03...
  • Page 704 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 2006.03...
  • Page 705 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 2006.03...
  • Page 706 The red HDC warning lamp blinks when the internal temperature goes over . When 350°C it reaches , the HDC warning lamp stays on. The HDC can be operated in this range 450°C even where the HDC warning lamp blinks. When the slope level is below 10% ACTYON 2006.03...
  • Page 707 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 2006.03...
  • Page 708 Basically, the brake system / apos;s basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: - Initial ignition ON - HDC system error occurs - Brake system overheat ACTYON 2006.03...
  • Page 709 - 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 2006.03...
  • Page 710 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 2006.03...
  • Page 711 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 2006.03...
  • Page 712 08-30 4892-01 7. INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM ▶ Input/Output of ESP System ACTYON 2006.03...
  • Page 713 08-31 4892-01 8. HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ACTYON 2006.03...
  • Page 714 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 2006.03...
  • Page 715 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 2006.03...
  • Page 716 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 2006.03...
  • Page 717 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 2006.03...
  • Page 718 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 2006.03...
  • Page 719 08-37 4892-01 1) Input and Output Diagram of ABS System ACTYON 2006.03...
  • Page 720 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 2006.03...
  • Page 721 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 2006.03...
  • Page 722 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 2006.03...
  • Page 723 (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 2006.03...
  • Page 724 08-4 4892-01 2. SECTIONAL DRAWING 1) Front Disc Brake 2) Rear Disc Brake ACTYON 2006.03...
  • Page 725 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 2006.03...
  • Page 726 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 2006.03...
  • Page 727 It is also a physical phenomenon and has no relation with the brake performance. ACTYON 2006.03...
  • Page 728 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 2006.03...
  • Page 729 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 2006.03...
  • Page 730 (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 2006.03...
  • Page 731 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 2006.03...
  • Page 732 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 2006.03...
  • Page 733 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 2006.03...
  • Page 734 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 2006.03...
  • Page 735 08-15 4892-01 The following figure shows the operating range according to driving conditions. Operating range Turning Turning ACTYON 2006.03...
  • Page 736 (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 2006.03...
  • Page 737 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 2006.03...
  • Page 738 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 2006.03...
  • Page 739 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 2006.03...
  • Page 740 · 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 2006.03...
  • Page 741 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 2006.03...
  • Page 742 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 2006.03...
  • Page 743 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 2006.03...
  • Page 744 The red HDC warning lamp blinks when the internal temperature goes over . When 350°C it reaches , the HDC warning lamp stays on. The HDC can be operated in this range 450°C even where the HDC warning lamp blinks. When the slope level is below 10% ACTYON 2006.03...
  • Page 745 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 2006.03...
  • Page 746 Basically, the brake system / apos;s basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: - Initial ignition ON - HDC system error occurs - Brake system overheat ACTYON 2006.03...
  • Page 747 - 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 2006.03...
  • Page 748 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 2006.03...
  • Page 749 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 2006.03...
  • Page 750 08-30 4892-01 7. INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM ▶ Input/Output of ESP System ACTYON 2006.03...
  • Page 751 08-31 4892-01 8. HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ACTYON 2006.03...
  • Page 752 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 2006.03...
  • Page 753 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 2006.03...
  • Page 754 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 2006.03...
  • Page 755 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 2006.03...
  • Page 756 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 2006.03...
  • Page 757 08-37 4892-01 1) Input and Output Diagram of ABS System ACTYON 2006.03...
  • Page 758 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 2006.03...
  • Page 759 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 2006.03...
  • Page 760 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 2006.03...
  • Page 761 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 2006.03...
  • Page 762 09-4 4610-01 1. SYSTEM LAYOUT POWER STEERING ACTYON 2006.03...
  • Page 763 09-5 4610-01 POWER STEERING ACTYON 2006.03...
  • Page 764 09-6 4610-01 2. COMPONENTS POWER STEERING ACTYON 2006.03...
  • Page 765 09-7 4610-01 POWER STEERING ACTYON 2006.03...
  • Page 766 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 2006.03...
  • Page 767 09-4 4610-01 1. SYSTEM LAYOUT POWER STEERING ACTYON 2006.03...
  • Page 768 09-5 4610-01 POWER STEERING ACTYON 2006.03...
  • Page 769 09-6 4610-01 2. COMPONENTS POWER STEERING ACTYON 2006.03...
  • Page 770 09-7 4610-01 POWER STEERING ACTYON 2006.03...
  • Page 771 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 2006.03...
  • Page 772 Curtain air bag collision G sensor BPT: Belt Pretensioner 40 ms after receiving the air bag deployment signal at the vehicle speed 3 km/h or higher, it sends out the door UNLOCK signal for 5 seconds. AIR BAG ACTYON 2006.03...
  • Page 773 (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 2006.03...
  • Page 774 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 2006.03...
  • Page 775 02-7 8810-03 AIR BAG ACTYON 2006.03...
  • Page 776 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 2006.03...
  • Page 777 (curtain air bags independently operate in case of the side collisions). Front View Rear View (1) Components Passenger's air bag module housing Inflator Air bag cushion Retainer AIR BAG ACTYON 2006.03...
  • Page 778 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 2006.03...
  • Page 779 02-11 8810-03 1) Components AIR BAG ACTYON 2006.03...
  • Page 780 This holds the occupant more securely in the seat. Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side) Curtain air bag G sensor Belt pretensioner (LH) Belt pretensioner (RH) AIR BAG ACTYON 2006.03...
  • Page 781 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 2006.03...
  • Page 782 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 2006.03...
  • Page 783 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 connetor Signal Ground terminal AIR BAG ACTYON 2006.03...
  • Page 784 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 2006.03...
  • Page 785 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 2006.03...
  • Page 786 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 2006.03...
  • Page 787 02-19 8810-03 10) ELECTRICAL WIRING DIAGRAM AIR BAG ACTYON 2006.03...
  • Page 788 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 2006.03...
  • Page 789 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 2006.03...
  • Page 790 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 2006.03...
  • Page 791 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 2006.03...
  • Page 792 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 2006.03...
  • Page 793 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 2006.03...
  • Page 794 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 2006.03...
  • Page 795 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 2006.03...
  • Page 796 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 2006.03...
  • Page 797 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 2006.03...
  • Page 798 04-3 7340-01 7340-01 SUNROOF 1. COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit (SCU) Sunroof Assembly Front Drain Hose Rear Drain Hose SUNROOF ACTYON 2006.03...
  • Page 799 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 2006.03...
  • Page 800 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 2006.03...
  • Page 801 04-6 7340-01 6) Circuit Diagram of Sunroof SUNROOF ACTYON 2006.03...
  • Page 802 04-3 7340-01 7340-01 SUNROOF 1. COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit (SCU) Sunroof Assembly Front Drain Hose Rear Drain Hose SUNROOF ACTYON 2006.03...
  • Page 803 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 2006.03...
  • Page 804 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 2006.03...
  • Page 805 04-6 7340-01 6) Circuit Diagram of Sunroof SUNROOF ACTYON 2006.03...
  • Page 806 Instrument Panel Glove Box and Instrument Instrument Lower Panel (Driver Side) Lower Panel (Passenger Side) Sun Visor A Pillar B Pillar C Pillar/D Pillar and Rear Quarter Panel Center Console Assembly C Pillar D Pillar Quarter Panel BODY INTERIOR ACTYON 2006.03...
  • Page 807 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 2006.03...
  • Page 808 Instrument Panel Glove Box and Instrument Instrument Lower Panel (Driver Side) Lower Panel (Passenger Side) Sun Visor A Pillar B Pillar C Pillar/D Pillar and Rear Quarter Panel Center Console Assembly C Pillar D Pillar Quarter Panel BODY INTERIOR ACTYON 2006.03...
  • Page 809 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 2006.03...
  • Page 810 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 2006.03...
  • Page 811 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 2006.03...
  • Page 812 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 2006.03...
  • Page 813 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 2006.03...
  • Page 814 07-3 4110-01 4110-01 BODY REPAIR 1. DIMENSIONS BODY REPAIR ACTYON 2006.03...
  • Page 815 07-4 4110-01 2. JACK-UP POINTS BODY REPAIR ACTYON 2006.03...
  • Page 816 Blocks the noise from engine and transmission and improves the reinforcement of vehicle body. Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision. BODY REPAIR ACTYON 2006.03...
  • Page 817 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 2006.03...
  • Page 818 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 2006.03...
  • Page 819 07-8 4110-01 5) Applied the Asphalt to the Body Panel (Improved Anti-Vibration) BODY REPAIR ACTYON 2006.03...
  • Page 821 07-3 4110-01 4110-01 BODY REPAIR 1. DIMENSIONS BODY REPAIR ACTYON 2006.03...
  • Page 822 07-4 4110-01 2. JACK-UP POINTS BODY REPAIR ACTYON 2006.03...
  • Page 823 Blocks the noise from engine and transmission and improves the reinforcement of vehicle body. Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision. BODY REPAIR ACTYON 2006.03...
  • Page 824 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 2006.03...
  • Page 825 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 2006.03...
  • Page 826 07-8 4110-01 5) Applied the Asphalt to the Body Panel (Improved Anti-Vibration) BODY REPAIR ACTYON 2006.03...
  • Page 828 This sensor is installed at the front A function that turns bottom of engine compartment. on/off the air source This changes the air source mode selection and air by detecting the air pollution and quality system. the ambient temperature. AIR CONDITIONER ACTYON 2006.03...
  • Page 829 Detects A/C switch position, A sensor that detects the refrigerant and coolant temperature, engine coolant temperature and reserves refrigerant condition and driving transmits it to engine to supply smoothly. condition to control the air ECU. conditioner. AIR CONDITIONER ACTYON 2006.03...
  • Page 830 01-4 6810-20 2. VENTILATION SYSTEM 1) Locations of Vents 2) Air Duct AIR CONDITIONER ACTYON 2006.03...
  • Page 831 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 2006.03...
  • Page 832 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 2006.03...
  • Page 833 01-7 6810-20 2) Components AIR CONDITIONER ACTYON 2006.03...
  • Page 834 01-8 6810-20 3) PTC Heater and FFH Heater Layout (1) PTC Heater Assembly Layout (2) FFH Heater Assembly Layout AIR CONDITIONER ACTYON 2006.03...
  • Page 835 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 2006.03...
  • Page 837 This sensor is installed at the front A function that turns bottom of engine compartment. on/off the air source This changes the air source mode selection and air by detecting the air pollution and quality system. the ambient temperature. AIR CONDITIONER ACTYON 2006.03...
  • Page 838 Detects A/C switch position, A sensor that detects the refrigerant and coolant temperature, engine coolant temperature and reserves refrigerant condition and driving transmits it to engine to supply smoothly. condition to control the air ECU. conditioner. AIR CONDITIONER ACTYON 2006.03...
  • Page 839 01-4 6810-20 2. VENTILATION SYSTEM 1) Locations of Vents 2) Air Duct AIR CONDITIONER ACTYON 2006.03...
  • Page 840 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 2006.03...
  • Page 841 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 2006.03...
  • Page 842 01-7 6810-20 2) Components AIR CONDITIONER ACTYON 2006.03...
  • Page 843 01-8 6810-20 3) PTC Heater and FFH Heater Layout (1) PTC Heater Assembly Layout (2) FFH Heater Assembly Layout AIR CONDITIONER ACTYON 2006.03...
  • Page 844 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 2006.03...
  • Page 846 ECU-GASOLINE 0000-00 ECU-GASOLINE 1. ECU-GASOLINE........
  • Page 848 0000-00 0000-00 ECU-GASOLINE 1. ECU-GASOLINE ECU-GASOLINE ACTYON 2006.03...
  • Page 849 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 850 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 851 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 852 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 853 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 854 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 855 0-10 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 856 0-11 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 857 0-12 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 858 0-13 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 859 0-14 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 860 0-15 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 861 0-16 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 862 0-17 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 863 0-18 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 864 0-19 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 865 0-20 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 866 0-21 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 867 0-22 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 868 0-23 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 869 0-24 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 870 0-25 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 871 0-26 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 872 0-27 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 873 0-28 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 874 0-29 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 875 0-30 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 876 0-31 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 877 0-32 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 878 0-33 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 879 0-34 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 880 0-35 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 881 0-36 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 882 0-37 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 883 0-38 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 884 0-39 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 885 0-40 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 886 0-41 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 887 0-42 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 888 0-43 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 889 0-44 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 890 0-45 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 891 0-46 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 892 0-47 0000-00 ECU-GASOLINE ACTYON 2006.03...
  • Page 894 ECU-DIESEL 0000-00 ECU-DIESEL DIAGNOSIS 1. ECU-DIESEL..........
  • Page 896 0000-00 0000-00 ECU-DIESEL 1. ECU-DIESEL ECU-DIESEL ACTYON 2006.03...
  • Page 897 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 898 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 899 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 900 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 901 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 902 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 903 0-10 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 904 0-11 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 905 0-12 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 906 0-13 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 907 0-14 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 908 0-15 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 909 0-16 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 910 0-17 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 911 0-18 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 912 0-19 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 913 0-20 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 914 0-21 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 915 0-22 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 916 0-23 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 917 0-24 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 918 0-25 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 919 0-26 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 920 0-27 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 921 0-28 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 922 0-29 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 923 0-30 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 924 0-31 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 925 0-32 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 926 0-33 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 927 0-34 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 928 0-35 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 929 0-36 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 930 0-37 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 931 0-38 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 932 0-39 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 933 0-40 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 934 0-41 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 935 0-42 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 936 0-43 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 937 0-44 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 938 0-45 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 939 0-46 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 940 0-47 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 941 0-48 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 942 0-49 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 943 0-50 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 944 0-51 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 945 0-52 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 946 0-53 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 947 0-54 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 948 0-55 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 949 0-56 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 950 0-57 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 951 0-58 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 952 0-59 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 953 0-60 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 954 0-61 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 955 0-62 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 956 0-63 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 957 0-64 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 958 0-65 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 959 0-66 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 960 0-67 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 961 0-68 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 962 0-69 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 963 0-70 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 964 0-71 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 965 0-72 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 966 0-73 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 967 0-74 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 968 0-75 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 969 0-76 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 970 0-77 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 971 0-78 0000-00 ECU-DIESEL ACTYON 2006.03...
  • Page 972 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
  • Page 974 0000-00 0000-00 BRAKE 1. BRAKE BRAKE ACTYON 2006.03...
  • Page 975 0000-00 BRAKE ACTYON 2006.03...
  • Page 976 0000-00 BRAKE ACTYON 2006.03...
  • Page 977 0000-00 BRAKE ACTYON 2006.03...
  • Page 978 0000-00 BRAKE ACTYON 2006.03...
  • Page 979 0000-00 BRAKE ACTYON 2006.03...
  • Page 980 0000-00 BRAKE ACTYON 2006.03...
  • Page 981 0-10 0000-00 BRAKE ACTYON 2006.03...
  • Page 982 0-11 0000-00 BRAKE ACTYON 2006.03...
  • Page 983 0-12 0000-00 BRAKE ACTYON 2006.03...
  • Page 984 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
  • Page 986 0000-00 0000-00 BRAKE 1. BRAKE BRAKE ACTYON 2006.03...
  • Page 987 0000-00 BRAKE ACTYON 2006.03...
  • Page 988 0000-00 BRAKE ACTYON 2006.03...
  • Page 989 0000-00 BRAKE ACTYON 2006.03...
  • Page 990 0000-00 BRAKE ACTYON 2006.03...
  • Page 991 0000-00 BRAKE ACTYON 2006.03...
  • Page 992 0000-00 BRAKE ACTYON 2006.03...
  • Page 993 0-10 0000-00 BRAKE ACTYON 2006.03...
  • Page 994 0-11 0000-00 BRAKE ACTYON 2006.03...
  • Page 995 0-12 0000-00 BRAKE ACTYON 2006.03...
  • Page 996 AIR-BAG 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG..........
  • Page 998 0000-00 0000-00 AIR-BAG 1. AIR-BAG AIR-BAG ACTYON 2006.03...
  • Page 999 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1000 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1001 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1002 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1003 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1004 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1005 0-10 0000-00 AIR-BAG ACTYON 2006.03...
  • Page 1006 CCCS 0000-00 CCCS DIAGNOSIS 1. CCCS.............
  • Page 1008 0000-00 0000-00 CCCS 1. CCCS CCCS ACTYON 2006.03...
  • Page 1009 0000-00 CCCS ACTYON 2006.03...
  • Page 1010 0000-00 CCCS ACTYON 2006.03...
  • Page 1011 0000-00 CCCS ACTYON 2006.03...
  • Page 1012 0000-00 CCCS ACTYON 2006.03...
  • Page 1013 0000-00 CCCS ACTYON 2006.03...
  • Page 1014 0000-00 CCCS ACTYON 2006.03...
  • Page 1015 0-10 0000-00 CCCS ACTYON 2006.03...
  • Page 1016 0-11 0000-00 CCCS ACTYON 2006.03...
  • Page 1017 0-12 0000-00 CCCS ACTYON 2006.03...
  • Page 1018 0-13 0000-00 CCCS ACTYON 2006.03...
  • Page 1019 0-14 0000-00 CCCS ACTYON 2006.03...
  • Page 1020 0-15 0000-00 CCCS ACTYON 2006.03...
  • Page 1021 0-16 0000-00 CCCS ACTYON 2006.03...
  • Page 1022 0-17 0000-00 CCCS ACTYON 2006.03...
  • Page 1023 0-18 0000-00 CCCS ACTYON 2006.03...

Table of Contents