SSANGYONG KYRON 2010.01 Manual
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SSANGYONG KYRON 2010.01 Manual

SSANGYONG KYRON 2010.01 Manual

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Table of Contents

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GENERAL
1. DIMENSIONS........................................
2. SPECIFICATIONS.................................
3. VEHICLE IDENTIFICATION...................
4. MAINTENANCE INTERVAL...................
LUBRICANTS........................................
6. JACK-UP POINTS .................................
CONNECTOR........................................
LAYOUT................................................
3
4
6
7
13
14
16
17
19
GENERAL
0000-00
GENERAL

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Summary of Contents for SSANGYONG KYRON 2010.01

  • 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 ......... 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR........8. ELECTRIC COMPONENTS AND LAYOUT..........9. STANDARD BOLTS SPECIFICATIONS.
  • Page 2 01-2 0000-00 GENERAL undefined...

  • Page 3: Dimensions

    01-3 0000-00 0000-00 GENERAL GENERAL 1. DIMENSIONS Unit: mm * ( ) : Optional GENERAL undefined...

  • Page 4: Specifications

    01-4 0000-00 2. SPECIFICATIONS * ( ) Optional GENERAL undefined...
  • Page 5 01-5 0000-00 * ( ) Optional GENERAL undefined...

  • Page 6: Vehicle Identification

    01-6 0000-00 3. VEHICLE IDENTIFICATION 1. Engine Number 2. Chassis Number Gasoline Engine: The chassis number is stamped on the frame The engine number is behind the front right tire. stamped on the lower area of cylinder block in exhaust manifold side.

  • Page 7: Maintenance Interval

    0000-00 4. MAINTENANCE INTERVAL 1) Diesel Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
  • Page 8 01-8 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 9 01-9 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 10 01-10 0000-00 2) Gasoline Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
  • Page 11 01-11 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 12 01-12 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.

  • Page 13: Recommended Fluids And Lubricants

    * IOP: Integrated Oil Pan * IRDA: Independent Rear Drive Axle Use only Ssangyong recommended fluids and lubricants. Keep the specified levels when adding or replacing the fluids. Do not mix any different types or brands of oils or fluids. This may cause damages.

  • Page 14: Jack-Up Points

    01-14 0000-00 6. JACK-UP POINTS 1) IRS - Lifting Point (Dotted Circles) GENERAL undefined...
  • Page 15 01-15 0000-00 2) 5 Link System - Lifting Point (Dotted Circles) GENERAL undefined...

  • Page 16: Pin Arrangement Of Diagnostic Connector

    01-16 0000-00 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR It is installed under the instrument panel and consists of 16 pins. 1) Functions of Terminal GENERAL undefined...

  • Page 17: Electric Components And Layout

    01-17 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement GENERAL undefined...
  • Page 18 01-18 0000-00 2) Components Locator GENERAL undefined...

  • Page 19: Standard Bolts Specifications

    01-19 0000-00 9. STANDARD BOLTS SPECIFICATIONS GENERAL undefined...
  • Page 20 01-20 0000-00 Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 21 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 23: General

    01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL undefined...
  • Page 24 01-4 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL undefined...

  • Page 25: Engine Controls Layout

    01-5 0000-00 2. ENGINE CONTROLS LAYOUT 1) ECU Related Componets FUNCTION FUNCTION Coolant reservoir HFM sensor VGT turbo charger Engine oil dipstick Engine Oil separator(PCV valve ) Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter &...
  • Page 26 01-6 0000-00 2) Engine And Sensors Camshaft Position Sensor Injector Glow Plug Fuel Pressure Sensor Booster Pressure Sensor Common Rail (Common Rail) ENGINE GENERAL undefined...
  • Page 27 01-7 0000-00 HP Pump Knock Sensor (1 EA) & Crankshaft Vacuum Modulator Water Temperature Sensor Position Sensor Water temp. sensor Knock sensor ENGINE GENERAL undefined...
  • Page 28 01-8 0000-00 3) Engine Accessories Related to ECU IP Interior Fuse Box (Passenger Side) Installed Engine ECU main relay Hazard warning lamp VGT & EGR vacuum modulators, HFM HP pumpIMV Engine ECU Mounting Location ENGINE GENERAL undefined...
  • Page 29 01-9 0000-00 HFM Sensor Accelerator Pedal Module Fuel Filter Sensor Integrated with 2 PPSs Priming Fuel Pump Filter Service Interval (Fuel Filter) Replace every 30,000 km (Draining water from fuel filter: Only whenever replacing the engine oil) Replace every 25,000 km General (Draining water from fuel filter: whenever replacing the engine oil)

  • Page 30: Electrical Components And Preheating System

    01-10 0000-00 3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM Battery Preheat Warning Lamp Glow Plug (Cluster) Engine compartment Alternator Starter motor fuse box PTC / FFH: 12V - 2.2kw 12V - 115A ENGINE GENERAL undefined...
  • Page 31 01-11 0000-00 Preheat Control Unit FUNCTION Glow plug terminal (#1 ~ #4) No G5 for 4 cylinders (Without D20DT) IG1 power supply terminal Glow plug control signal (ECU113) Ground terminal Battery main wire Preheat completion transmit terminal : No use for vehicle without remote engine start K-line (ECU 34) ENGINE GENERAL...

  • Page 32: Intake System Layout

    01-12 0000-00 4. INTAKE SYSTEM LAYOUT Intake outlet hose Air cleaner Front air duct Terbocharger intercooler Supplying Compressed Air with Intake Manifold Turbocharger's Operation To corresponding cylinders Coolant port Air cleaner Inter cooler Turbo charger From intercooler ENGINE GENERAL undefined...
  • Page 33 01-13 0000-00 Recirculation of Exhaust Gas when Turbocharger Intercooler EGR Valve Operates EGR valve Intake com pressed air Exhaust gas HFM Sensor Plug-in sensor Temperature Pretension Air cleaner Turbo - charger - Sensor graph ENGINE GENERAL undefined...

  • Page 34: Exhaust System Layout

    01-14 0000-00 5. EXHAUST SYSTEM LAYOUT EEGR Pipe Passage for recirculation of exhaust gas DOC (Diesel Catalytic Converter) Exhaust Manifold To turbo - To EGR charger pipe From cylinders ENGINE GENERAL undefined...
  • Page 35 01-15 0000-00 VGT Turbocharger EGR Valved Vacuum modulator To exhaust Intake com - pipe (DOC) pressed air Exhaust Exhaust gas manifold PCV Oil Separator Turbocharger Vacuum Modulator Cylinder head cover (oil + gas) Blow-by gas Vacuum (air duct hose) pump Inlet port Turbo - charger...

  • Page 36: Lubrication System Layout

    01-16 0000-00 6. LUBRICATION SYSTEM LAYOUT Oil dipstick gauge Cylinder Head Cover Oil Pressure Warning Lamp (Cluster) Oil Pan and Baffle Plate (Integrated Type) Oil Strainer ENGINE GENERAL undefined...
  • Page 37 01-17 0000-00 Oil Filter & Oil Cooler PCV Oil Separator Cylinder head cover (oil + gas) Blow-by gas cooler filter (air duct hose) Inlet port (oil gauge pipe) The first separation will happen when blow- by gas passes through baffle plates in cylinder head cover.

  • Page 38: Cooling System Layout

    01-18 0000-00 7. COOLING SYSTEM LAYOUT Coolant reservoir Coolant inlet hose Return hose Coolant outlet hose PWM electric Radiator Coolant Port Water Pump & Pipe Thermostat (inside) Coolant - Cylinder outlet port Radiator block Reservoir (Coolant inlet hose) Radiator Assembly Cooling Fan and Fan Clutch ENGINE GENERAL undefined...
  • Page 39 01-19 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL undefined...

  • Page 40: Fuel System Layout

    01-20 0000-00 8. FUEL SYSTEM LAYOUT HP Pump Injector Fuel Filter & Priming Pump Priming pump Fuel filter Connector HP Pump Fuel return port Fuel return port Fuel tempera - ture sensor Venturi IMV connector IMV valve High pres - sure fuel supply port Low pres - sure fuel supply port ENGINE GENERAL...
  • Page 41 01-21 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL undefined...

  • Page 42: Fuel Supply System

    01-22 0000-00 9. FUEL SUPPLY SYSTEM According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals.

  • Page 43: Cleanness

    01-23 0000-00 10. CLEANNESS 1) CLEANNESS OF DI ENGINE FUEL SYSTEM AND SERVICE PROCEDURES The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.
  • Page 44 01-24 0000-00 2) Job Procedures Always keep the workshop and lift clean (especially, from dust). Always keep the tools clean (from oil or foreign materials). Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
  • Page 45 01-25 0000-00 Follow the job procedures. If you find a defective component, replace it with new one. Disconnect the negative battery cable. For safety reasons: check pressure is low before opening the HP systems (pipes) Use special tools and torque wrench to perform the correct works. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones.
  • Page 46 01-26 0000-00 Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. Clear the high pressure offset value by SCAN-100 after replacing high pressure pump. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.
  • Page 47 01-27 0000-00 3) DI Engine and Its Expected Problems and Remedies Can be Caused by Water in Fuel System Supplement Against Paraffin Separation. ▶ In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally.

  • Page 48: Maintenance And Repair

    01-28 0000-00 11. MAINTENANCE AND REPAIR 1) Maintenance And Lubrication ▶ Normal Vehicle Use The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to "Wheels and Tire"...
  • Page 49 01-29 0000-00 ▷ Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. Brake System Service ▷ Check the disc brake pads or the drum brake linings.

  • Page 50: Guidelines For Service Work Safety

    01-30 0000-00 12. GUIDELINES FOR SERVICE WORK SAFETY 1) General To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures. Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service...
  • Page 51 01-31 0000-00 2) Cautions on Inspection/Service During service works, be sure to observe below general items for your safety. For service works, be sure to disconnect battery negative (-) terminal if not starting · and inspection. While inspecting vehicle and replacing various consumable parts, be sure to take ·...
  • Page 52 01-32 0000-00 3) Guidelines on Engine Service To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 53 01-33 0000-00 ▶ Fuel and lubrication system Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system.

  • Page 54: During Service Work For Inspection

    01-34 0000-00 13. DURING SERVICE WORK FOR INSPECTION Before lifting up the vehicle with lift, correctly support the lifting points and lift When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work.
  • Page 55 01-35 0000-00 Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new. If reused, normal functions cannot be maintained. Align the disassembled parts in clean according to disassembling order and group for easy assembling. According to installing positions, the bolts and nuts have different hardness and design.

  • Page 56: During Service Work For Electric Devices

    01-36 0000-00 14. DURING SERVICE WORK FOR ELECTRIC DEVICES Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key.

  • Page 57: Owner Inspections And Services

    01-37 0000-00 15. OWNER INSPECTIONS AND SERVICES 1) While Operating The Vehicle ▶ Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. ▶ Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking.
  • Page 58 01-38 0000-00 2) At Each Fuel Fill A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately. ▶ Engine Oil Level Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
  • Page 59 01-39 0000-00 5) At Least Twice A Year Power Steering System Reservoir Level ▶ Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 4G, Power Steering System. Brake Master Cylinder Reservoir Level ▶...
  • Page 60 01-40 0000-00 7) At Least Annually Lap and Shoulder Belts Condition and Operation ▶ Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors. Movable Head Restraint Operation ▶ On vehicles with movable head restraints, the restraints must stay in the desired position. ▶...

  • Page 61: Standard Bolts Specifications

    01-41 0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL undefined...
  • Page 62 01-42 0000-00 Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 63 02-2 1212-01 1212-01 ENGINE ASSEMBLY GENERAL 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
  • Page 64 02-3 1212-01 Vacuum modulator ABS/ESP Brake fluid modulator EGR valve reservoir Battery Fuel filter & priming pump Washer fluid reservoir Power steering oil PWM electric reservoir fan & fan shroud ENGINE ASSEMBLY undefined...
  • Page 65 02-4 1212-01 1) Engine Structure Front View Cam position sensor 12 ± 1.7 Nm Oil dipstick gauge Oil separator (with PCV) VGT Turbo charger EGR pipe Water pump pulley Alternator Crankshaft pulley Oil pan Auto tensioner Air conditioner compressor Auto tensioner pulley Power steering pump pulley Power steering pump EGR valve...
  • Page 66 02-5 1212-01 Top View Oil separator Injector cover (10 ± 1.0 Nm → 180 + 20°) Oil pipe (40 ± 4.0 Nm) Fuel pressure sensor Water outlet port EGR valve Oil filler Booster pressure sensor 10 ± 1.0 Nm Common rail (25 ±...
  • Page 67 02-6 1212-01 Right Side View EGR valve Knock sensor 20 ± 2.6 Nm Power steering pump oil reservoir Power steering pump HP pump assembly Air conditioner compressor Engine mounting bracket Vacuum modulator for VGT turbocharger actuator Flywheel Crank position sensor 0.8 ±...
  • Page 68 02-7 1212-01 Left Side View Cylinder head jack valve screw VGT Turbo charger assembly Cylinder block assembly Engine mounting bracket Oil pan Alternator Water pump EGR pipe Oil dipstick gauge Oil separator (with PCV) ENGINE ASSEMBLY undefined...
  • Page 69 02-8 1212-01 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY undefined...
  • Page 70 02-9 1212-01 2) Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE ASSEMBLY undefined...
  • Page 71 02-10 1212-01 3. TIGHTENING TORQUE ENGINE ASSEMBLY undefined...
  • Page 72 02-11 1212-01 ENGINE ASSEMBLY undefined...
  • Page 73 02-12 1212-01 ENGINE ASSEMBLY undefined...
  • Page 74 03-3 1881-01 1881-01 ENGINE FUEL SYSTEM GENERAL 1. CAUTIONS FOR DI ENGINE This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine, warning lights, symptoms when engine malfunctioning, causes and actions. 1) DI Engine Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high power and reduces less emission.
  • Page 75 03-4 1881-01 Fuel Filter and Water Separator 1. Fuel filter 2. Water drain plug(water separating operation:every 10,000km) 3. Priming pump 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.
  • Page 76 03-5 1881-01 6) Draining the Water From Fuel Filter Place the water container under the fuel filter. Turn the drain plug (2) to "A" direction to drain the water. Wait until a certain amount of fuel gets out from the port, then turn the drain plug to "B"...
  • Page 77 03-6 1881-01 OVERVIEW AND OPERATION PROCESS 1. ELECTRONIC CONTROL OF FUEL SYSTEM Supply line Return line ECU connecting line Components High pressure fuel pump Fuel rail Fuel pressure sensor Fuel injectors Electronic control unit(ECU) Various sensors and actuators According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time.
  • Page 78 03-7 1881-01 2. COMPOSITION OF FUEL SYSTEM Components in fuel system are designed to generate and distribute high pressure, and they are controlled electronically by engine ECU. Accordingly, fuel system is completely different from injection pump type fuel supply system on the conventional Diesel engine. The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure, high pressure section that transfers fuel in high pressure and ECU control section.
  • Page 79 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 undefined...
  • Page 80 03-9 1881-01 4. COMPONENTS OF LOW PRESSURE TRANSFER LINE Low pressure stage is to supply sufficient fuel to high pressure section and components are as below. Fuel tank (including strainer) Hand priming pump Fuel filter Transfer pump Other low pressure fuel hoses 1) Fuel Tank Fuel tank is made of anti-corrosion material and its allowable pressure is 2 times of...
  • Page 81 03-10 1881-01 3) Fuel Filter It requires more purified fuel supply than conventional diesel engine. If there are foreign materials in the fuel, fuel system including pump components, delivery valve and injector nozzles may be damaged. Fuel filter purifies fuel before it reaches to high pressure pump...
  • Page 82 03-11 1881-01 5. COMPONENTS OF HIGH PRESSURE TRANSFER LINE In the high pressure section, sufficient fuel pressure that injectors requires will be generated and stored. The components are as below: High pressure pump Rail pressure sensor Pressure limit valve Common rail High pressure pipe Injector Fuel pressure regulating valve (IMV)
  • Page 83 03-12 1881-01 3) High Pressure Pipe (Fuel Pipe) Fuel line transfers high pressure fuel. Accordingly, it is made of steel to endure intermittent high frequency pressure changes that occur under maximum system pressure and injection stops. Injection lines between rail and injectors are all in the same length;...
  • Page 84 03-13 1881-01 6. CIRCUIT DIAGRAM ENGINE FUEL SYSTEM undefined...
  • Page 85 03-14 1881-01 ENGINE FUEL SYSTEM undefined...
  • Page 86 03-15 1881-01 ENGINE FUEL SYSTEM undefined...
  • Page 88 04-3 2321-01 2321-01 ENGINE INTAKE SYSTEM GENERAL 1. ENGINE INTAKE SPECIFICATIONS 1) Specifications Element Type Dry-Element Type - Initial cleaning: 5,000 km, Clean or change every 10,000 km as required. However, change every 30,000 km. Service Interval - If the vehicle is operated under severe condition (short distance driving, extensive ldling or driving in dusty condition): More frequent maintenance is required.
  • Page 89 04-4 2321-01 OVERVIEW AND OPERATION PROCESS 1. INTAKE SYSTEM LAYOUT 1) Work Flow of Intake System VGT Turbocharger Exhaust pipe Turbocharger (diesel catalytic actuator converter) Intake (air cleaner) pressed air (intercooler) Exhaust gas HFM Sensor Air Cleaner The HFM sensor is installed in the air intake passage between the air cleaner and the intake manifold.
  • Page 90 04-5 2321-01 EGR Valve and Its Location (* For details, refer to "EGR" section.) Intake air Intake Intake Intake manifold manifold Exhaust Exhaust gas Vacuum Modulator Intake Manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum valve pump IP interior fuse (RH) Engine ECU No.63-7.5A No.
  • Page 91 04-6 2321-01 2) Layout ENGINE INTAKE SYSTEM undefined...
  • Page 92 04-7 2321-01 3) Components (1) Intake Manifold Assembly The intake manifold assembly is built for the optimized mixture of the EGR gas in the intake chamber when the compressed air in the turbocharger is sent to the intake port. The intake port is composed of the dual port (tangential and helical port) which increases the swirl ratio in mid/low operating range, improves acceleration/fuel consumption and decreases particle materials.
  • Page 93 04-8 2321-01 The SUS + Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect. Intake Manifold Coolant emission port Coolant emission port Incoming of intake air and Incoming of intake air (No exhaust gas (Operation of operation of EGR valve) EGR valve)
  • Page 94 04-9 2321-01 (2) Turbocharger Intercooler Assembly The turbocharger is designed to improve the engine power by introducing more air (oxygen) into the engine. However, the intake air is heated during the compression process in the turbocharger compressor and the density is lowered. The intercooler is the device which cools (50 ~ 60°C) the air entering the engine from high temperature (100 ~ 110°C)
  • Page 95 04-10 2321-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE INTAKE SYSTEM undefined...
  • Page 96 05-3 1913-01 1913-01 ENGINE EXHAUST SYSTEM GENERAL 1. INSPECTION BEFORE DIAGNOSIS The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in related system as the first priority.When abnormal condition occurs with the EGR system, the basic approach is, as described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan tool or vacuum tester.
  • Page 97 05-4 1913-01 ▶ HUBER EGR System for IDI Engine (Including the EGR Valve Potentiometer) The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator, one is same as being the modulator for EGR valve whereas the HUBER EGR system's the other modulator controls ALDA of injection pump and the DI engine's the other modulator controls waist gate of the turbo charger.
  • Page 98 05-5 1913-01 OVERVIEW AND OPERATION PROCESS 1. EXHAUST SYSTEM LAYOUT EGR Valve and Installation Location Intake air Intake (intercooler) manifold Intake Intake manifold manifold EGR pipe EGR pipe (LH) Exhaust Manifold Exhaust manifold To turbo- To EGR EGR pipe (RH) charger valve Diesel catalytic converter →...
  • Page 99 05-6 1913-01 2) Exhaust Gas Flows ENGINE EXHAUST SYSTEM undefined...
  • Page 100 06-3 1533-01 1533-01 LUBRICATION SYSTEM GENERAL 1. SPECIFICATIONS ▶ Severe Condition: When most trips include extended idling and/or frequent low-speed operation as in stop- and-go traffic. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km) When operating in dusty, sandy and salty areas In hilly or moutainous terrain...
  • Page 101 06-4 1533-01 OVERVIEW AND PERATION PROCESS 1. LAYOUT AND OVERVIEW 1) Lubrication System Oil dipstick gauge PCV Oil Separator The first separation will happen when blowby Cylinder head cover (oil + gas) gas passes through baffle plates in cylinder head cover. Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port.
  • Page 102 06-5 1533-01 Oil pressure Warning Lamp Cylinder Head Cover (Cluster) Oil Pan and Baffle Plate Oil Strainer Oil Filter & Oil Cooler (Integrated Type) cooler filter LUBRICATION SYSTEM undefined...
  • Page 103 06-6 1533-01 2) Lubrication System Layout Cylinder Head Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 Return hole: φ 14 Chain nozzle: φ 1 HP pump bearing: φ 6 Cylinder Block LUBRICATION SYSTEM undefined...
  • Page 104 06-7 1533-01 2. LUBRICATION DIAGRAM Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of cylinder head LUBRICATION SYSTEM undefined...
  • Page 105 07-3 9210-05 9210-05 ENGINE COOLING SYSTEM GENERAL 1. ENGINE COOLING SPECIFICATIONS COOLING SYSTEM undefined...
  • Page 106 07-4 9210-05 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS ENGINE COOLING Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor COOLING SYSTEM undefined...
  • Page 107 07-5 9210-05 2. COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side · Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side · Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump COOLING SYSTEM undefined...
  • Page 108 07-6 9210-05 3. FUNCTION DESCRIPTION OF COOLING SYSTEM Intake manifold Cylinder head Coolant outlet port Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1) Improved shape and gasket material to prevent coolant from leaking ·...
  • Page 109 08-3 1461-01 1461-01 ENGINE ELECTRICAL SYSTEM GENERAL 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE ELECTRIC DEVICES undefined...
  • Page 110 08-4 1461-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ELECTRIC IN ENGINE Fuel Pressure Camshaft Position Coolant Temperature Fuel Temperature Sensor Sensor Sensor Sensor Booster Pressure Oil Pressure Switch Crankshaft Position Knock Sensor Sensor Sensor (1 EA) ENGINE ELECTRIC DEVICES undefined...
  • Page 111 08-5 1451-01 2. COMPONENTS OF ELECTRIC DEVICES IN ENGINE Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE ELECTRIC DEVICES undefined...
  • Page 112 08-6 1461-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1) Preheating ENGINE ELECTRIC DEVICES undefined...
  • Page 113 08-7 1461-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1) Starting & Charging ENGINE ELECTRIC DEVICES undefined...
  • Page 114 09-3 1491-01 1491-01 EGINE CONTROL SYSTEM GENERAL 1. ENGINE ECU AND OTHER COMPONENTS Coolant reservoir Return hose Coolant inlet hose Coolant outlet hose Radiator Water Pump and Pipe Coolant Port Thermostat (inside) Cylinder block Coolant outlet Radiator port Reservior (coolant inlet hose) Engine Oil Filter and Cooler Oil Filter cap Oil cooler...
  • Page 115 09-4 1491-01 2. TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE CONTROL SYSTEM undefined...
  • Page 116 09-5 1491-01 3. SIDE VIEW Coolant Temperature Knock Sensors (1 EA) Sensor Fuel Temperature Sensor Fuel Pressure Crankshaft Position Regulating Valve Sensor ENGINE CONTROL SYSTEM undefined...
  • Page 117 09-6 1491-01 OVERVIEW AND OPERATION PROCESS 1. ECU INPUTS/OUTPUTS Inputs Output Control Booster pressure sensor Injector Atmospheric pressure sensor EGR system (Built-in ECU) Fuel pressure regulating valve Air flow sensor (HFM) (IMV) Coolant temperature sensor Electrical fan control Fuel temperature sensor (Low/High-speed) Fuel pressure sensor A/C compressor relay...
  • Page 118 09-7 1491-01 2. STRUCTURE AND FUNCTION OF ECU 1) Function of ECU ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and analyzes to control respective actuators. ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft angle based on input data and stored specific map to control the engine power and emission gas.
  • Page 119 09-8 1491-01 4. FUEL PRESSURE CONTROL 1) Fuel Pressure Control Elements Pressure control consists of 2 principle modules. Determines rail pressure according to engine operating conditions. Controls IMV to make the rail pressure to reach to the required value. Pressure in the fuel rail is determined according to engine speed and load on the engine. The aim is to adapt the injection pressure to the engine's requirements.
  • Page 120 09-9 1491-01 5. FUEL INJECTION CONTROL 1) Fuel Injection Control Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors. Injection control consists as below. Injection timing Injection volume Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver.
  • Page 121 09-10 1491-01 ▶ Pilot injection timing control The pilot injection timing is determined as a function of the engine speed and of the total flow. The elements are: A first correction is made according to the air and coolant temperatures. This correction allows the pilot injection timing to be adapted to the operating temperature of the engine.
  • Page 122 09-11 1491-01 6. FUEL FLOW CONTROL 1) Main Flow Control The main flow represents the amount of fuel injected into the cylinder during the main injection. The pilot flow represents the amount of fuel injected during the pilot injection. The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
  • Page 123 09-12 1491-01 A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the engine. Until the stating phase has finished, the system uses the supercharged fuel. Once the engine changes to normal operation, the system uses the total fuel. The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
  • Page 124 09-13 1491-01 2) Driver Demand The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes of the pedal position.
  • Page 125 09-14 1491-01 3) Idle Speed Controller The idle speed controller consists of 2 principal modules: The first module determines the required idle speed according to: The operating conditions of the engine (coolant temperature, gear engaged) · · Any activation of the electrical consumers (power steering, air conditioning, others) The battery voltage ·...
  • Page 126 09-15 1491-01 5) Pilot Flow Control The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined according to the engine speed and the total flow. A first correction is made according to the air and water temperature. This correction allows the pilot flow to be adapted to the operating temperature of the engine.
  • Page 127 09-16 1491-01 7) Accelerometer Strategy ▶ Resetting the pilot injection The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the detection of the combustion noises.
  • Page 128 09-17 1491-01 ▶ Detection of leaks in the cylinders The accelerometer is also used to detect any injector which may have stuck open. The detection principle is based on monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-ignites as soon as the temperature and pressure conditions are favorable (high engine speed, high load and small leak).
  • Page 129 09-18 1491-01 7. INDIVIDUAL INJECTOR CALIBRATION (C2I) Injected fuel is proportional to square root of injection time and rail pressure. It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the following shape. Common rail injectors are very accurate components.
  • Page 130 09-19 1491-01 C2I is composed of models on these characteristics of injectors. C2I consists of 16-digit composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I, characteristics of each injector, to make the most optimal fuel injection. When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector's C2I value.
  • Page 131 09-20 1491-01 8. MINIMUM DRIVE PULSE (MDP) LEARNING When the pulse value that the injector starts injection is measured, it is called mininum drive pulse (MDP). Through MDP controls, can correct pilot injections effectively. Pilot injection volume is very small, 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors.
  • Page 132 10-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
  • Page 133 10-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
  • Page 134 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
  • Page 135 10-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
  • Page 136 10-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
  • Page 137 10-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
  • Page 138 10-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
  • Page 139 10-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
  • Page 140 01-3 1114-00 1114-00 ENGINE ASSEMBLY GENERAL 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The electronically controlled advanced D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
  • Page 141 01-4 1114-00 1) Engine Assembly Structure Front View Touch idler equipped (for A/T) Top View ENGINE ASSEMBLY undefined...
  • Page 142 01-5 1114-00 Right Side View Left Side View ENGINE ASSEMBLY undefined...
  • Page 143 01-6 1114-00 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY undefined...
  • Page 144 01-7 1114-00 2) Engine Performance Curve (1) Output and Torque General (2) Oil Temperature/Pressure and Boost Pressure General ENGINE ASSEMBLY undefined...
  • Page 145 01-8 1114-00 3. TIGHTENING TORQUE ENGINE ASSEMBLY undefined...
  • Page 146 01-9 1114-00 ENGINE ASSEMBLY undefined...
  • Page 147 01-10 1114-00 ENGINE ASSEMBLY undefined...
  • Page 148 01-11 1114-00 1) Engine Head Bolt Tightening Torque Head bolt wrench and tightening torque according to the cylinder head bolt changes of the DI engine (D20DT) Cylinder head bolt wrench W9912 003 0B I.D. of head bolt head: 14.5 mm O.D.
  • Page 149 01-12 1114-00 4. MAJOR CHANGES IN D20DT (EU-IV) ENGINE (COMPARED TO D20DT) 1) Engine Assembly D20DT (EURO 4) Engine D20DT Engine Front Side View Touch idler equipped (for A/T) Top Side View Right Side View Left Side View ENGINE ASSEMBLY undefined...
  • Page 150 01-13 1114-00 2) Major Changes and Summary D20DT (EURO 4) Engine D20DT Engine Remarks Injector * Injector label D20DT: Green (Cap) (16 digits: C2I value) D20DT (EURO 4): Red (Cap) (20 digits: C3I value) C3I Label C2I Label Fuel pipe * Diameter increased D20DT: ID (2.4 mm), OD (6.0 mm)
  • Page 151 01-14 1114-00 D20DT (EURO 4) Engine D20DT Engine Remarks * Version up HFM 6.0 HFM 5.0 D27DT: HFM5-CI (Analog signal) D27DTP: HFM6-ID (Digital signal added) Vacuum modulator * D20DT (EURO4) engine uses Vacuum modulator controlling turbo charger electric ally controlled E- actuator valve.
  • Page 152 01-15 1114-00 D20DT (EURO 4) Engine D20DT Engine Remarks Increase of Oil separator PCV oil separator capacity (approx. 10%) - D20DT (EURO 4): 160 /min - D20DT: 120 /min Blow-by gas Blow-by gas (To air duct (To air duct hose) hose) valve valve...
  • Page 153 02-3 1881-09 1881-09 ENGINE FUEL SYSTEM GENERAL 1. MAJOR CHANGES IN FUEL SYSTEM OF ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D20DT (EURO 4) engine. The major changes are as follows. Refer to the next pages for further details. 1) Injector Two nozzle holes are added (currently 7) to the tip of the injector to increase the...
  • Page 154 02-4 1881-09 3) Fuel Rail - Chrome Color The I.D and O.D of the fuel rail between Fuel pipe (Common rail → Injector) HP pump and common rail are increased according to the increased amount of fuel injection. Also, the engine ECU, HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely.
  • Page 156 02-6 1881-09 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF FUEL SYSTEM Injector (7-way Injection and C3I Coding) Fuel nozzle holes (7) Common Rail (Orifice for Preventing Fuel Pulsation Added) Orifice Orifice for HP pump fuel outlet Fuel Supply Rail (Increase in I.D) Fuel pipe Common rail Fuel rail...
  • Page 157 02-7 1881-09 Fuel filter Priming Pump Fuel filter Priming pump Connector Fuel from Fuel filter HP pump Fuel tank HP pump Fuel tank HP Pump Fuel temperature Fuel return Fuel return port sensor port IMV valve Venturi High pressure Low pressure fuel supply port fuel supply port (orifice included)
  • Page 158 02-8 1881-09 2. FUEL FLOW OF D20DT (EU-IV) ENGINE ENGINE FUEL SYSTEM undefined...
  • Page 159 04-3 1792-01 1792-01 ENGINE EXHAUST SYSTEM OVERVIEW AND OPERATION PROCESS 1. COMPONENTS The components of the exhaust system for the D20DT (EURO4) engine have been changed as follows: ▶ E-EGR valve - Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) ▶...
  • Page 160 3) System Met with EURO IV Regulations The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December 2007 comply with the EURO IV regulations. Modified components from the old...
  • Page 161 05-4 1881-09 2. CDPF (EU-IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and Sensors Differential Pressure Sensor (ΔP sensor) Under air cleaner in right side of engine compartment As the soot is filtered in the CDPF, the pressure between the front side and the rear side of...
  • Page 162 05-5 1881-09 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
  • Page 163 05-6 1881-09 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW As the solution for environmental regulations and PM (Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
  • Page 164 05-7 1881-09 2.CDPF (EU-IV) SYSTEM CONTROL 1) General Description As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
  • Page 165 05-8 1881-09 2) System Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
  • Page 166 05-9 1881-09 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type. CDPF undefined...
  • Page 167 05-10 1881-09 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
  • Page 168 05-11 1881-09 Front temperature sensor Rear temperature sensor (Measuring the temperature of (Measuring the temperature of exhaust exhaust gas passedthrough gas passed through DOC) exhaust manifold) Differrential pressure sensor Differrential pressure sensor (Front pressure port) (Rear pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects intoCDPF assembly after...
  • Page 169 05-12 1881-09 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 170 05-13 1881-09 ▶ Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration tem- perature due to low speed driving or other reason during the regeneration process, the soot is con- tinuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to in-form this situation to the driver.
  • Page 171 05-14 1881-09 4. COMPONENTS OF CDPF SYSTEM 1) Mounting Condition and Location Differential Pressure Sensor Rear exhaust gas temperature sensor Engine compartment (RH) Rear pressure port Differential Front pressure port pressure sensor CDPF assembly Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
  • Page 172 06-3 0000-00 0000-00 LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1. OVERVIEW OIL SEPARATORS For the D20DT (EURO4) engine, the PCV oil separator's capacity has been increased by 10% compared to the conventional PCV oil separator for D20DT engine to separate the oil and the gas more efficiently.
  • Page 173 06-4 0000-00 Performance of PCV Separator and Oil/Carbon Accumulation in Intake Manifold It is not possible to separate the blowby gas (oil and unburned gas) completely from the crankcase. This problem is related to the engine control and the PCV oil separator is designed to recirculate approx.
  • Page 174 ENGINE COOLING SYSTEM 2112-00/1520-00 ENGINE COOLING SYSTEM COOLING SYSTEM 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE....... WATER PUMP 1. OVERVIEW..........
  • Page 175 07-2 2112-00 ENGINE COOLING SYSTEM undefined...
  • Page 176 07-3 2112-00 2112-00 COOLING SYSTEM 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT (EURO4) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
  • Page 177 07-4 1520-00 1520-00 WATER PUMP 1. OVERVIEW The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and, therefore, cannot be disassembled. The capacity of water pump has been increased due to the EGR cooler, increased engine power and additional coolant port in the cylinder block.
  • Page 178 07-5 1520-00 1) Structure of Water Pump for D20DT Engine ENGINE COOLING SYSTEM undefined...
  • Page 180 08-3 1491-01 1491-01 ENGINE ELECTRIC DEVICES OVERVIEW AND OPERATION PROCESS 1. OVERVIEW OF ENGINE ECU The engine ECUs are various according to the engine model (D20DT engine, D20DT (EURO4) engine). For the D20DT (EURO4) engine, one connector is added to the engine ECU (2 connectors total) to control the additional sensor, actuator and exhaust gas control function.
  • Page 181 08-4 1491-01 2. D20DT (EU-IV) ENGINE'S ECU CIRCUIT ENGINE ELECTRICAL SYSTEM undefined...
  • Page 182 09-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
  • Page 183 09-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
  • Page 184 09-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
  • Page 185 09-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
  • Page 186 09-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
  • Page 187 09-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
  • Page 188 09-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
  • Page 189 09-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
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  • Page 191 ENGINE GENERAL 0000-00 ENGINEGENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT....2. COMPONENTS IN D20DT ENGINE AND D27DT ENGINE........3. ENGINE CONTROLS LAYOUT....4. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM......5. INTAKE SYSTEM LAYOUT....6. EXHAUST SYSTEM LAYOUT....7. LUBRICATION SYSTEM LAYOUT..8. COOLING SYSTEM LAYOUT....9.

  • Page 193: General

    01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH Side View D20DT D27DT ENGINE D20DT undefined...
  • Page 194 01-4 0000-00 2) RH side view D20DT D27DT ENGINE D20DT undefined...
  • Page 195 01-5 0000-00 3) Front view D20DT D27DT ENGINE D20DT undefined...
  • Page 196 01-6 0000-00 4) Fan belt D20DT D27DT ENGINE D20DT undefined...

  • Page 197: Components In D20Dt Engine And D27Dt Engine

    01-7 0000-00 2. COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ENGINE D20DT undefined...
  • Page 198 01-8 0000-00 ENGINE D20DT undefined...
  • Page 199 01-9 0000-00 ENGINE D20DT undefined...
  • Page 200 01-10 0000-00 ENGINE D20DT undefined...

  • Page 201: Engine Controls Layout

    01-11 0000-00 3. ENGINE CONTROLS LAYOUT 1) Ecu related componets (1) D20DT Engine ENGINE D20DT undefined...
  • Page 202 01-12 0000-00 (2) D27DT Engine ENGINE D20DT undefined...
  • Page 203 01-13 0000-00 2) ENGINE AND SENSORS (1) D20DT Engine ENGINE D20DT undefined...
  • Page 204 01-14 0000-00 (2) D27DT Engine ENGINE D20DT undefined...

  • Page 205: Electrical Components And Preheating System

    01-15 0000-00 4. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1) D20DT Engine ENGINE D20DT undefined...
  • Page 206 01-16 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 207: Intake System Layout

    01-17 0000-00 5. INTAKE SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT undefined...
  • Page 208 01-18 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 209: Exhaust System Layout

    01-19 0000-00 6. EXHAUST SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT undefined...
  • Page 210 01-20 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 211: Lubrication System Layout

    01-21 0000-00 7. LUBRICATION SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT undefined...
  • Page 212 01-22 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 213: Cooling System Layout

    01-23 0000-00 8. COOLING SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT undefined...
  • Page 214 01-24 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 215: Fuel System Layout

    01-25 0000-00 9. FUEL SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT undefined...
  • Page 216 01-26 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 217: Fuel Supply System

    01-27 0000-00 10. FUEL SUPPLY SYSTEM 1) D20DT Engine According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals.
  • Page 218 01-28 0000-00 2) D27DT Engine ENGINE D20DT undefined...

  • Page 219: Cleanness

    01-29 0000-00 11. CLEANNESS 1) Cleanness of di engine fuel system and service procedures The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.
  • Page 220 01-30 0000-00 2) Job procedures Always keep the workshop and lift clean (especially, from dust). Always keep the tools clean (from oil or foreign materials). Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
  • Page 221 01-31 0000-00 6. Follow the job procedures. If you find a defective component, replace it with new one. Disconnect the negative battery cable. For safety reasons: check pressure is low before opening the HP systems (pipes) Use special tools and torque wrench to perform the correct works. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones.
  • Page 222 01-32 0000-00 Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. Clear the high pressure offset value by SCAN- 100 after replacing the high pressure pump. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard.
  • Page 223 01-33 0000-00 3) Di engine and its expected problems and remedies can be caused by water in fuel ▶ SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION. In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally.

  • Page 225: Maintenance And Repair

    01-35 0000-00 12. MAINTENANCE AND REPAIR 1) Maintenance and lubrication ▶ Normal Vehicle Use The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to "Wheels and Tire"...
  • Page 226 01-36 0000-00 ▷ Spark Plug Wire Replacement Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed. ▷ Brake System Service Check the disc brake pads or the drum brake linings.

  • Page 227: Guidelines For Service Work Safety

    01-37 0000-00 13.GUIDELINES FOR SERVICE WORK SAFETY 1) General To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures. Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service...
  • Page 228 01-38 0000-00 2) Cautions on Inspection/Service During service works, be sure to observe below general items for your safety For service works, be sure to disconnect battery negative (-) terminal if not starting and · inspection. While inspecting vehicle and replacing various consumable parts, be sure to take ·...
  • Page 229 01-39 0000-00 3) Guidelines on engine service To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/ repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 230 01-40 0000-00 ▶ Fuel and lubrication system Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system.

  • Page 231: During Service Work For Inspection

    01-41 0000-00 14. DURING SERVICE WORK FOR INSPECTION Before lifting up the vehicle with lift, correctly support the lifting points and lift When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work.
  • Page 232 01-42 0000-00 Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new. If reused, normal functions cannot be maintained. Align the disassembled parts in clean according to disassembling order and group for easy assembling. According to installing positions, the bolts and nuts have different hardness and design.

  • Page 233: During Service Work For Electric Devices

    01-43 0000-00 15. DURING SERVICE WORK FOR ELECTRIC DEVICES Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key.

  • Page 234: Owner Inspections And Services

    01-44 0000-00 16. OWNER INSPECTIONS AND SERVICES 1) While Operating The Vehicle ▶ Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. ▶ Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking.
  • Page 235 01-45 0000-00 2) At each fuel fill A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately. ▶ Engine Oil Level Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
  • Page 236 01-46 0000-00 5) At least twice a year ▶ Power Steering System Reservoir Level Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 4G, Power Steering System. ▶ Brake Master Cylinder Reservoir Level Check the fluid and keep it at the proper level.
  • Page 237 01-47 0000-00 7) At least annually ▶ Lap and Shoulder Belts Condition and Operation Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors. ▶ Movable Head Restraint Operation On vehicles with movable head restraints, the restraints must stay in the desired position. ▶...

  • Page 238: Standard Bolts Specifications

    01-48 0000-00 17. STANDARD BOLTS SPECIFICATIONS *Diameter X pitch in millimeters ENGINE D20DT undefined...
  • Page 239 01-49 0000-00 Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 241 02-3 1114-01 1114-01 ENGINE ASSEMBLY GENERAL 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT 1) D20DT ENGINE The advanced electronically controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
  • Page 242 02-4 1114-01 2) D27DT ENGINE Coolant reservoir Fuel filter FFH device ABS/ESP unit Brake fluid reservoir Priming pump Washer fluid reservoir EGR valve Common rail Air cleaner assembly Fuse box Turbo charger Battery Oil dipstick ENGINE D20DT undefined...
  • Page 243 02-5 1114-01 2. ENGINE STRUCTURE 1) Front View D20DT TVD (Torsional Vibration Damper) Air conditioner compressor Power steering pump pulley Idle pulley Water pump pulley Alternator Viscos clutch pulley Auto tensioner pulley Auto tensioner Poly-grooved belt Cam position sensor EGR valve Power steering pump EGR center pipe TVD (Torsional Vibration Damper)
  • Page 244 02-6 1114-01 2) Top View D20DT Cylinder head cover Intake manifold Water outlet port Common rail Fuel pressure sensor Fuel pipe Injector Fuel return line Oil filler cap Glow plug Booster pressure sensor PCV valve and oil separator Oil dipstick EGR-LH pipe Cylinder head cover D27DT...
  • Page 245 02-7 1114-01 3) Right Side View D20DT 29. Cylinder head 30. Cylinder block 31. Oil pan 32. Drain plug 33. Turbo charger 34. EGR-RH pipe 35. PCV valve and oil separator 36. Oil dipstick 37. Exhaust manifold 29. Cylinder head D27DT 30.
  • Page 246 02-8 1114-01 4) Left Side View D20DT 38. High pressure pump 39. Turbo charger booster vacuum modulator (Gray) 40. EGR valve vacuum modulator 41. EGR valve (Black) 38. High pressure pump D27DT 39. Turbo charger booster vacuum modulator (Gray) 40. EGR valve vacuum modulator 41.
  • Page 247 02-9 1114-01 3. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE D20DT undefined...
  • Page 248 02-10 1114-01 2) Engine Performance Curve (1) Vehicle with A/T Output and Torque ▶ D20DT engine D27DT engine ENGINE D20DT undefined...
  • Page 249 02-11 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT undefined...
  • Page 250 02-12 1114-01 (2) Vehicle with M/T ▶ Output and Torque D20DT engine D27DT engine ENGINE D20DT undefined...
  • Page 251 02-13 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT undefined...
  • Page 252 02-14 1114-01 4. TIGHTENING TORQUE ENGINE D20DT undefined...
  • Page 253 02-15 1114-01 ENGINE D20DT undefined...
  • Page 254 02-16 1114-01 ENGINE D20DT undefined...
  • Page 255 03-3 1881-01 1881-01 ENGINE FUEL SYSTEM GENERAL 1. CAUTIONS FOR DI ENGINE This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine, warning lights, symptoms when engine malfunctioning, causes and actions. 1) DI Engine Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high power and reduces less emission.
  • Page 256 03-4 1881-01 6) Fuel Filter and Water Separator Fuel filter Priming pump Water drain plug (water separating operation: every 10,000 km) 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.
  • Page 257 03-5 1881-01 ▶ Draining the Water From Fuel Filter Place the water container under the fuel filter. Turn the drain plug (2) to "A" direction to drain the water. Wait until a certain amount of fuel gets out from the port, then turn the drain plug to "B"...
  • Page 258 03-6 1881-01 OVERVIEW AND OPERATION PROCESS 1. ELECTRONIC CONTROL OF FUEL SYSTEM Supply line Return line ECU connecting line System composition High pressure fuel pump Fuel rail Fuel pressure sensor Fuel injector Electronic control unit(ECU) Other sensors and actuators According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time.
  • Page 259 03-7 1881-01 2. COMPOSITION OF FUEL SYSTEM Components in fuel system are designed to generate and distribute high pressure, and they are controlled electronically by engine ECU. Accordingly, fuel system is completely different from injection pump type fuel supply system on the conventional Diesel engine. The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure, high pressure section that transfers fuel in high pressure and ECU control section.
  • Page 260 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) ENGINE D20DT undefined...
  • Page 261 03-9 1881-01 4. COMPONENTS OF LOW PRESSURE TRANSFER LINE Low pressure stage is to supply sufficient fuel to high pressure section and components are as below. Fuel tank (including strainer) Hand priming pump Fuel filter Transfer pump Other low pressure fuel hoses 1) Fuel tank Fuel tank is made of anti-corrosion material and its allowable pressure is 2 times of...
  • Page 262 03-10 1881-01 3) Fuel filter It requires more purified fuel supply than conventional diesel engine. If there are foreign materials in the fuel, fuel system including pump components, delivery valve and injector nozzles may be damaged. Fuel filter purifies fuel before it reaches to high pressure pump...
  • Page 263 03-11 1881-01 5. COMPONENTS OF HIGH PRESSURE TRANSFER LINE In the high pressure section, sufficient fuel pressure that injectors requires will be generated and stored. The components are as below: High pressure pump Rail pressure sensor Pressure limit valve Common rail High pressure pipe Injector Fuel pressure regulating valve (IMV)
  • Page 264 03-12 1881-01 3) High pressure pipe (fuel pipe) Fuel line transfers high pressure fuel. Accordingly, it is made of steel to endure intermittent high frequency pressure changes that occur under maximum system pressure and injection stops. Injection lines between rail and injectors are all in the same length; it means the lengths between the rail and each injector are the same and the differences in length are compensated by each bending.
  • Page 265 03-13 1881-01 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 D20DT undefined...
  • Page 266 03-14 1881-01 7) Circuit Diagram ENGINE D20DT undefined...
  • Page 267 03-15 1881-01 ENGINE D20DT undefined...
  • Page 268 03-16 1881-01 ENGINE D20DT undefined...
  • Page 269 04-3 2321-01 2321-01 INTAKE SYSTEM GENERAL 1. ENGINE INTAKE SPECIFICATIONS 1) Specifications Element Type Dry-Element Type ­ Initial cleaning: 5,000 km, Clean or change every 10,000 km as required. However, change every 30,000 km. Service Interval ­ If the vehicle is operated under severe condition (short distance driving, extensive ldling or driving in dusty condition): More frequent maintenance is required.
  • Page 270 04-4 2321-01 OVERVIEW AND OPERATION PROCESS 1. ENGINE INTAKE COMPONENTS LOCATOR 1) D20DT Engine Air Cleaner Intake Manifold Cover Housing Elemen HFM Sensor Intercooler ENGINE D20DT undefined...
  • Page 271 04-5 2321-01 2) D27DT Engine Air Cleaner Intake Manifold Cover Element Housing HFM Sensor Intercooler ENGINE D20DT undefined...
  • Page 272 04-6 2321-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE D20DT undefined...
  • Page 273 04-7 2321-01 OVERVIEW AND OPERATION PROCESS null AIR FLOW SENSOR 2321-01 (HOT FILM AIR MASS SENSOR) ▶Change history inner tube added + grid (No.3) added + sensing chip changed + sensing section design changed ▶Results Durability has enhanced 60 times (lab test results) <CI Type HFM Sensor Structure>...
  • Page 274 04-8 2321-01 Intake air temperature sensor is a part of HFM sensor and a thermister and resister and detects air temperature changes that flow into the engine. There occurs high resistance when temperature is low and low resistance when high (NTC type). ECU supplies 5 V to intake air temperature sensor and then measures voltage changes to determine the intake air temperature.
  • Page 275 04-9 2321-01 <Circuit Diagram of HFM Sensor> ENGINE D20DT undefined...
  • Page 276 04-10 2330-01 INTERCOOLER 2330-01 The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However, the intake air is heated (100 ~ 110°C) during the compression process in turbo charger compressor and the density is lowered. The intercooler is the device which cools (50 ~ 60°C) the air entering the engine.
  • Page 277 04-11 1715-01 INTAKE MANIFOLD ASSEMBLY 1715-01 D20DT D27DT 1) System Characteristics 1. Shape that delivers the required capacity of compressed air from turbo charger to inlet port 2. Optimized EGR gas mixture in inlet chamber 3. Maximized intake efficiency with helical and tangential inlet port 1) Improving the swirl ratio in low and mid operating range 2) Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range...
  • Page 278 05-3 1913-01 1913-01 EXHAUST SYSTEM GENERAL 1. INSPECTION BEFORE DIAGNOSIS The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is, as described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan tool or vacuum tester.
  • Page 279 05-4 1913-01 D20DT D27DT HUBER EGR System for IDI Engine EGR System for DI Engine (Including the EGR Valve Potentiometer) ENGINE D20DT undefined...
  • Page 280 05-5 1913-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS LOCATOR OF EXHAUST SYSTEM 1) D20DT ENGINE Exhaust Manifold EGR Valve Muffler Catalytic Converter Vacuum Modulator Turbo Charger EGR Pipe (DOC) ENGINE D20DT undefined...
  • Page 281 05-6 1913-01 Exhaust Manifold EGR Valve Muffler Catalytic Converter Vacuum Modulator Turbo Charger EGR Pipe (DOC) ENGINE D20DT undefined...
  • Page 282 05-7 1913-01 2. EXHAUST GAS FLOWS ENGINE D20DT undefined...
  • Page 283 06-3 1533-01 1533-01 ENGINE LUBRICATION SYSTEM GENERAL SPECIFICATIONS OF ENGINE LUBRICATION Severe Condition: 1. When most trips include extended idling and/or frequent low-speed operation as in stop-and- go traffic. 2. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km) 3.
  • Page 284 06-4 1533-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF LUBRICATION SYSTEM 1)D20DT ENGINE Cylinder Head Cover Oil Dipstick Oil Separator Oil Filter Oil Pump Oil Pan Oil Cooler Oil Pressure Switch ENGINE D20DT undefined...
  • Page 285 06-5 1533-01 2)D27DT Engine Cylinder Head Cover Oil Dipstick Oil Separator Oil Filter Oil Pump Oil Pan Oil Cooler Oil Pressure Switch ENGINE D20DT undefined...
  • Page 286 06-6 1533-01 2.LUBRICATION SYSTEM LAYOUT Cylinder Head Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 Return hole: φ 14 Chain nozzle: φ 1 HP pump bearing: φ 6 Cylinder Block ENGINE D20DT undefined...
  • Page 287 06-7 1533-01 3. LUBRICATION DIAGRAM ※ 1. Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar 2. To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of cylinder head ENGINE D20DT undefined...
  • Page 288 07-3 2112-01 9210-05 ENGINE COOLING SYSTEM GENERAL 1. ENGINE COOLING SPECIFICATIONS ENGINE D20DT undefined...
  • Page 289 07-4 2112-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS ENGINE COOLING 1) D20DT Engine Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor ENGINE D20DT undefined...
  • Page 290 07-5 2112-01 2) D27DT Engine Coolant Coolant Reservoir Temperature Sensor Radiator Water Pump Cooling Fan ENGINE D20DT undefined...
  • Page 291 07-6 2112-01 2. COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side · Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side · Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump ENGINE D20DT undefined...
  • Page 292 07-7 2112-01 3. FUNCTION DESCRIPTION OF COOLING SYSTEM Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1) Improved shape and gasket material to prevent coolant from leaking · D20DT D27DT Intake manifold Intake manifold Cylinder Cylinder head...
  • Page 293 08-3 1461-01 1461-01 ENGINE ELECTRIC SYSTEM GENERAL 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE D20DT undefined...
  • Page 294 08-4 1461-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ELECTRIC IN ENGINE 1) D20DT ENGINE Fuel Pressure Camshaft Position Coolant Temperature Fuel Temperature Sensor Sensor Sensor Sensor Booster Pressure Oil Pressure Switch Crankshaft Position Knock Sensor (1 Sensor Sensor ENGINE D20DT undefined...
  • Page 295 08-5 1461-01 2) D27DT ENGINE Booster Pressure Camshaft Position Fuel Pressure Fuel Temperature Sensor Sensor Sensor Sensor Coolant Temperature Oil Pressure Crankshaft Position Knock Sensor (2 Sensor Switch Sensor ENGINE D20DT undefined...
  • Page 296 08-6 1461-01 2. COMPONENTS OF ELECTRIC DEVICES IN ENGINE 1) D20DT ENGINE Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE D20DT undefined...
  • Page 297 08-7 1461-01 1) D27DT ENGINE Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE D20DT undefined...
  • Page 298 08-8 1461-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM ENGINE D20DT undefined...
  • Page 299 08-9 1461-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ENGINE D20DT undefined...
  • Page 300 10-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
  • Page 301 10-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
  • Page 302 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration ENGINE D20DT undefined...
  • Page 303 10-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
  • Page 304 10-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
  • Page 305 10-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
  • Page 306 10-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
  • Page 307 10-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
  • Page 308 ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. STRUCTURE AND COMPARISON..2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE......3. TIGHTENING TORQUE......4. MAJOR CHANGES IN D27DTP(POWER UP ENGINE(COMPARED TO D27DT)..OERVIEW AND OPERATION PROCESS 1. ENGINE COMPARTMENT..... 2. SYSTEM IN ENGINE COMPARTMENT.

  • Page 310: Structure And Comparison

    01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. STRUCTURE AND COMPARISON ▶D27DT (EU IV) Engine - Front View ▶D27DT (EU IV) Engine - Front View ENGINE GENERAL undefined...
  • Page 311 01-4 0000-00 ▶D27DT (EU IV) Engine - Side View ▶D27DT (EU IV) Engine - Left Side View ENGINE GENERAL undefined...
  • Page 312 01-5 0000-00 ▶D27DT Engine (General) - Front View ▶D27DT Engine (General) - Top View ENGINE GENERAL undefined...
  • Page 313 01-6 0000-00 ▶D27DT Engine (General) - Side View ▶D27DT Engine (General) - Left Side View ENGINE GENERAL undefined...

  • Page 314: Engine Specifications And Performance Curve

    01-7 0000-00 2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE GENERAL undefined...
  • Page 315 01-8 0000-00 2) D27DT Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE GENERAL undefined...

  • Page 316: Tightening Torque

    01-9 0000-00 3. TIGHTENING TORQUE This table shows the tightening torques for removal/mounting and disassembly/reassemly of the engine. ENGINE GENERAL undefined...
  • Page 317 01-10 0000-00 ENGINE GENERAL undefined...
  • Page 318 01-11 0000-00 ENGINE GENERAL undefined...

  • Page 319: Major Changes In D27Dtp(Power Up Engine(Compared To D27Dt)

    01-12 0000-00 MAJOR CHANGES IN D27DTP (POWER UP) ENGINE (COMPARED TO D27DT) The shape and size of D27DTP (POWER UP) are slightly different from those of D27DT engine but the basic configuration of two systems is almost same. 1) Engine Assembly ENGINE GENERAL undefined...
  • Page 320 01-13 0000-00 2) Major Changes and Summary ENGINE GENERAL undefined...
  • Page 321 01-14 0000-00 ENGINE GENERAL undefined...
  • Page 322 01-15 0000-00 ENGINE GENERAL undefined...
  • Page 323 01-16 0000-00 ENGINE GENERAL undefined...
  • Page 324 01-17 0000-00 ENGINE GENERAL undefined...
  • Page 325 01-18 0000-00 ENGINE GENERAL undefined...
  • Page 326 01-19 0000-00 ENGINE GENERAL undefined...
  • Page 327 01-20 0000-00 ENGINE GENERAL undefined...

  • Page 328: Engine Compartment

    01-21 0000-00 OVERVIEW AND OPERATION PROCESS 1. ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows: ENGINE GENERAL undefined...
  • Page 329 01-22 0000-00 ENGINE GENERAL undefined...
  • Page 330 01-23 0000-00 ▶Engine Compartment Layout Engine assembly FFH Assembly (Only for vehicle with FFH) Engine oil dipstick Power steering oil tank Vacuum pump Engine oil filler cap Oil filter and cooler Fan shroud Fuel filter and priming pump E-EGR Valve Brake booster High-capacity PCV oil separator Brake oil tank...
  • Page 331 01-24 0000-00 ▶Major Sensors and Components ENGINE GENERAL undefined...

  • Page 332: System In Engine Compartment

    01-25 0000-00 2. SYSTEMS IN ENGINE COMPARTMENT 1) Engine Accessories Related to ECU ENGINE GENERAL undefined...
  • Page 333 01-26 0000-00 ENGINE GENERAL undefined...
  • Page 334 01-27 0000-00 2) Preheat System ENGINE GENERAL undefined...
  • Page 335 01-28 0000-00 3) Fuel System ENGINE GENERAL undefined...
  • Page 336 01-29 0000-00 ▶Fuel Supply System ENGINE GENERAL undefined...
  • Page 337 01-30 0000-00 4) Lubrication System ENGINE GENERAL undefined...
  • Page 338 01-31 0000-00 5) Cooling System ENGINE GENERAL undefined...
  • Page 339 01-32 0000-00 6) Intake System ENGINE GENERAL undefined...
  • Page 340 01-33 0000-00 7) Exhaust System ENGINE GENERAL undefined...
  • Page 341 02-3 1881-09 1881-09 ENGINE FUEL SYSTEM OVERVIEW AND OPERATION PROCESS MAJOR CHANGES IN FUEL SYSTEM OF D27DTP (POWER UP) ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D27DTP (POWER UP) engine. The major changes are as follows. Refer to the next pages for further details.
  • Page 342 02-4 1881-09 2) Common Rail The orifice is added to the connection to · D27DTP & D27DT (EU IV) the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume.
  • Page 343 02-5 1881-09 3) Fuel Rail - Chrome Color · The I.D and O.D of the fuel rail between D27DTP & D27DT (EU IV) HP pump and common rail are increased * Fuel pipe (Common rail → Injector) according to the increased amount of fuel injection.
  • Page 344 02-6 1881-09 2. COMPONENTS OF FUEL SYSTEM ENGINE FUEL SYSTEM undefined...
  • Page 345 02-7 1881-09 ▶Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System ENGINE FUEL SYSTEM undefined...
  • Page 346 03-3 2321-01 2321-01 ENGINE INTAKE SYSTEM OVERVIEW AND OPERATION PROCESS 1. INTAKE SYSTEM LAYOUT The intake system for the D27DTP (POWER UP) engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off. Therefore, the structure of the intake manifold has been changed.
  • Page 347 04-3 1792-01 1792-01 ENGINE EXHAUST SYSTEM OVERVIE AND OPERATION PROCESS 1. COMPONENTS The components of the exhaust system for the D27DTP (POWER UP) engine have been changed as follows: 1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) 2.
  • Page 348 3) System Met with EURO IV Regulations The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December 2007 comply with the EURO IV regulations. Modified components from the old...
  • Page 349 05-4 1881-09 2. CDPF (EU-IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and Sensors Differential Pressure Sensor (ΔP sensor) Under air cleaner in right side of engine compartment As the soot is filtered in the CDPF, the pressure between the front side and the rear side of...
  • Page 350 05-5 1881-09 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
  • Page 351 05-6 1881-09 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW As the solution for environmental regulations and PM (Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
  • Page 352 05-7 1881-09 2.CDPF (EU-IV) SYSTEM CONTROL 1) General Description As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
  • Page 353 05-8 1881-09 2) System Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
  • Page 354 05-9 1881-09 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type. CDPF undefined...
  • Page 355 05-10 1881-09 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
  • Page 356 05-11 1881-09 Front temperature sensor Rear temperature sensor (Measuring the temperature of (Measuring the temperature of exhaust exhaust gas passedthrough gas passed through DOC) exhaust manifold) Differrential pressure sensor Differrential pressure sensor (Front pressure port) (Rear pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects intoCDPF assembly after...
  • Page 357 05-12 1881-09 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 358 05-13 1881-09 ▶ Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration tem- perature due to low speed driving or other reason during the regeneration process, the soot is con- tinuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to in-form this situation to the driver.
  • Page 359 05-14 1881-09 4. COMPONENTS OF CDPF SYSTEM 1) Mounting Condition and Location Differential Pressure Sensor Rear exhaust gas temperature sensor Engine compartment (RH) Rear pressure port Differential Front pressure port pressure sensor CDPF assembly Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
  • Page 360 NO DATA...
  • Page 361 07-3 1520-01 1520-01 ENGINE COOLING SYSTEM OVERVIEW AND OPERATION PROCESS 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D27DTP (POWER UP) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
  • Page 362 07-4 1520-01 ▶Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine ENGINE COOLING SYSTEM undefined...
  • Page 363 NO DATA...
  • Page 364 09-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
  • Page 365 09-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
  • Page 366 09-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
  • Page 367 09-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
  • Page 368 09-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
  • Page 369 09-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
  • Page 370 09-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
  • Page 371 09-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
  • Page 372 NO DATA...
  • Page 373 NO DATA...
  • Page 374 ENGINE INFORMATION 0000-00 ENGINE INFORMATION GENERAL) 1. COMPONENT LOCATOR....... 2. DESCRIPTION AND OPERATION..
  • Page 377 01-4 0000-00 0000-00 ENGINE GENERAL GENERAL 1. COMPONENT LOCATOR 1) Front View ENGINE INFORMATION KYRON 2010.01...
  • Page 378 Connecting rod Resonance flap Exhaust manifold Cylinder head cover Crankshaft Exhaust camshaft Engine mounting Intake camshaft Starter Cylinder head Crankcase Spark plug connector Oil pump sprocket Valve tappet Oil strainer Injector Oil pan Exhaust valve Drain plug ENGINE INFORMATION KYRON 2010.01...
  • Page 379 01-6 0000-00 2) SIDE VIEW FUNCTION FUNCTION Camshaft adjuster Oil pump drive chain Cooling fan and viscous clutch Oil return pipe Piston Timing chain Flywheel of drive plate ENGINE INFORMATION KYRON 2010.01...
  • Page 380 Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.g ENGINE INFORMATION KYRON 2010.01...
  • Page 382 02-3 1113-01 1113-01 ENGINE ASSEMBLY GENERAL 1. SPECIFICATIONS 1) ENGINE SPECIFICATIONS ENGINE ASSEMBLY KYRON 2010.01...
  • Page 383 02-4 1113-01 2) PERFORMANCE CURVE ENGINE ASSEMBLY KYRON 2010.01...
  • Page 384 02-5 1113-01 2. SPECIAL TOOLS AND EQUIPMENT ENGINE ASSEMBLY KYRON 2010.01...
  • Page 385 02-6 1113-01 ENGINE ASSEMBLY KYRON 2010.01...
  • Page 386 02-7 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin ENGINE ASSEMBLY KYRON 2010.01...
  • Page 387 02-8 1113-01 3. FASTENER TIGHTENING SPECIFICATIONS ENGINE ASSEMBLY KYRON 2010.01...
  • Page 388 02-9 1113-01 4. FASTENER TIGHTENING SPECIFICATIONS (CONT' D) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 389 It is therefore recommended that earthed pumps with integrally earthed hoses be used, and that storage containers be properly earthed during all noncommercial fueling operations. ENGINE FUEL SYSTEM KYRON 2010.01...
  • Page 390 03-4 2211-22 ▶ temperature vs resistance ENGINE FUEL SYSTEM KYRON 2010.01...
  • Page 391 NO DATA...
  • Page 392 (HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx). ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 393 05-4 2420-01 4. FASTENER TIGHTENING SPECIFICATIONS ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 394 06-3 9210-01 9210-01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1. OIL CIRCULATION LUBRICATION SYSTEM KYRON 2010.01...
  • Page 395 (from oil pump to oil filter) Oil gallery (at cylinder head) Main oil gallery Oil return line Ball (φ 15mm) (oil returns to the oil pan when replacing the filter element) Oil restriction inner (φ 4mm) LUBRICATION SYSTEM KYRON 2010.01...
  • Page 396 07-3 2110-01 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS COOLING SYSTEM KYRON 2010.01...
  • Page 397 07-4 2110-01 2. SPECIAL TOOLS AND EQUIPMENT COOLING SYSTEM KYRON 2010.01...
  • Page 398 07-5 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS COOLING SYSTEM KYRON 2010.01...
  • Page 399 The coolant reservoir maintains the correct coolant level. The cooling system for this vehicle has no radiator cap or filler neck. The coolant is added to the cooling system through the coolant reservoir. COOLING SYSTEM KYRON 2010.01...
  • Page 400 07-7 2110-01 2. COMPONENT LOCATOR COOLING SYSTEM KYRON 2010.01...
  • Page 401 Bolt (M6, 8 pieces) Reserver tank Bolt (M6, 4 pieces) Bolt (M6, 2 piece) Bolt (M6, 4 pieces) Cooling fan Upper radiator insulator Viscous clutch Lower radiator insulator Bolt (M6, 1 piece) Plate Bolt (M6, 3 piece) Clip COOLING SYSTEM KYRON 2010.01...
  • Page 402 08-3 1452-01 1452-01 ENGINE ELECTRIC DEVICES GENERAL 1. GENERAL SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2010.01...
  • Page 403 08-4 1452-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2010.01...
  • Page 404 The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically. ENGINE ELECTRIC DEVICES KYRON 2010.01...
  • Page 405 Each EI system ignition coil provides the high voltage to two spark plugs simultaneously; 3.2L DOHC T1/1: cylinder 2 and 5 T1/2: cylinder 3 and 4 T1/3: cylinder 1 and 6 The EI system ignition coil is not serviceable and must be replaced as an assembly. ENGINE ELECTRIC DEVICES KYRON 2010.01...
  • Page 406 08-7 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT ENGINE ELECTRIC DEVICES KYRON 2010.01...
  • Page 407 09-3 1522-16 1522-16 ENGINE CONTROL SYSTEM GENERAL 1. ENGINE DATA DISPLAY TABLE ENGINE CONTROL SYSTEM KYRON 2010.01...
  • Page 408 09-4 1522-16 1) TEMPERATURE VS RESISTANCE 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE CONTROL SYSTEM KYRON 2010.01...
  • Page 409 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 KYRON 2010.01...
  • Page 410 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 KYRON 2010.01...
  • Page 411 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2010.01...
  • Page 412 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 KYRON 2010.01...
  • Page 413 (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 KYRON 2010.01...
  • Page 414 (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 KYRON 2010.01...
  • Page 415 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 KYRON 2010.01...
  • Page 416 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2010.01...
  • Page 417 Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 418 Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 419 01-5 1113-01 2. G23D ENGINE ASSEMBLY Front View Rear View ENGINE ASSEMBLY KYRON 2010.01...
  • Page 420 01-6 1113-01 LH Side View RH Side View ENGINE ASSEMBLY KYRON 2010.01...
  • Page 421 01-7 1113-01 3. G23D ENGINE STRUCTURE Front View Side View ENGINE ASSEMBLY KYRON 2010.01...
  • Page 422 Side View FUNCTION FUNCTION Camshaft Adjuster Oil Pump Drive Chain Oil Filler Cap Oil Strainer Engine Hanger Bracket Oil Pump Cooling Fan and Viscous Clutch Ring Gear and Flywheel of Drive Plate Oil Filter Piston Timing Chain ENGINE ASSEMBLY KYRON 2010.01...
  • Page 423 Apply an aerosol-type powder (such as foot powder) to the suspected area. Operate the vehicle under normal operating conditoins. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 424 The seal bore is damaged (scratched, burred or nicked). The seal is damaged or worn. Improper installation is evident. There are cracks in the components. The shaft surface is scratched, nicked or damaged. A loose or worn bearing is causing excess seal wear. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 425 Measure the compression pressure of the other cylinders in the same way. If measured value is not within the specifications, perform the cylinder pressure leakage test. Discharge the combustion residues in the cylinders before testing the compression pressure. Apply the parking brake before cranking the engine. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 426 Max. 10 % At Piston and Piston Ring Max. 20 % Cylinder Number ▶ 1, 4 OT (TDC) 2, 3 UT (BDC 180 °) ▶ Cylinder Number Cylinder Pressure Bosch, EFAW210A Sun, CLT 228 Leakage Tester ENGINE ASSEMBLY KYRON 2010.01...
  • Page 427 Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable. Perform the pressure test according to the firing order. Firing Order: 1 - 3 - 4 - 2 Compare the leakage pressure with the specifications. ENGINE ASSEMBLY KYRON 2010.01...
  • Page 428 01-14 1113-01 5. GENERAL DIAGNOSIS ENGINE ASSEMBLY KYRON 2010.01...
  • Page 429 01-15 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 430 01-16 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 431 01-17 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 432 01-18 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 433 01-19 1113-01 6. SPECIFICATIONS 1) Engine Specifications MSE : Engine Control Module 3.53D : 4 Cylinder Version ENGINE ASSEMBLY KYRON 2010.01...
  • Page 434 01-20 1113-01 2) Fastener Tightening Specifications ENGINE ASSEMBLY KYRON 2010.01...
  • Page 435 01-21 1113-01 ▶ Fastener Tightening Specifications (Cont'd) ENGINE ASSEMBLY KYRON 2010.01...
  • Page 436 01-22 1113-01 2) Performance Curve ENGINE ASSEMBLY KYRON 2010.01...
  • Page 438 02-3 1713-08 1713-08 ENGINE INTAKE SYSTEM GENERAL 1. SPECIFICATIONS (1) Fastener Tightening Specifications ENGINE INTAKE SYSTEM KYRON 2010.01...
  • Page 439 ENGINE EXHAUST SYSTEM 2420-01 ENGINE EXHAUST SYSTEM GENERAL 1. SPECIFICATION ........OVERVIEW AND OPERATION PROCESS 1. DESCRIPTION AND OPERATION ..REMOVAL AND INSTALLATION 2420-01 EXHAUST LINE......
  • Page 441 03-3 2420-01 2420-01 ENGINE EXHAUST SYSTEM GENERAL 1. SPECIFICATION (1) Fastener Tightening Specifications ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 442 000~500,000ft3. (10 times of a football field) Generally Alumina (AL2 O3) is used as a raw materialand its 7 phases of gamma, delta, theta have big areas and high stability for the temperature, and nowadays gamma Alumina is used usually. ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 443 HC and CO. Catalytic material supplies Oxygen adheres to catalytic Catalytic material conversion each CO and HC with O2 for process by DOC material : below 180°C their oxidation : above 180°C ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 444 EGR valve is installed on the diesel engine of Musso, Korando, Istana and Rexton. And micro switch is installed together to control EGR valve. The setting method of micro switch is identical with the existing one. ENGINE EXHAUST SYSTEM KYRON 2010.01...
  • Page 445 04-3 2112-01 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 446 04-4 2112-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 447 10. Lower Radiator Insulator 3. Inlet Hose 11. Plate 4. Outlet Hose 12. Clip 5. 3 way Hose 13. Upper Radiator Insulator 6. Clamp 14. Bracket 7. Clamp 15. PWM Electric Fan 8. Bolt (M6, 2 piece) ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 448 This keeps the radiator filled with the coolant to the desired level at all times and increases the cooling efficiency. Maintain the coolant level between the MIN and MAX marks on the coolant reservoir when the system is cold. ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 449 If a fan blade is bent or damaged in any way, no attempt should be made to repair or reuse the damaged part. A bent or damaged fan assembly should always be replaced with a new one to prevent possible injury. ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 450 The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal voltage to the Engine Control Module (ECM). 8) Coolant Temperature Gauge The coolant temperature gauge controls the instrument panel temperature indicator. The coolant temperature gauge is located with ECT sensor. ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 451 1) Function The PWM (Pulse Width Modulation) high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise. 2) Mounting Location Fan shroud PWM unit Electric fan ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 452 PWM unit is over 120~150°C. Communication function when failing: The fail signal is transmitted to the ECU when the PWM unit is malfunctioning. Soft start function: The motor speed is gradually increased when the motor is initially operated. ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 453 2.4 kg/cm2. A/C compressor is turned off when the refrigerant pressure is over 30 kg/cm2 and then is turned on when the refrigerant pressure is below 21.4 kg/cm2. ENGINE COOLING SYSTEM KYRON 2010.01...
  • Page 454 05-3 1452-01 0000-00 ENGINE ELECTRIC DEVICES GENERAL 1. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Ignition System ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 455 05-4 1452-01 2) Ignition System (Cont'd) ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 456 Expressed in minutes, the RC rating is the time required for a fully charged battery, at a temperature of 27°C(80°F) and being discharged at a current of 25 amperes, to reach a terminal voltage of 10.5 volts. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 457 Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, the current accepted by the battery is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 458 (AH) to restore the battery to a usable state. If the charge current is still not measurable after using the charging time calculated by · the above method, the battery should be replaced. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 459 Remove the jumper cables by reversing the above sequence exactly, removing the negative cable from the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any other metal while the other end remains attached. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 460 When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be released immediately after the engine starts. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 461 The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected electrically. ENGINE ELECTRICAL SYSTEM KYRON 2010.01...
  • Page 462 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 KYRON 2010.01...
  • Page 463 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 KYRON 2010.01...
  • Page 464 06-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2010.01...
  • Page 465 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 KYRON 2010.01...
  • Page 466 (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 KYRON 2010.01...
  • Page 467 (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 KYRON 2010.01...
  • Page 468 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 KYRON 2010.01...
  • Page 469 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2010.01...
  • Page 470 ELECTRIC SYSTEM ELECTRIC SYSTEM ELECTRIC SYSTEM 0000-00 ELECTRIC SYSTEM ELECTRIC GENERAL 1. LOCATIONS OF INTERIOR UNITS AND SENSORS ..........2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT...... 3. INTERIOR SWITCHES......4. AUDIO / VIDEO SYSTEM..... 5. ELECTRIC COMPONENTS AND LAYOUT..........

  • Page 471: Electric General

    Steering Wheel Angular Sensor / Immobilizer Immobilizer Steering wheel angular sensor Door lock relay Chime bell Curtain air bag module Sun sensor Buzzer for PAS TV antenna amplifier RK STICS PAS Unit TCCU and TCU Driver Seat Memory Switch TCCU ELECTRIC SYSTEM KYRON 2010.01...
  • Page 472 Air Bag ECU Curtain air bag module TV antenna amplifier DVD changer Curtain Air Bag Sensor DSP amp TV tuner woofer Interior Temperature and Engine ECU and SSPS Unit Humidity Sensor SSPS unit (under the engine ECU) ELECTRIC SYSTEM KYRON 2010.01...

  • Page 473: Switches, Units And Sensors In Engine Compartment

    01-4 0000-00 2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT FFH Assembly Receiver Drier and Triple Pressure Switch Horn (RH) FFH Ambient Temperature Sensor FFH ambient temperature sensor ELECTRIC SYSTEM KYRON 2010.01...
  • Page 474 01-5 0000-00 ESP Pressure Sensor / ABS (ESP) HECU Primary, Secondary IWE Vacuum Solenoid Valve (4WD) Hood Contact Switch Horn (LH) Theft Deterrent Horn (Under Fuse and Relay Box the Battery) ELECTRIC SYSTEM KYRON 2010.01...

  • Page 475: Interior Switches

    Bezel Assembly on Outside Rearview Mirror Adjusting Switch Outside rearview ESP OFF switch mirror folding switch Outside rearview mirror adjusting switch Seat Position Memory Switch Driver's Power Window Main (Driver's Door) Switch ELECTRIC SYSTEM KYRON 2010.01...
  • Page 476 Bezel Assembly on Hazard Switch HDC switch Outside rearview mirror and rear glass heated switch Hazard switch TRIP switch Front defogger switch Center Fascia Switch switch Driver seat warmer switch Passenger seat warmer switch Passenger's Power Window Switch ELECTRIC SYSTEM KYRON 2010.01...

  • Page 477: Audio / Video System

    AV Head Unit Front speaker (RH) Tweeter speaker Sub woofer (amplifier integrated type) DVD changer DVD+tape Center speaker AV head unit Sub Woofer Tweeter speaker Front speaker (LH) (LH) Other Audio Head Unit 6-INDASH CD+TAPE+RADIO CD+RADIO ELECTRIC SYSTEM KYRON 2010.01...
  • Page 478 0000-00 Location: Inside of panel 6 DVD changer above glove box TV antenna amplifier (RH) Rear speaker (RH) Tweeter Radio antenna amplifier Tuner/Amp speaker Tweeter TV antenna speaker (LH) amplifier (LH) Rear speaker (LH) AV System ELECTRIC SYSTEM KYRON 2010.01...

  • Page 479: Electric Components And Layout

    01-10 0000-00 5. ELECTRIC COMPONENTS AND LAYOUT ▶ Wiring Harness Arrangement ELECTRIC SYSTEM KYRON 2010.01...
  • Page 480 01-11 0000-00 ▶ Components Locator ELECTRIC SYSTEM KYRON 2010.01...
  • Page 482 - Windshield de-icer relay (previously installed next to floor on the driver side) - Turn signal lamp relay (previously installed to passenger side fuse & relay box) PREVIOUS MODEL NEW MODEL * Some relays have been integrated into the ICM box. FUSE AND RELAY KYRON 2010.01...
  • Page 483 (1) In engine compartment Fuse & Relay Box Interior Fuse & Relay InEngine Box On The Driver Side Compartment (RH) (2) In vehicle Interior Fuse & Relay Mounting Location of ICM Box On The Driver Side (LH) FUSE AND RELAY KYRON 2010.01...
  • Page 484 Therefore, there are more fuses and relays than indicated. For details about the connection of fuses and relays, refer to the power distribution circuit diagram on the following pages. FUSE AND RELAY KYRON 2010.01...
  • Page 485 02-6 8410-02 4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY 1) Interior Fuse and Relay Box On the Driver Side FUSE AND RELAY KYRON 2010.01...
  • Page 486 02-7 8410-02 2) Interior Fuse and Relay Box On the Passenger Side FUSE AND RELAY KYRON 2010.01...
  • Page 487 - Turn signal lamp relay (previously installed to passenger side fuse & relay box) 2) Mounting Location Relays in the ICM box cannot be replaced respectively; so if the components on the PCB are defective, the ICM box should be replaced as an assembly. FUSE AND RELAY KYRON 2010.01...
  • Page 488 In order to check the operation of the relay, measure the voltage at the connector of the ICM box and check the output through the ICM box after operating the corresponding door. Of course, the components for the corresponding system should be checked in advance. FUSE AND RELAY KYRON 2010.01...
  • Page 489 If the system receives signals for the turn signal lamp operation during this function is activated, this function is immediately deactivated. While the turn signal lamp signals are already inputted, pressing the hazard warning lamp switch does not activate the hazard warning lamp function. FUSE AND RELAY KYRON 2010.01...
  • Page 490 Pressing the windshield de-icer switch activates the de-icer for 12 minutes and pressing the switch again deactivates the de-icer. At this time, pressing the switch again activates the de-icer for 12 minutes from the time the switch is pressed again. FUSE AND RELAY KYRON 2010.01...
  • Page 491 (remote controller) and other electronic systems to transmit and receive the data. The STICS also includes a diagnosis function that can inspect the error for related devices. PAS Buzzer Door Lock Relay STICS Door Lock Relay STICS KYRON 2010.01...
  • Page 492 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 KYRON 2010.01...
  • Page 493 03-5 8710-01 ▶ Rated Load STICS KYRON 2010.01...
  • Page 494 03-6 8710-01 ▶ Input Signals STICS KYRON 2010.01...
  • Page 495 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 KYRON 2010.01...
  • Page 497 ECU. Refer to the informationthat follows for specific functions and their descriptions. IMMO KYRON 2010.01...
  • Page 498 If you press and hold the door unlock and panic buttons, the buzzer will sound for 27 seconds. The function is inactivated if any button of remote control is pressed. With REKES key Without REKES key IMMO KYRON 2010.01...
  • Page 500 (Bottom of diver's seat) ▶ Functions of SPWM Adjusting the power seat's position with the seat adjusting switch Adjusting the angle of the outside rearview mirrors (OSRVM) Seat memory positions: for 3 persons Folding/Unfolding the outside rearview mirrors SPWM KYRON 2010.01...
  • Page 501 06-3 8010-01 8010-01 CLUSTER GENERAL 1. DESCRIPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the data through CAN communication.The HDC warning light and the engine hood open warning light are newly introduced. CLUSTER KYRON 2010.01...
  • Page 502 06-4 8010-01 CLUSTER KYRON 2010.01...
  • Page 504 06-6 8010-01 2.WARNING / INDICATOR PANE CLUSTER KYRON 2010.01...
  • Page 505 06-7 8010-01 CLUSTER KYRON 2010.01...
  • Page 506 1. LOCATIONS OF LAMPS AND SPECIFICATIONS 1) EXTERIOR LAMPS Headlamp Assembly Low beam High beam and Turn signal lamp position lamp Fog Lamp Assembly Fog lamp angle adjustment Fog lamp angle adjustment Quarter Combination Lamp Assembly Stop/Position lamp Turn signal lamp LAMP KYRON 2010.01...
  • Page 507 07-3 8310-01 Side Repeater Assembly High Mounted Stop Lamp Assembly License Plate Assembly Reflector Assembly Tailgate Combination Lamp Assembly Tail lamp Backup lamp Rear fog lamp or stop lamp (Rear fog lamp: Regulation required only) LAMP KYRON 2010.01...
  • Page 508 07-4 8310-01 ▶ BULB SPECIFICATIONS LAMP KYRON 2010.01...
  • Page 510 But, when any door is open, the lamp direction, the lamp will go off and will not come comes on and stays for 30 seconds. When the on even if the tailgate is open. door is closed, the lamp will go off. LAMP KYRON 2010.01...
  • Page 511 (1, 2). However, the front lamps are turned on when opening a door and turned off when closing it. The front room lamps and center are turned on when pressing the room lamp main switch (3). LAMP KYRON 2010.01...
  • Page 512 Press this switch to turn on the windshield heated glass. It will operate for about 12 minutes. ▶ TRIP Switch To choose a desired driving distance display mode, press the switch: Changing sequence: ODO - TRIP A - TRIP B - ODO SWITCH KYRON 2010.01...
  • Page 513 Audio Remote Control Switch Sun roof switch Main room lamp switch Room lamp operating switch T/C Control Switch ▲ MODER MUTER Driver's Seat ▼ Warmer Switch POWER Passenger's Seat ▲ Warmer Switch SEEK SEEK ▼ SWITCH KYRON 2010.01...
  • Page 514 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 KYRON 2010.01...
  • Page 515 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 KYRON 2010.01...
  • Page 516 The figure below shows the changes of spraying direction according to the spraying time. Whirlwind Washer fluid outlet Passage Counter-current Spray passage Washer fluid inlet It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle. WIPER KYRON 2010.01...
  • Page 517 1. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR) Multifunction Wiper and Rain Sensor Unit Front Nozzle Assembly Washer Switch Washer Reservoir Rear Washer Nozzle and Check Valve Tank Assemblyt Rear nozzle assembly Rear nozzle Check valve WIPER KYRON 2010.01...
  • Page 518 The rear washer system uses the front washer fluid reservoir. Because of this, the washer hose is supposed to be long between front reservoir tank and rear washer nozzle. To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone WIPER KYRON 2010.01...
  • Page 519 09-8 7810-01 2. WIPER / WASHER RELATED FUNCTION AND SPECIFICATION 1) Wiper and Washer Fluid Switch Operation WIPER KYRON 2010.01...
  • Page 520 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 KYRON 2010.01...
  • Page 521 It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. WIPER KYRON 2010.01...
  • Page 522 "OFF", the washer motor output is activated for 1 second. If the system recognizes this output, the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second. Then, the wiper relay output is deactivated after 3 cycles. WIPER KYRON 2010.01...
  • Page 523 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 KYRON 2010.01...
  • Page 524 09-13 7810-01 3. WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS WIPER KYRON 2010.01...
  • Page 525 The followings are comparison of the system equipped in NEW KYRON with the system in previous version of KYRON. Previous version KYRON (from March '07) Wiper Manufacturer: Kamco Manufacturer: Dongyang mechatronics motor Blade length: 12 Blade length: 14 Blade Manufacturer: Kamco Manufacturer: KCW Corporation Circuit Modification in connector pin arrangement diagram WIPER KYRON 2010.01...
  • Page 526 Emitter lens The LED emits the infrared rays is located at bottom and the lens guides the infrared Enlarged auto light rays to target point. sensor section Horizon autolight sensor Auto light sensor Vertical autolight sensor RAIN SENSOR KYRON 2010.01...
  • Page 527 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 KYRON 2010.01...
  • Page 528 "AUTO" position from any other positions (while the ignition key is in "ON" position). When the wiper switch is turned to "ON" position again from other positions, the system Drives the wiper motor through LOW relay one cycle only when the rain sensor detects the "Rain Detected" signal. RAIN SENSOR KYRON 2010.01...
  • Page 529 "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 KYRON 2010.01...
  • Page 530 4) Auto Light Control Only when the auto light switch is in "AUTO" position, control the tail lamp and headlamp by communicating with the rain sensor (while the ignition key is in "ON" position). RAIN SENSOR KYRON 2010.01...
  • Page 531 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 KYRON 2010.01...
  • Page 532 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 (2) from the rain sensor (while the ignition key is in "ON" position and the INT switch is in "ON" position). RAIN SENSOR KYRON 2010.01...
  • Page 533 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 KYRON 2010.01...
  • Page 534 10-11 8610-09 3. ELECTRICAL WIRING DIAGRAM RAIN SENSOR KYRON 2010.01...
  • Page 535 Detecting type: Supersonic wave Detecting distance: 25 cm ~ 100 cm (direct distance between sensor and obstacle) 2) Parking Aid Sensor Detecting type: Supersonic wave (Piezometric ceramic element) measuring time taken that the emitted supersonic wave is reflected and returned to the sensor. KYRON 2010.01...
  • Page 536 PAS unit. Parking Aid Unit PAS Sensor Components KYRON from '07 March and earlier KYRON are not compatible with the PAS unit and its sensor parts each other. KYRON 2010.01...
  • Page 537 65 ms. If found any failure due to open circuit to sensor or communication error, the data in failed sensor is transmitted to notice its failure by buzzer sound. If more than one sensor is defective, warning buzzer sounds for 3 seconds. KYRON 2010.01...
  • Page 538 11-6 8790-00 ▶ When failed KYRON 2010.01...
  • Page 539 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. When the vehicle height is lowered due to operation of EAS. KYRON 2010.01...
  • Page 540 The instrument panel sends operating signals to the buzzer not only for parking aid system, but also for other warning functions, such as ESP warning, overspeed warning and insufficient fuel warning functions. Warning functions which use the buzzer may vary depending on regions where vehicles are sold. KYRON 2010.01...
  • Page 541 DVD + Cassette player : 10 speakers (center speaker, woofer speakers, tweeter speakers) AV head unit DVD + Cassette + Radio DVD title insert slot Cassette tape slot MUTE button Tuner DVD 6 DISC changer Subwoofer DSP amplifier KYRON 2010.01...
  • Page 542 12-4 8930-14 OVERVIEW AND OPERATION PROCESS 1. AV SYSTEM CONFIGURATION AV System (DVD Head Unit + DVD Changer) ▶ ▶ Audio System - 6 Speakers KYRON 2010.01...
  • Page 543 12-5 8930-14 6 DISC changer + TAPE + RADIO CD + RADIO DISC changer CD slot Tape KYRON 2010.01...
  • Page 544 AM/ FM audio signals to are to receive TV and AM radio (quarter RH glass) tuner. signals and transmits each 2-channel video and audio signals to tuner. Each AMP amplifies receives TV signals and then transmits to tuner. KYRON 2010.01...
  • Page 545 12-7 8930-14 KYRON 2010.01...
  • Page 546 3. AV SYSTEM FUNCTIONS AV system head unit operates Radio, TV, Audio CD, DVD and Video CD. The touch screen type 6.5" TFT LCD monitor is installed on the system. DVD slot Display when turning on the monitor KYRON 2010.01...
  • Page 547 12-9 8930-14 4. AV SYSTEM SPECIFICATIONS AND CONTROL KYRON 2010.01...
  • Page 548 12-10 8930-14 ▶ Function Settings on Touch Panel (Example) KYRON 2010.01...
  • Page 549 Press "BAL/POS" button in "SET/ADJ" screen and select a seat position (driver's, passenger's, rear seats, all seats) on the screen (Position setting). To, adjust the balance, use the arrows on the BALANCE function and POSITION function screen. cannot be used simultaneously. KYRON 2010.01...
  • Page 550 13-3 8930-01 8930-01 AUDIO SYSTEM OVERVIEW AND INSTALLATION 1. AUDIO SYSTEM OVERVIEW Audio System - 6 Speakers AUDIO SYSTEM KYRON 2010.01...
  • Page 551 01-3 3410-01 3410-01 ION 4-SPEED GENERAL 1. SPECIFICATIONS ION 4-SPEED KYRON 2010.01...
  • Page 552 01-4 3410-01 2. FASTENER TIGHTENING SPECIFICATIONS ION 4-SPEED KYRON 2010.01...
  • Page 553 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 KYRON 2010.01...
  • Page 554 01-6 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 KYRON 2010.01...
  • Page 555 01-7 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 KYRON 2010.01...
  • Page 556 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. ION 4-SPEED KYRON 2010.01...
  • Page 557 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 KYRON 2010.01...
  • Page 558 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 KYRON 2010.01...
  • Page 559 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 KYRON 2010.01...
  • Page 560 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 KYRON 2010.01...
  • Page 561 01-13 3410-01 ION 4-SPEED KYRON 2010.01...
  • Page 562 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 KYRON 2010.01...
  • Page 563 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 KYRON 2010.01...
  • Page 564 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 KYRON 2010.01...
  • Page 565 01-17 3410-01 ▶ Solenoid Operation during Gearshifts ION 4-SPEED KYRON 2010.01...
  • Page 566 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 KYRON 2010.01...
  • Page 567 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 KYRON 2010.01...
  • Page 568 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 KYRON 2010.01...
  • Page 569 01-21 3410-01 1) Hydraulic Control Circuit ION 4-SPEED KYRON 2010.01...
  • Page 570 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 KYRON 2010.01...
  • Page 571 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 KYRON 2010.01...
  • Page 572 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 KYRON 2010.01...
  • Page 573 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 KYRON 2010.01...
  • Page 574 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 KYRON 2010.01...
  • Page 575 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 KYRON 2010.01...
  • Page 576 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 KYRON 2010.01...
  • Page 577 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 KYRON 2010.01...
  • Page 578 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 KYRON 2010.01...
  • Page 579 01-31 3410-01 ION 4-SPEED KYRON 2010.01...
  • Page 580 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 KYRON 2010.01...
  • Page 581 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 KYRON 2010.01...
  • Page 582 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 KYRON 2010.01...
  • Page 583 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 KYRON 2010.01...
  • Page 584 01-36 3410-01 1) Park and Neutral ION 4-SPEED KYRON 2010.01...
  • Page 585 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 KYRON 2010.01...
  • Page 586 01-38 3410-01 2) Reverse ION 4-SPEED KYRON 2010.01...
  • Page 587 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 KYRON 2010.01...
  • Page 588 01-40 3410-01 3) Manual 1 ION 4-SPEED KYRON 2010.01...
  • Page 589 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 KYRON 2010.01...
  • Page 590 01-42 3410-01 4) Drive 1 ION 4-SPEED KYRON 2010.01...
  • Page 591 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 KYRON 2010.01...
  • Page 592 01-44 3410-01 5) Drive 2 and Manual 2 ION 4-SPEED KYRON 2010.01...
  • Page 593 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 KYRON 2010.01...
  • Page 594 01-46 3410-01 6) Drive 3 and Manual 3 ION 4-SPEED KYRON 2010.01...
  • Page 595 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 KYRON 2010.01...
  • Page 596 01-48 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 3 and Manual 3 ION 4-SPEED KYRON 2010.01...
  • Page 597 01-49 3410-01 7) Drive 3 Lock Up and Manual 3 Lock Up ION 4-SPEED KYRON 2010.01...
  • Page 598 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 KYRON 2010.01...
  • Page 599 01-51 3410-01 8) Drive 4 (Overdrive) ION 4-SPEED KYRON 2010.01...
  • Page 600 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 KYRON 2010.01...
  • Page 601 01-53 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED KYRON 2010.01...
  • Page 602 01-54 3410-01 9) Drive 4 Lock Up ION 4-SPEED KYRON 2010.01...
  • Page 603 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 KYRON 2010.01...
  • Page 604 This function improves shifting quality significantly. And, the driver can select "S" (Standard) mode or "W" (Winter) mode according to the driving conditions. DC 5-SPEED KYRON 2010.01...
  • Page 605 1→ 2 → 3 → 4 → D The shiftable gear is down The shiftable gear is up by by one step as the lever is one step as the lever is moved to left (-) direction. moved to right (+) direction. DC 5-SPEED KYRON 2010.01...
  • Page 606 02-6 3650-01 2. AUTOMATIC TRANSMISSION (DC 5-SPEED) APPEARANCE Left Side Without Torque Rear View With Torque Converter Converter DC 5-SPEED KYRON 2010.01...
  • Page 607 4. Disc brake B1 10. Output shaft 16. Freewheel F1 (Front planetary gear set) 5. Disc clutch C1 11. Parking lock gear 17. Stator shaft 6. Disc clutch C2 12. Intermediate shaft 18. Converter lockup clutch DC 5-SPEED KYRON 2010.01...
  • Page 608 02-8 3650-01 ▶ Specifications DC 5-SPEED KYRON 2010.01...
  • Page 609 02-9 3650-01 DC 5-SPEED KYRON 2010.01...
  • Page 610 When promptly operating the → accelerator pedal (C), the 4 3 shift is done in shaded area (93% of pedal position). 4th gear: 1.000 5th gear: 0.833 Rev. 1st gear: 3.147 Rev. 2nd gear: 1.93 DC 5-SPEED KYRON 2010.01...
  • Page 611 (C), the 4 3 shift is done in shaded area (93% of pedal position). 4th gear: 1.000 5th gear: 0.833 Rev. 1st gear: 3.147 Rev. 2nd gear: 1.93 Lockup Mode (Open/Slipping) WINTER Mode DC 5-SPEED KYRON 2010.01...
  • Page 612 02-12 3650-01 ▶ General Characteristics DC 5-SPEED KYRON 2010.01...
  • Page 613 02-13 3650-01 OVERVIEW AND OPERATION PROCESS 1. POWER FLOW Brake B1(disk) Brake B3 (disk) Brake B2 (disk) assembly assembly assembly C1 (Disk clutch) C2 (Disk clutch) C3 (Disk clutch) assembly assembly assembly DC 5-SPEED KYRON 2010.01...
  • Page 614 02-14 3650-01 ▶ Shifting Elements ※ 1) Selector program switch: S mode 2) Selector program switch: W mode 3) Overrun DC 5-SPEED KYRON 2010.01...
  • Page 615 Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed Center ring gear: Clockwise rotation Center sun gear: Locked by B2, Rotation with reduced speed Output shaft: Clockwise rotation 3) Overrun ※ DC 5-SPEED KYRON 2010.01...
  • Page 616 Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed Center ring gear: Clockwise rotation Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed Output shaft: Clockwise rotation ※ 3) Overrun DC 5-SPEED KYRON 2010.01...
  • Page 617 Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Center ring gear: Clockwise rotation by clutch 2 activation (direct connection) Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed Output shaft: Clockwise rotation DC 5-SPEED KYRON 2010.01...
  • Page 618 Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection) Center sun gear: Clockwise rotation by C3 activation Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection) Output shaft: Clockwise rotation DC 5-SPEED KYRON 2010.01...
  • Page 619 Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear(increased speed) Center sun gear: Clockwise rotation with increased speed by clutch C3 activation Center planetary gear carrier: Clockwise rotation (increased speed) Output shaft: Clockwise rotation (increased speed) ※ 3) Overrun DC 5-SPEED KYRON 2010.01...
  • Page 620 Rear planetary gear carrier: Locked by B3 Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) Center ring gear: Locked by B3 Center planetary gear carrier: Counterclockwise rotation (reduced speed) Output shaft: Counterclockwise rotation 3) Overrun ※ DC 5-SPEED KYRON 2010.01...
  • Page 621 Rear ring gear: Clockwise rotation Rear planetary gear carrier and center ring gear: Locked by brake B3 Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) Center planetary gear carrier: Counterclockwise rotation (reduced speed) Output shaft: Counterclockwise rotation DC 5-SPEED KYRON 2010.01...
  • Page 622 DSI M78 6-SPEED A/T 3110-01/3650-01/3660-01/3680-01/3721-01/9210-01 DSI M78 6-SPEED A/T 3650-01 DSI M78 6-SPEED A/T GENERAL INFORMATION ASSEMBLY........1. DSI M78 6-SPEED AUTOMATIC 3660-01 VALVE BODY....... TRANSMISSION GENERAL....3110-01 TCU..........2. STRUCTURE CHARACTERISTICS AND 3721-01 TGS LEVER......... SPECIFICATIONS......... 3650-01 INHIBITOR SWITCH..... 3.

  • Page 623: Dsi M78 6-Speed Automatic Transmission General

    Using all of these input signals, the TCU can determine when the time and conditions are right for a shift, or when to apply or release the torque converter clutch. It will also determine the pressure needed to optimise shift feel. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 624 Shift schedule points are optimised for fuel to depress the brake pedal with efficiency and general driving conditions. the ignition switch "ON". DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 625: Structure Characteristics And Specifications

    03-4 3650-01 2. STRUCTURE CHARACTERISTICS AND SPECIFICATIONS 1) Specifications DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 626 03-5 3650-01 2) Appearance ▶ 4WD Automatic Transmission Torque converter Oil cooler outlet Oil cooler return Servo Inhibiter switch Adapter housing ▶ 2WD Automatic Transmission DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 627 03-6 3650-01 3) Internal Assembly Figure DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 628 03-7 3650-01 4) Shift Pattern DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 629: Tightening Torque

    03-8 3650-01 3. TIGHTENING TORQUE DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 630: Overview And Operation Process

    The automatic transmission is electronically controlled. The control system is comprised of the following elements: External transmission control unit (TCU) Internal embedded memory module (EMM) Input and output speed sensors Valve body unit comprised of four on/off solenoid valves and six variable bleed solenoids Torque converter DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 631: Advanced Six Speed Features

    Upon installation, the TCU will download the data from the EMM and utilise this data in the operation of the transmission. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 632 Torque demand downshifts occur (automatically) when the driver demand for torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 633: Function Of Each Mode

    P : Parking R : Reverse N : Neutral D : Driving (5) Tip Switch (Manual Gear Adjustment) The shiftable gear can be adjusted by this switch when the gear selector lever is in "M" position. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 634 5th gear has engine braking available. ▶ 6st Gear State The 6th gear state will display on the instrument cluster. 6-5, 6-4 automatic kick-down shifts are available. 6th gear has engine braking availabl DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 635: Limp Home Mode

    The best way to transport the vehicle is to load it to a truck and transport it, especially if the vehicle is 4WD. - If towing the vehicle with the propeller shaft connected, the transmission or oil pump of transfer case may malfunction, resulting in internal damage due to poor lubrication. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 636: Transmission Electronic Control System

    Ambient air temperature Barometric pressure This information is used by the TCU to decide which shift pattern to select and for shift energy management. Electro-hydraulic solenoid valves and variable bleed solenoids control the transmission gear changes. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 637 This function is used for: - Increasing the transmission service life by shortening the slipping time - Improving the shift comfort by reducing the step change in torque caused by the gearshift DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 638 When winter mode is selected, starting in second gear is facilitated and the WINTER mode indicator light is switched ON. To prevent wheel spin on slippery surfaces, the transmission will not allow first gear unless manually overridden. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 639 The fluid temperature must be below 105캜 to exit all hot modes. ▶ Cruise When cruise control is activated the engine ECU may request the transmission to downshift under trailing throttle conditions to increase engine braking. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 640: Configuration Of Can Related To Tcu

    The EMM data contains transmission specific characterisation information. Upon installation, the TCU will upload the data from the EMM and utilise this data in the operation of the transmission. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 641: Power Train

    Power train - D 3rd gear Power train - D 4th gear - D 4th gear - limp home mode Power train - D 5th gear Power train - D 6th gear ▶ Gear States Summary DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 642 03-21 3650-01 ▶ Overall Hydraulic Circui DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 643 S5 regulates pressure supplied to the C1 Clutch S6 regulates pressure supplied to the C2 Clutch S7 regulates pressure supplied to the C3 Clutch & B2 Band S8 regulates pressure supplied to the B1 Band ▶ Gear States Summary DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 644: Dsi M78 6-Speed A/Tassembly

    Drive oil that engages C2 Clutch is regulated by VBS S6. ▶ Connecting Components Manual 1st is not achieved by moving the Manual Valve into a certain position. This gear state is obtained electronically by solenoids S1 & S7. ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 645 03-24 3650-01 ▶ Manual 1st - C2 & B2 ON (3.536) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 646 S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch. C2 Shift Valve (S2 OFF) is open allowing drive oil to engage C2 Clutch. Drive oil that engages C2 Clutch is regulated by VBS S6. Connecting Components ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 647 03-26 3650-01 ▶ Auto 1st - C2 & OWC ON (3.536) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 648 Drive oil that engages C2 Clutch is regulated by VBS S6. S4 ON moves B1 Shift Valve to its left-end position allowing engagement of B1 Band. Drive oil that engages B1 Band is regulated by VBS S8. ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 649 03-28 3650-01 ▶ Auto 2nd - C2 & B1 ON (2.143) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 650 03-29 3650-01 4) Power Train - "D" (Drive) 2nd - Lockup ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 651 03-30 3650-01 ▶ 2nd Lockup - C2, B1 & TCC ON DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 652 S3 & S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch. ▶ Connecting Components C3 Clutch cannot be engaged without S7 being ON and supplying pressure to the C3 Regulator Valve. ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 653 03-32 3650-01 ▶ 3rd Gear - C2 & C3 ON (1.478) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 654 C2 Shift Valve is OPEN (S2 OFF) allowing drive oil to engage C2 Clutch. Drive oil that engages C1 & C2 Clutches is regulated by S5 & S6 VBS, respectively for each clutch. Connecting Components ▶ 4th GEAR is used as a LHM state. ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 655 03-34 3650-01 ▶ 4th & 4th LHM - C1 & C2 ON (1.156) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 656 C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch S3 ON and with S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutc. Connecting Components ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 657 03-36 3650-01 ▶ 5th Gear - C1 & C3 ON (0.866) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 658 S2 ON moves C2 Shift Valve to its left-end position not allowing the application of the C2 Clutch. C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch S4 ON moves B1 Shift Valve to its left-end position allowing the engagement of B1 Band. Connecting Components ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 659 03-38 3650-01 ▶ 6th Gear - C1 & B1 ON (0.677) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 660 Line pressure is directed via Manual Valve to apply B2 Band directly. S3 ON allows ramping and regulating pressure supplied to the C3. S1 & S2 are ON not allowing engagement either C1 or C2 Clutch at any circumstances. Connecting Components ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 661 03-40 3650-01 ▶ Reverse - C3 & B2 ON (-3.094) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 662 03-41 3650-01 10) Power Train - Reverse (Limp Home Mode) ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 663 03-42 3650-01 ▶ Reverse at LHM - C3 & B2 ON DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 664 03-43 3650-01 11) Power Train - Parking ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 665 03-44 3650-01 ▶ Park DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 666 03-45 3650-01 12) Power Train - Neutral ▶ Power flow diagram ▶ Connecting Components DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 667 03-46 3650-01 ▶ Neutral DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 668: Diagnosis And Testing

    03-94 3110-01 DIAGNOSIS AND TESTING 1. WIRING DIAGRAM DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 669: Wire Harness Connector Chart

    03-95 3110-01 2. WIRE HARNESS CONNECTOR CHART Connector Front View 3. UNIT CONNECTOR DESCRIPTION 1) Transmission Control Unit ▶ Connector J1 (A) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 670 03-96 3110-01 ▶ Connector J2 (B) ▶ Connector J3 (C) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 671 03-97 3110-01 2) Transmission Connector Front View Connector J4 ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 672 03-98 3110-00 3) Inhibitor Switch ▶ Connector J5 DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 673: Trouble Code Eiagnosis

    03-99 3110-00 TROUBLE CODE DIAGNOSIS 1. DIAGNOSTIC TROUBLE CODE LIST DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 674 03-100 3110-00 DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 675: System Diagnosis

    If a transmission component degrades to a point whereby the TCU is unable to adapt its shift data to maintain shift quality, the TCU will set a DTC. ▶ Connector J5 DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 676 03-102 3110-00 ▶ Schematic Connector Details ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 677 03-103 3110-00 ▶ DTC Details DTC Clearing ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 678 There is a different resistance value for each position of the TGS lever. ▶ DTC Description ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 679 03-105 3110-00 ▶ Resistance Values Gear Lever Position Sensor Specifications ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 680 03-106 3110-00 DTC Clearing ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 681 The TCU also monitors the rate of temperature change according to current operating conditions (performance). If the temperature sensor performance is outside a pre-determined set of values, DTC P0711 will set. ▶ DTC Description ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 682 When the transmission fluid is cold, the sensor resistance is high, with the sensor resistance decreasing as the fluid temperature increases. ▶ DTC Description ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 683 03-109 3110-00 ▶ Resistance Values DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 684 03-110 3110-00 ▶ DTC Details DTC Clearing ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 685 The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 36 times per revolution of the C2 cylinder. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 686 03-112 3110-00 ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 687 03-113 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 688 03-114 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 689 6) Transmission Gear Select Lever The transmission gear select lever contains the mode switch, manual mode active switch and up/down switches. These switches are connected directly to the TCU. ▶ DTC Description ▶ Schematic DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 690 03-116 3110-00 ▶ Connector Details ▶ Resistance Values Transmission Gear Select Lever ▶ Resistance Values DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 691 03-117 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 692 The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 22 times per revolution of the transmission output shaft. ▶ DTC Description Schematic ▶ ▶ Connector Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 693 03-119 3110-00 ▶ DTC Details ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 694 Transmission gear change is controlled by the TCU. The TCU receives inputs from various engine and vehicle sensors to select shift schedules and to control the shift feel and torque converter clutch (TCC) operation at each gear change. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 695 03-121 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 696 03-122 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 697 (VBS). During operation, the TCU evaluates torque converter slip speed and compares this against what is expected. If torque converter slip is not within predefined parameters, a DTC will set to indicate a torque converter lock-up problem. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 698 03-124 3110-00 ▶ DTC Details DTC Clearing ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 699 The steering wheel contains transmission gear select (TGS) up/down switches and are directly connected to the TCU. These switches operate in parallel with the TGS lever switches directly to the TCU. ▶ DTC Description Schematic ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 700 03-126 3110-00 ▶ Connector Details ▶ Resistance Values DTC Details ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 701 03-127 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 702 During operation, the TCU evaluates the actual current delivered to the solenoid and compares this against what is expected. If the current is not within predefined parameters, a DTC will be set to indicate the load on the TCU is abnormal. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 703 03-129 3110-00 ▶ DTC Description Schematic ▶ Connector Details ▶ DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 704 03-130 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 705 03-131 3110-00 DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 706 03-132 3110-00 DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 707 03-133 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 708 During operation, the TCU evaluates the actual current delivered to the on/off solenoid and compares this against what is expected. If the current is not within predefined parameters, a DTC will be set to indicate the load on the TCU is abnormal. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 709 03-135 3110-00 ▶ Schematic ▶ Connector Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 710 03-136 3110-00 ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 711 03-137 3110-00 DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 712 03-138 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 713 The TCU obtains the majority if its information via this network. If the TCU does not receive information at regular intervals from the electronic control units connected to the bus, the TCU will set a communication DTC. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 714 03-140 3110-00 ▶ Schematic Connector Details ▶ ▶ DTC Details DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 715 03-141 3110-00 ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 716 TCU software or calibration may be upgraded at service. These DTC뭩 protect the TCU against corrupted files being loaded into the TCU. They also ensure only the correct calibration parameters are used with the software version currently loaded into the TCU. ▶ DTC Description DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 717 03-143 3110-00 ▶ DTC Details ▶ DTC Clearing DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 718: Maintenance Operations

    Raise up the vehicle with a proper lift. Clean up the surroundings of the filler plug before removing the plug. After removing the plug, clean up the plug thoroughly and inspect the O-ring for any damage. DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 719 Replace the filler plug with a new one. Wipe off oil on the transmission or other parts of the vehicle. Apply the specified torque to tighten up the filler plug (30 ~ 35 Nm). DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 720: Stall Test

    Press Accelerator Pedal to 100 % for 6 seconds Observe Engine speed Release Accelerator Pedal Shift To Reverse Press Accelerator Pedal to 100 % for 6 seconds Observe Engine speed If engine speed is observed > 3000 rpm; transmission hardware failure DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 721: Transmission Reset Procedure

    (engine not running). Set the parameter Set Km Travelled to 0 Km. Run the task Reset Adaptive Data. Turn the ignition key to the OFF position. Start the vehicle and check for normal operation. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 722: Fluid Level Inspection

    Allow transmission fluid to drain from the fluid level hole for 50 seconds. Reinstall the fluid level plug and tighten the plug to the correct torque specification. Lower the vehicle to the ground and road test the vehicle to check vehicle operation and for fluid leaks. DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 723: Transmission Cooler And Hydraulic Line Flushing Procedure

    Whist the engine is running, have an assistant pump transmission fluid into the transmission fluid level hole. Connect the rear transmission cooler line to the transmission. Check the transmission fluid level; refer to Fluid Level Inspection on page 69. 6. LUBRICATION Automatic transmission fluid....Caltex PED 1712 ATF DSI M78 6-SPEED A/T KYRON 2010.01...

  • Page 724: Transmission Cooler And Hydraulic Line Flushing Procedure(New Transmission)

    03-150 3680-01 7. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE(NEW TRANSMISSION) DSI M78 6-SPEED A/T KYRON 2010.01...
  • Page 726 2. LOCATIONS AND COMPONENTS Tip switch (-) Tip switch (+) TGS lever knob Tip switch TGS lever TGS LEVER KYRON 2010.01...
  • Page 727 "R" position. Also, it detects signals from the tip switches on the lever knob and the steering wheel and sends them to TCU to shift into a gear driver wants. TGS LEVER KYRON 2010.01...
  • Page 728 05-3 3721-01 3710-01 T/M LEVER OVERVIEW AND OPERATION PROCESS 1. CIRCUIT OF ION 4-SPEED AUTOMATIC T/M T/M LEVER KYRON 2010.01...
  • Page 729 05-4 3721-01 2. CIRCUIT OF SHIFT INTER LOCK T/M LEVER KYRON 2010.01...
  • Page 730 TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement. The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model. KYRON 2010.01...
  • Page 731 06-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications 2) Tightening Torque KYRON 2010.01...
  • Page 732 06-5 3170-01 OVERVIEW AND OPERATION PROCESS 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch N (Neutral) Switch Outside N Switch Inside N Switch KYRON 2010.01...
  • Page 733 RPM. In case of Kyron, 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 Kyron KYRON 2010.01...
  • Page 734 When depressing the brake pedal, the HDC operation state is maintained and the braking power is enhanced. In this case, the HECU emits an abnormal noise and the brake pedal may feel very rigid, but this is a normal occurrence resulted from the HDC operation. KYRON 2010.01...
  • Page 735 The G Sensor within the sensor cluster detects the inclination of driving roads. When the HDC switch is in operation, if the G sensor detects a downhill inclination exceeding 10%, it transmits the HDC operation signal to the ESP HECU. KYRON 2010.01...
  • Page 736 The G sensor within the sensor cluster measures the actual road inclination. However, it may recognize a sharp turn or rough road as a downhill with a inclination exceeding 10%, and the HDC may operate. For the specific information, please refer to the ABS/ESP section. ※ KYRON 2010.01...
  • Page 737 Rexton is connected to the ECU through wires. Thus, if you set the variant coding in the engine ECU, you must do it differently, and you must set the variant coding differently according to the vehicle category and specification as below. Variant Coding Options KYRON 2010.01...
  • Page 739 07-3 3010-01 GENERAL 1. CLUTCH SPECIFICATIONS 2. TIGHTTENING TORQUE CLUTCH KYRON 2010.01...
  • Page 740 This system provides higher efficiency than conventional clutch system, and its durability is superior. 1) Clutch master cylinder (mounted on clutch pedal) 2) Concentric slave cylinder pipe (mounted inside of transmission) CLUTCH KYRON 2010.01...
  • Page 741 07-5 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH KYRON 2010.01...
  • Page 742 07-6 3010-01 Cross Sectional View of Clutch Assembly 1. Transmission housing 3. Clutch disc cover assembly 5. Washer 2. Clutch disc assembly 4. Bolt 6. Bolt CLUTCH KYRON 2010.01...
  • Page 743 08-3 4120-01 GENERAL 1. AXLE SPECIFICATIONS Specification Torque Gear ratio ← ← Type ← → → ← Size Offset ← Housing ← Specification ← Capacity Length ← ← Width Weight ← AXLE KYRON 2010.01...
  • Page 744 Rear Drive Axle) is adopted for the independent type suspension in this vehicle. The below figures for rear axle show the rear axle with the independent type suspension (4WD, A/T). Front Axle Rear Axle IRDA (Independent Rear Drive Axle) AXLE KYRON 2010.01...
  • Page 745 The 2007 Kyron is equipped with different types of front and rear axles. As the IOP axle is installed, AWD (All Wheel Driver) transfer case and the switchable engine mount are installed. This vehicle is equipped with front IOP axle system and IRDA with new technology. AXLE (IOP) KYRON 2010.01...
  • Page 746 Rear Axle There is not much different in the rear axle system. However, as Independent suspension EAS and EPB with new technology are adopted, suspension type rear axle (IRDA) specification and rear axle module have been changed. AXLE (IOP) KYRON 2010.01...
  • Page 747 Before performing the wheel alignment, unload all the items from the vehicle. When setting the wheel alignment tools, the above adjustment values should be followed. The difference of the front camber and the caster at both ends should be below 30' (0.5°). AXLE (IOP) KYRON 2010.01...
  • Page 748 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. PART TIME TRANSFER CASE SPECIFICATIONS KYRON 2010.01...
  • Page 749 10-4 3240-01 OVERVIEW AND OPERATION PROCESS 1. STRUCTURE Front axle Front locking hub system (IWE) Front propeller shaft Transmission Part time transfer case Rear propeller shaft Rear axle (IRS type) KYRON 2010.01...
  • Page 750 (for 1 pin) Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly T/C motor Oil drain plug (Tightening torque: 19 ~ 30 Nm) Damper Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm) KYRON 2010.01...
  • Page 751 1) System Layout Indicators (T/C control indicator lamp) HECU (Wheel speed signal) T/C control switch TCCU CAN Communication Output Solenoid valve Transfer case Vacuum line Atmo sphere Magnetic clutch Motor Front output shaft FL Locking hub FR Locking hub KYRON 2010.01...
  • Page 752 It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear. Operating Process Vacuum generation process in front hub actuator: KYRON 2010.01...
  • Page 753 Atmosphere (in 4WD mode) 2WD (applying vacuum pressure to hub actuator) The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear. KYRON 2010.01...
  • Page 754 3240-01 4. POWER FLOW 1) POWER FLOW Switch Transfer 2H, 4H → 4L TCCU Locking Hub Solenoid Locking Hub Operation (Internal vacuum released) Transfer Front Propeller Shaft Rear Propeller Shaft Front Axle Front Axle Front Wheel Rear Wheel KYRON 2010.01...
  • Page 755 10-10 3240-01 2) 2H MODE (2WD) Power Flow ▶ Transmission Rear Wheel Output Shaft Transfer Case Input Shaft Rear Propeller Shaft Rear Axle ↓ Output Shaft Rear Wheel KYRON 2010.01...
  • Page 756 3) 4H MODE (4WD - HIGH SPEED) Power Flow ▶ Transmission Motor TCCU Input Shaft Shift Cam, Rail, Fork Magnetic T/C Output Clutch Shaft 4WD-HI Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Rear Propeller Front Wheel Drive Shaft KYRON 2010.01...
  • Page 757 4) 4L MODE (4WD - LOW SPEED) Power Flow ▶ Transmission TCCU Motor Input Shaft Shift Planetary Cam, Rail, Fork Gear 4WD-LO Locking Hub Solenoid Magnetic Output Operation Clutch Shaft Engagement of Front Drive Rear Propeller Shaft and Locking Hub Shaft Front Wheel Drive KYRON 2010.01...
  • Page 758 PROPELLER SHAFT 3310-01/3310-00/3310-06 PROPELLER SHAFT GENERAL 1. SPECIFICATION........OVERVIEW AND OPERATION PROCESS 1. OVERVIEW..........2. COMPONENT LOCATOR....... 3310-01 FRONT PROPELLER SHAFT..3310-06 REAR PROPELLER SHAFT..3310-00 DISASSEMBLY AND REASSEMBLY PROPELLER SHAFT.........

  • Page 760: Specification

    11-3 3310-00 3310-00 PROPELLER SHAFT GENERAL 1. SPECIFICATION PROPELLER SHAFT KYRON 2010.01...

  • Page 761: Overview And Operation Process

    The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration. PROPELLER SHAFT KYRON 2010.01...

  • Page 762: Component Locator

    8. Split washer 2. Journal bearing cap 9. Slip tube shaft 3. Spider journal 10. Tube 4. Slip yoke assembly 11. Tube yoke 5. Grease nipple 12. Flange yoke 6. Dust cap 13. Center bearing 7. Oil seal PROPELLER SHAFT KYRON 2010.01...
  • Page 763 11-6 3310-00 2) Propeller Shaft Assemble 1. Propeller shaft 4. Yoke (front) 2. Joint (propeller front) 5. Yoke (rear) 3. Joint (propeller rear) PROPELLER SHAFT KYRON 2010.01...

  • Page 764: Front Propeller Shaft

    Manual Transmission (For Gasoline Engine) Remove the flange yoke mounting bolt on the transfer case side of the front propeller shaft. Put installation marks on the yoke to the propeller and the flange to the transfer case. PROPELLER SHAFT KYRON 2010.01...
  • Page 765 Remove the flange yoke mounting bolt and nut on the front axle side of the front propeller shaft. Put installation marks on the yoke to the propeller and the flange to the transfer case. Remove the front propeller shaft. PROPELLER SHAFT KYRON 2010.01...

  • Page 766: Rear Propeller Shaft

    3310-06 Remove the yoke mounting bolt and nut on the transfer case side of the rear propeller shaft. Put installation marks on the yoke of the rear propeller shaft and the flange of the transfer case. PROPELLER SHAFT KYRON 2010.01...
  • Page 767 11-10 3310-06 Remove the intermediate bearing(center) bolts. Remove the yoke and flage mounting bolts and nuts on the rear axle side of the rear propeller shaft. Then, remove the rear propeller shaft. PROPELLER SHAFT KYRON 2010.01...

  • Page 768: Disassembly And Reassembly Propeller Shaft

    Remove the other bearings with same manner. If it cannot be removed, hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer. PROPELLER SHAFT KYRON 2010.01...
  • Page 769 11-12 3310-00 Disassemble the universal joint. The universal joint compensates the angle changes due to vertical movement of the axle shaft. Remove the intermediate bearing bracket and remove the bearing with special tool. PROPELLER SHAFT KYRON 2010.01...
  • Page 770 When using the general bolts Excessive wear of universal joint Stuck in sleeve joint Vibration is mainly caused by the angle changes in front and rear universal joint. It normally occurs when the vehicle speed is 60 ~ 100 km/h. PROPELLER SHAFT KYRON 2010.01...
  • Page 771 Adjust the clearance of spider below 0.1 mm and install the snap ring. Install the intermediate bearing to the rear propeller shaft. Apply the grease on the propeller shaft and install it. PROPELLER SHAFT KYRON 2010.01...
  • Page 772 12-3 4411-01 4411-01 SUSPENSION GENERAL 1. FRONT SUSPENSION SPECIFICATIONS 2. REAR SUSPENSION SPECIFICATIONS SUSPENSION KYRON 2010.01...
  • Page 773 When ABS/ESP is installed on the independent ABS/ESP + 5Link Suspension: solid type disc suspension, ventilated disc (disc ABS/ESP + Independent suspension: thickness: approx. 20 mm) is installed. ventilated disc Rear Disc and Caliper (1 Internal Cylinder) KYRON 2010.01...
  • Page 774 Parking brake system: The hand operated type parking brake is installed on vehicles with the manual transmission and the foot operated type parking brake is installed on vehicles with the automatic transmission. Hand Operated Type Foot Operated Type (Vehicle with Manual Transmission) (Vehicle with Automatic Transmission) KYRON 2010.01...
  • Page 775 13-5 4890-01 3) SECTIONAL DRAWING Front Disc Brake Rear Disc Brake KYRON 2010.01...
  • Page 776 The wheel speed sensor is connected to the engine ECU (terminal 36), where its signal is processed, and is connected to other related systems through CAN communication. Location of the wheel speed sensor Location of the Sensor Connector (rear right wheel) Connector Appearance In vehicle without ABS In vehicle with ABS/ESP KYRON 2010.01...
  • Page 777 13-7 4890-01 2. BRAKE SYSTEM SPECIFICATIONS KYRON 2010.01...
  • Page 778 It is also a physical phenomenon and has no relation with the brake performance. KYRON 2010.01...
  • Page 779 HDC operation. The warning lamp flashes and warning beep sounds when the ESP is operating When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flashes and beep comes on every 0.1 seconds. KYRON 2010.01...
  • Page 780 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. KYRON 2010.01...
  • Page 781 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) KYRON 2010.01...
  • Page 782 HDC Switch ESP HECU The transfer case (T/C) installed on this vehicle doesn't have the internal speed sensing device and receives the speed signal for T/C control from ESP HECU via CAN bus. [Conventional T/C] With speed sensor KYRON 2010.01...
  • Page 783 13-13 4890-01 [New T/C] Without speed sensor KYRON 2010.01...
  • Page 784 Therefore, the front wheel end system (including disc) should be removed before removing the front wheel speed sensor. Rear Wheel Speed Sensor (IRS Type) Front Wheel Speed Sensor (4WD) Backing plate Wheel speed sensor Wheel Speed Sensor Wheel speed sensor Backing plate KYRON 2010.01...
  • Page 785 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2010.01...
  • Page 786 2 pressure sensors installed on the master cylinder Sensor cluster (integrated yaw rate sensor and lateral sensor) and longitudinal sensor installed in IP. SWAS (Steering Wheel Angle Sensor) installed in the steering column. ▶ Comparison with ABS System KYRON 2010.01...
  • Page 788 The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output (coupled with the ASR system). Under Steering Over Steering KYRON 2010.01...
  • Page 789 In this way, the vehicle does not lose its driving direction and the does not lose its driving direction and the driver can steer the vehicle as he or she driver can steer the vehicle as driver intends. intends. KYRON 2010.01...
  • Page 790 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. KYRON 2010.01...
  • Page 791 (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. KYRON 2010.01...
  • Page 792 When the system is designed to apply high braking force when brake pedal 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. KYRON 2010.01...
  • Page 793 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: 1. Pressure: over 20 bar 2. Pressure changes: over 1500 bar/sec 3. Vehicle speed: over 7 Km/h KYRON 2010.01...
  • Page 794 ESP system and its function is useless when the situation overcomes the physical power. Following picture shows how the ARP compensates the vehicle position by varying each wheel's braking power to overcome the physical tendency of the vehicle rollover during sharp turns. KYRON 2010.01...
  • Page 795 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. KYRON 2010.01...
  • Page 796 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. KYRON 2010.01...
  • Page 798 4. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode). · The vehicle speed given in step (3) varies according to the vehicle driving mode, and the speed ranges by the vehicle driving mode and condition are as follows. KYRON 2010.01...
  • Page 799 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. KYRON 2010.01...
  • Page 800 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. KYRON 2010.01...
  • Page 801 13-31 4890-01 4) Input/Output Signals for HDC Operation KYRON 2010.01...
  • Page 802 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 KYRON 2010.01...
  • Page 804 13-34 4890-01 6. ESP COMPONENTS AND LOCATIONS Sensor cluster: Master cylinder Steering wheel angle (Yaw rate + lateral sensor pressure sensor sensor +longitudinal sensor) HECU (Valve body and ECU integrated type) Valve body Motor pump KYRON 2010.01...
  • Page 805 13-35 4890-01 ▶ Comparison with ABS System Active Wheel Speed Sensor HDC Switch HDC Indicator ESP OFF Switch ABS / ESP Indicator KYRON 2010.01...
  • Page 806 13-36 4890-01 7. INPUT/OUTPUT SIGNALS FOR HDC OPERATION ▶ Input/Output of ESP System KYRON 2010.01...
  • Page 807 13-37 4890-01 8. ESP HYDRAULIC CIRCUIT DIAGRAM KYRON 2010.01...
  • Page 808 When the brake is applied under these is being supplied. Then the pump operates conditions, the brake fluid will be sent to to allow fast oil drainage. each wheel via the separation valve and inlet valve. KYRON 2010.01...
  • Page 809 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. KYRON 2010.01...
  • Page 810 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 are will stay closed. When the wheel starts to lock, the HBA function cancels and switches to ABS operation. KYRON 2010.01...
  • Page 811 Active Wheel Speed Sensor (for 4WD) The transfer case (T/C) installed on this vehicle doesn't have the internal speed sensing device and receives the speed signal for T/C control from ABS HECU. Conventional Transfer Case With Speed Sensor KYRON 2010.01...
  • Page 812 13-42 4890-01 New Transfer Case Without Speed Sensor KYRON 2010.01...
  • Page 813 Therefore, the front wheel end system (including disc) should be removed before removing the front wheel speed sensor. Front Wheel Speed Sensor Rear Wheel Speed Sensor Backing Plate Wheel Speed Sensor Backing Plate Wheel Speed Sensor KYRON 2010.01...
  • Page 814 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2010.01...
  • Page 815 13-45 4890-01 12. CONFIGURATION OF ABS SYSTEM The following figure shows the basic system components of the ABS. This system consists of HECU (valve body and ECU integrated type), front wheel speed sensor, and rear wheel speed sensor. KYRON 2010.01...
  • Page 816 13-46 4890-01 13. INPUT AND OUTPUT DIAGRAM OF ABS ▶ Input/Output of ABS (without TPMS) KYRON 2010.01...
  • Page 817 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. KYRON 2010.01...
  • Page 818 The speed of the wheel that hydraulic At this moment, the outlet valve is closed. pressure is delivered reduces gradually. This procedure helps the wheel to maintain a stable hydraulic pressure. KYRON 2010.01...
  • Page 819 The ABS ECU operates the pump to some vibration and noises at the brake circulate the oil in the low pressure chamber pedal. to the master cylinder. This may make the driver to feel the brake pedal vibration and some noises. KYRON 2010.01...
  • Page 820 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. POWER STEERING SPECIPICATIONS STEERING KYRON 2010.01...
  • Page 821 40 ~ 50 Nm 1. Power steering pump assembly 4. Tie rod end 2. Power steering return pipe 5. Power steering gear box pipe 3. Power steering high pressure hose and pipe 6. Power steering gear box assembly STEERING KYRON 2010.01...
  • Page 822 14-5 4610-00 With SSPS SSPS Solenoid Valve cannot be replaced 1. Power steering gear box 3. Power steering high pressure hose and pipe 2. Gear box pipe 4. Return hose and pipe STEERING KYRON 2010.01...
  • Page 823 14-6 4610-00 Pipe bracket bolt (10 mm) Pipe bracket bolt (10 mm) 9 ~ 14 Nm 9 ~ 14 Nm Gear box mounting bolt Pipe mounting nut 20 ~ 26 Nm Installation Drawing of SSPS STEERING KYRON 2010.01...
  • Page 824 40 ~ 60 Nm 20 ~ 25 Nm Steering wheel Column shaft Lower shaft 18 ~ 25 Nm Tie rod end 30 ~ 40 Nm 70 ~ 90 Nm 45 ~ 50 Nm Steering gear box 35 ~ 45 Nm STEERING KYRON 2010.01...
  • Page 825 14-8 4610-00 Steering wheel Lower shaft Column shaft Steering gear box STEERING KYRON 2010.01...
  • Page 826 In other words, the steering wheel gets lighter by adjusting steerability in stop or low speed and provides steering stability by adjusting steering wheel to become heavier in high speed. SSPS (Speed Sensitive Power Steering) If the SSPS solenoid valve is defective, the power steering assembly should be replaced. STEERING KYRON 2010.01...
  • Page 827 This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV. Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from SSPS control unit. STEERING KYRON 2010.01...
  • Page 828 The changes of hydraulic pressure applied to input shaft according to the pressure changes applied to the reaction plunger provide proper steerability based on the amount of electric current. (2) Specifications STEERING KYRON 2010.01...
  • Page 829 The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to reaction plunger. At this time, the reaction plunger transmits the reaction force to V-groove in input shaft to provide heavy steerability. STEERING KYRON 2010.01...
  • Page 830 333 Hz frequency and sets the target current to 1A during 1 second after the ignition is "ON". When a trouble occurs in the system, the SSPS control unit generates a trouble code using fail safe function. Location SSPS unit STEERING KYRON 2010.01...
  • Page 831 14-14 4610-00 3) CIRCUIT DIAGRAM STEERING KYRON 2010.01...
  • Page 832 Then, the spool located in PCV compresses the upper spring and elevates upward, and the working pressure from oil pump (A port) is not able to flow to the reaction plunger (C port). As a result, the pressing force from the reaction plunger disappears and the steerability enhances. STEERING KYRON 2010.01...
  • Page 833 Then, the spool located PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C port) through B port. As a result, the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier. STEERING KYRON 2010.01...
  • Page 834 FATC controller. This sensor is installed at the front bottom of Ambient Temperature Sensor engine compartment. This changes the air source mode by detecting the air pollution and the ambient temperature. Ambient temperature sensor AIR CONDITIONER KYRON 2010.01...
  • Page 835 Absorbs moisture in the Detects A/C switch position, A sensor that detects coolant refrigerant and reserves coolant temperature, engine temperature and transmits to refrigerant to supply smoothly. condition and driving condition engine ECU. to control the air conditioner. AIR CONDITIONER KYRON 2010.01...
  • Page 836 01-4 6810-20 2. VENTILATION SYSTEM COMPONENTS Locations of Vents ▶ ▶ Air Duct AIR CONDITIONER KYRON 2010.01...
  • Page 837 Mode door actuator Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air mix door actuator Main wire connector Intake sensor Active incar sensor (interior temperature sensor) and humidity sensor Air conditioner controller unit AIR CONDITIONER KYRON 2010.01...
  • Page 838 Coolant Temperature Sensor Power Transistor/Blower Intake Sensor Motor Power transistor Blower motor Air Source Door Actuator Air Conditioner Filter Interior Temperature Sensor A/C Controller Unit (Interior Humidity Sensor) Mode Door Actuator Interior temperature and humidity sensor AIR CONDITIONER KYRON 2010.01...
  • Page 839 01-7 6810-15 3) Components AIR CONDITIONER KYRON 2010.01...
  • Page 840 01-8 6810-15 4. PTC HEATER AND FFH HEATER LAYOUT 1) PTC HEATER ASSEMBLY LAYOUT 2) FFH HEATER ASSEMBLY LAYOUT AIR CONDITIONER KYRON 2010.01...
  • Page 841 01-9 6810-15 5. AMBIENT TEMPERATURE SENSOR The ambient temperature sensor is installed in the front area of the engine compartment to detect the ambient temperature. Ambient temperature sensor Ambient temperature sensor Connector AIR CONDITIONER KYRON 2010.01...
  • Page 842 Measure the voltage to the sun sensor from FATC connector. (approx. 2.5 V under sunlight and 4.8 V under shade.) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONER KYRON 2010.01...
  • Page 843 Incar temperature sensor ▶ This sensor is a negative temperature coefficient (NTC) thermistor and detects the interior temperature with air coming from sensor hole and then sends the voltage value according to the changed resistance to FATC controller. AIR CONDITIONER KYRON 2010.01...
  • 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 KYRON 2010.01...
  • Page 845 FATC controller connector. (standard: approx. 2 V at 25°C) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONER KYRON 2010.01...
  • Page 846 Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6. The specified voltage value in each stage: If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the power transistor. AIR CONDITIONER KYRON 2010.01...
  • Page 847 FOOT and DEF mode to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed. Mode door actuator AIR CONDITIONER KYRON 2010.01...
  • Page 848 And measure the voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONER KYRON 2010.01...
  • Page 849 2 minutes to burn the residual fuel inside the system when stopping the engine during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction. Components Locator AIR CONDITIONER KYRON 2010.01...
  • Page 850 4. FFH water pump bracket 10. Fuel pump bracket 16. Intake hose 5. FFH NO.3 inlet hose 11. Fuel pipe NO.1 17. Clamp 6. FFH NO.2 inlet hose 12. Fuel pipe NO.2 18. FFH NO.1 inlet hose AIR CONDITIONER KYRON 2010.01...
  • Page 851 01-19 6810-15 (2) Exploded View AIR CONDITIONER KYRON 2010.01...
  • Page 852 01-20 6810-15 AIR CONDITIONER KYRON 2010.01...
  • Page 853 15. Bush for flame sensor (graphite) 32. Screw (M4 x 16 TORX / 4x) 16. Control and overheating sensor with cable 33. Screw (M4 x 44 TORX / 4x) 17. O-ring 34. Controller cable harness 35. Insulation washer AIR CONDITIONER KYRON 2010.01...
  • Page 854 01-22 6810-15 (3) SPECIFICATIONS AIR CONDITIONER KYRON 2010.01...
  • Page 855 80°C and starts to be operated in LO mode (low output: approx. 2,300 W) from 81°C. When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be met again. AIR CONDITIONER KYRON 2010.01...
  • Page 856 Fill the heater and water hoses with coolant before connecting to the coolant circuit. When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts. Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures. Secure all hose connections with hose clamps. AIR CONDITIONER KYRON 2010.01...
  • Page 857 01-25 6810-15 4) Circuit Diagram AIR CONDITIONER KYRON 2010.01...
  • Page 858 It is possible to diagnose the system by connecting the diagnostic device to controller. For details, refer to the "Diagnosis Procedures" section. If an emergency shutdown -EMERGENCY OFF- is necessary during operation, proceed as follows; Pull the fuse (Ef6: 20A) out. Disconnect the heater from the battery. AIR CONDITIONER KYRON 2010.01...
  • Page 859 01-27 6810-15 6) Specification - Water Pump 7) Characteristic Curve of Water Pump (12 V) AIR CONDITIONER KYRON 2010.01...
  • Page 860 01-28 6810-15 8) Function Diagram 9) Switching Diagram According to Temperature Changes AIR CONDITIONER KYRON 2010.01...
  • Page 861 These are located inside the left and right B-pillar panel bottoms. When collision occurs, the air bag at the side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the air bag at the side of collision deploys, not both. AIR BAG KYRON 2010.01...
  • Page 862 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 KYRON 2010.01...
  • Page 863 These are located inside the left and right B-pillar panel bottoms. When a collision occurs, the air bag at the side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the air bag at the side of collision deploys, not both. AIR BAG KYRON 2010.01...
  • Page 864 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 KYRON 2010.01...
  • Page 866 02-8 8810-03 2. AIR BAG SYSTEM LOCATIONS AND RELATED COMPONENTS ▶ When the curtain air bag (LH) deploys Curtain air bag collision G sensor BPT: Belt Pretensioner ▶ When the curtain air bag (RH) deploys AIR BAG KYRON 2010.01...
  • Page 867 When the front collision G sensor sends out only the air bag deployment signal, the signal deploys the two front air bags and activates their seat belt pretensioners. AIR BAG KYRON 2010.01...
  • Page 868 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. ▶ Air Bag System Block Diagram (Functions and Roles Included) AIR BAG KYRON 2010.01...
  • Page 869 02-11 8810-03 AIR BAG KYRON 2010.01...
  • Page 870 At this point, the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver. (1) Components Air bag cover Air bag housing Horn switch Retainer ring Air bag cushion (approx. 50 liters) Inflator* (approx. 190 Kpa) AIR BAG KYRON 2010.01...
  • Page 871 (curtain air bags independently operate in case of the side collisions). Front View Rear View (1) Components Air bag cushion Retainer Passenger's air bag module housing Inflator AIR BAG KYRON 2010.01...
  • Page 872 When the Curtain Air Bag is Installed Terms of the Curtain Air Bag Curtain air bag mounting point Inflator Nut and bolt mounting point Wrapper cover Air bag cushion Gas guide Inflator When the Curtain Air Bag Deploys AIR BAG KYRON 2010.01...
  • Page 873 02-15 8810-03 (1) Components Tightening torque: 8 ~ 10 Nm Tightening torque: 8 ~ 10 Nm a - a b - b Sectimal view a-a Sectimal view b-b AIR BAG KYRON 2010.01...
  • Page 874 This holds the occupant more securely in the seat. Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side) 35 ~ 55 Nm 35 ~ 55 Nm Belt pretensioner (LH) Belt pretensioner (RH) Curtain air bag G sensor AIR BAG KYRON 2010.01...
  • Page 875 (1) Components 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 KYRON 2010.01...
  • Page 876 02-18 8810-03 5 )Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel. Location of Air Bag AIR BAG KYRON 2010.01...
  • Page 877 But incorrect tightening torque may break the sensor or make it insecure. As a result, the sensor may have inaccurate judgment and have the air bag deployed inaccurately. Driver's Side Passenger's Side 9 Nm ± 1 Nm Connector Signal Ground terminal AIR BAG KYRON 2010.01...
  • Page 878 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 KYRON 2010.01...
  • Page 879 5 seconds. Even though the ignition switch is turned off in the middle of the unlock signal being sent out, the unlock signal continues for the remaining time. This function cancels when the ignition key is withdrawn. AIR BAG KYRON 2010.01...
  • Page 880 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 will be performed and the unlock will be ignored. AIR BAG KYRON 2010.01...
  • Page 881 When it is recorded as a system failure in the air bag unit, the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second. Then the waning lamp stays on. AIR BAG KYRON 2010.01...
  • Page 882 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 KYRON 2010.01...
  • Page 883 02-25 8810-03 8. AIR BAG ELECTRICAL WIRING DIAGRAM AIR BAG KYRON 2010.01...
  • Page 884 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
  • Page 886 0000-00 0000-00 BRAKE 1. BRAKE BRAKE KYRON 2010.01...
  • Page 887 0000-00 BRAKE KYRON 2010.01...
  • Page 888 0000-00 BRAKE KYRON 2010.01...
  • Page 889 0000-00 BRAKE KYRON 2010.01...
  • Page 890 0000-00 BRAKE KYRON 2010.01...
  • Page 891 0000-00 BRAKE KYRON 2010.01...
  • Page 892 0000-00 BRAKE KYRON 2010.01...
  • Page 893 0-10 0000-00 BRAKE KYRON 2010.01...
  • Page 894 0-11 0000-00 BRAKE KYRON 2010.01...
  • Page 895 0-12 0000-00 BRAKE KYRON 2010.01...
  • Page 896 AIR-BAG 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG..........
  • Page 898 0000-00 0000-00 AIR-BAG 1. AIR-BAG AIR-BAG KYRON 2010.01...
  • Page 899 0000-00 AIR-BAG KYRON 2010.01...
  • Page 900 0000-00 AIR-BAG KYRON 2010.01...
  • Page 901 0000-00 AIR-BAG KYRON 2010.01...
  • Page 902 0000-00 AIR-BAG KYRON 2010.01...
  • Page 903 0000-00 AIR-BAG KYRON 2010.01...
  • Page 904 0000-00 AIR-BAG KYRON 2010.01...
  • Page 905 0-10 0000-00 AIR-BAG KYRON 2010.01...
  • Page 906 CCCS 0000-00 CCCS DIAGNOSIS 1. CCCS.............
  • Page 908 0000-00 0000-00 CCCS 1. CCCS CCCS KYRON 2010.01...
  • Page 909 0000-00 CCCS KYRON 2010.01...
  • Page 910 0000-00 CCCS KYRON 2010.01...
  • Page 911 0000-00 CCCS KYRON 2010.01...
  • Page 912 0000-00 CCCS KYRON 2010.01...
  • Page 913 0000-00 CCCS KYRON 2010.01...
  • Page 914 0000-00 CCCS KYRON 2010.01...
  • Page 915 0-10 0000-00 CCCS KYRON 2010.01...
  • Page 916 0-11 0000-00 CCCS KYRON 2010.01...
  • Page 917 0-12 0000-00 CCCS KYRON 2010.01...
  • Page 918 0-13 0000-00 CCCS KYRON 2010.01...
  • Page 919 0-14 0000-00 CCCS KYRON 2010.01...
  • Page 920 0-15 0000-00 CCCS KYRON 2010.01...
  • Page 921 0-16 0000-00 CCCS KYRON 2010.01...
  • Page 922 0-17 0000-00 CCCS KYRON 2010.01...
  • Page 923 0-18 0000-00 CCCS KYRON 2010.01...
  • Page 924 0-19 0000-00 CCCS KYRON 2010.01...
  • Page 925 0-20 0000-00 CCCS KYRON 2010.01...
  • Page 926 0-21 0000-00 CCCS KYRON 2010.01...
  • Page 927 0-22 0000-00 CCCS KYRON 2010.01...
  • Page 928 0-23 0000-00 CCCS KYRON 2010.01...
  • Page 929 0-24 0000-00 CCCS KYRON 2010.01...
  • Page 930 0-25 0000-00 CCCS KYRON 2010.01...
  • Page 931 0-26 0000-00 CCCS KYRON 2010.01...
  • Page 932 0-27 0000-00 CCCS KYRON 2010.01...
  • Page 934 FATC 0000-00 FATC DIAGNOSIS 1. SELF DIAGNOSIS........
  • Page 936 1) Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds. Check LED segments on the vacuum fluorescent display (VFD). Press OFF switch more than 5 seconds. FATC KYRON 2010.01...
  • Page 937 If any failure exists, the appropriate trouble code is displayed as below. The symbol "-" in front of step number "2" means a short circuit of the blinking sensor. Short-circuit in the ambient air temperature sensor Trouble Code FATC KYRON 2010.01...
  • Page 938 Slightly turn the TEMP switch in step 3 until "41" is displayed on the display window. When pressing DEF switch , mode changes as shown below in turns to check each function. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4 FATC KYRON 2010.01...
  • Page 939 (other than TEMP switch) in step 5. Starts the trouble Compensates the diagnosis step 6 temperature turning turning TEMP speed dial. dial. Min. temperature Max. temperature Step 6 compensation value compensation value FATC KYRON 2010.01...
  • Page 940 0000-00 DIAGNOSIS 1. FFH............
  • Page 942 0000-00 0000-00 1. FFH KYRON 2010.01...
  • Page 943 0000-00 KYRON 2010.01...
  • Page 944 0000-00 KYRON 2010.01...
  • Page 945 0000-00 KYRON 2010.01...
  • Page 946 P/TRUNK 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK..........
  • Page 948 0000-00 0000-00 P/TRUNK 1. P/TRUNK P/TRUNK KYRON 2010.01...
  • Page 949 0000-00 P/TRUNK KYRON 2010.01...
  • Page 950 RAIN SENSOR 0000-00 RAIN SENSOR DIAGNOSIS 1. TROUBLE SHOOTING......
  • Page 952 Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity. RAIN SENSOR KYRON 2010.01...
  • Page 953 The wiper responses are too fast or slow. Check whether the variable resistance knob on the wiper switch is set in "FAST" or "SLOW". Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage. RAIN SENSOR KYRON 2010.01...
  • Page 954 STICS 0000-00 STICS DIAGNOSIS 1. STICS............
  • Page 956 0000-00 0000-00 STICS 1. STICS STICS KYRON 2010.01...
  • Page 957 0000-00 STICS KYRON 2010.01...
  • Page 958 0000-00 DIAGNOSIS 1. TC............
  • Page 960 0000-00 0000-00 1. TC KYRON 2010.01...
  • Page 961 0000-00 KYRON 2010.01...
  • Page 962 0000-00 KYRON 2010.01...
  • Page 963 0000-00 KYRON 2010.01...
  • Page 964 0000-00 DIAGNOSIS 1. TCU............
  • Page 966 0000-00 0000-00 1. TCU KYRON 2010.01...
  • Page 967 0000-00 KYRON 2010.01...
  • Page 968 0000-00 KYRON 2010.01...
  • Page 969 0000-00 KYRON 2010.01...
  • Page 970 0000-00 KYRON 2010.01...
  • Page 971 0000-00 KYRON 2010.01...
  • Page 972 0000-00 KYRON 2010.01...
  • Page 973 0-10 0000-00 KYRON 2010.01...
  • Page 974 0-11 0000-00 KYRON 2010.01...
  • Page 975 0-12 0000-00 KYRON 2010.01...
  • Page 976 0-13 0000-00 KYRON 2010.01...
  • Page 977 0-14 0000-00 KYRON 2010.01...
  • Page 978 0-15 0000-00 KYRON 2010.01...
  • Page 979 0-16 0000-00 KYRON 2010.01...
  • Page 980 0-17 0000-00 KYRON 2010.01...
  • Page 981 0-18 0000-00 KYRON 2010.01...
  • Page 982 0-19 0000-00 KYRON 2010.01...
  • Page 984 TGS LEVER 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER...........
  • Page 986 0000-00 0000-00 TGS LEVER 1. TGS LEVER TGS LEVER KYRON 2010.01...
  • Page 987 0000-00 TGS LEVER KYRON 2010.01...
  • Page 988 0000-00 TGS LEVER KYRON 2010.01...
  • Page 989 0000-00 TGS LEVER KYRON 2010.01...
  • Page 990 GENERAL INFORMATION 0000-00 GENERAL INFORMATION GENERAL INFORMATION 1. HOW TO READ ELECTRICAL WIRING DIAGRAM..........
  • Page 992 01-3 0000-00 * D-146 UPDATE DETAILS GENERAL INFORMATION KYRON 2010.01...
  • Page 993 - Internal circuit of component (Switch) (Component Name, Terminal Number and Connecting Wiring Circuit) - Lower horizontal line : Ground line ·Ground position (G101 ~ G402) ·B : Body Ground ·Refer to Major Ground Position (Section2) GENERAL INFORMATION KYRON 2010.01...
  • Page 994 Battery Voltage (B+) supply in Ignition Switch “ON” and “ACC” Battery Voltage (B+) supply directly regardless of Ignition Switch Ground connected to battery (-) Battery Voltage (B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit) GENERAL INFORMATION KYRON 2010.01...
  • Page 995 □ 9□□ In the locating section, the assignment for part number startsfrom left bottom and proceeds clockwise. In the fuse and relay box or the instrument panel, the partnumber is assigned from left top to light bottom. GENERAL INFORMATION KYRON 2010.01...
  • Page 997 CONNECTOR/GROUND 8201-00/8210-00/8210-02/8210-03/8210-09/8210-10/8210-06/8210-07/8210-08 CONNECTOR/GROUND WIRING HARNESS 0000-00 WIRING HARNESS, COMPONENTS LOCATION..
  • Page 999 02-3 0000-00 WIRING HARNESS WIRING HARNESS, COMPONENTS LOCATION 0000-00 1) WIRING HARNESS 2) COMPONENTS LOCATION CONNECTOR/GROUND KYRON 2010.01...
  • Page 1000 02-4 0000-00 3) CONNECTOR, GROUND & SPLICE PACK INFORMATION ▶ CONNECTOR CONNECTOR/GROUND KYRON 2010.01...
  • Page 1001 02-5 0000-00 4) SPLICE PACK CIRCUIT ▶ GROUND ▶ S101 ▶ S201 ▶ SPLICE PACK ▶ S202 (CAN) CONNECTOR/GROUND KYRON 2010.01...
  • Page 1002 02-6 0000-00 ▶ S203 (GND) ▶ S206 ▶ S301 (CAN) ▶ S204 (ILL+) ▶ S302 ▶ S205 (GND) CONNECTOR/GROUND KYRON 2010.01...
  • Page 1003 02-7 0000-00 5) CONNECTOR ▶ ▶ WIRNING CONNECTOR WIRNING CONNECTOR ▶ WIRNING CONNECTOR ▶ MODE CONNECTOR CONNECTOR/GROUND KYRON 2010.01...
  • Page 1004 02-8 0000-00 ▶ UNIT CONNECTOR ▶ SWITCH CONNECTOR ▶ LAMP CONNECTOR ▶ SENSOR CONNECTOR CONNECTOR/GROUND KYRON 2010.01...
  • Page 1005 02-9 0000-00 ▶ ETC. CONNECTOR/GROUND KYRON 2010.01...
  • Page 1007 0-18 8210-00 CONNECTOR W/H ENGINE ROOM 8210-00 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1008 0-19 8210-02 W/H MAIN 8210-02 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1009 0-20 8210-03 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1010 0-21 8210-03 W/H FLOOR 8210-03 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1011 0-22 8210-03 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1012 0-23 8210-09 W/H ROOF W/H FRT DOOR 8210-09 8210-07 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1013 0-24 8210-10 W/H RR DOOR W/H DECK 8210-08 8210-10 CONNECTOR/GROUND ACTYON SPORTS 2006.03...
  • Page 1014 POWER DISTRIBUTION 8410-02/8410-04/8401-06 POWER DISTRIBUTION FUSE/RELAY 8210-00 ENGINE ROOM FUSE / RELAY BOX......... 8410-00 I/P - LH FUSE / RELAY BOX..8401-00 I/P - RH FUSE / RELAY BOX..ELECTRICITY DIVIDE 8210-00 ENGINE ROOM FUSE / RELAY BOX CIRCUIT....8410-00 I/P - LH FUSE / RELAY BOX CIRCUIT....

  • Page 1016: Fuse/Relay

    03-3 8210-00 FUSE / RELAY ENGINE ROOM FUSE / RELAY BOX 8210-00 1) UPPER 3) ENGINE ROOM FUSE / RELAY BOX 2) LOW 4) ENGINE ROOM FUSE / RELAY BOX (RUSSIA) POWER DISTRIBUTION KYRON 2010.01...
  • Page 1017 03-4 8210-00 5) USAGE OF FUSE IN ENGINE ROOM FUSE BOX 6) ENGINE ROOM FUSE BOX CONNECTOR NUMBER POWER DISTRIBUTION KYRON 2010.01...

  • Page 1018: I/P - Lh Fuse / Relay Box

    03-5 8410-00 I/P - LH FUSE / RELAY BOX 8410-00 1) I/P - LH FUSE / RELAY BOX 2) POWER SUPPLY POWER DISTRIBUTION KYRON 2010.01...

  • Page 1019: I/P - Rh Fuse / Relay Box

    03-6 8410-00 I/P - RH FUSE / RELAY BOX 8410-00 1) I/P - RH FUSE / RELAY BOX POWER DISTRIBUTION KYRON 2010.01...

  • Page 1020: Electricity Divide

    03-7 8210-00 ELECTRICITY DIVIDE ENGINE ROOM FUSE / RELAY BOX CIRCUIT 8210-00 1) SB5, SB6, Ef4, Ef5, Ef11, HORN RELAY, HEAD LAMP RELAY (HI, LO) 2) SB2 ~ SB4, SB7 ~ SB9, Ef3, P/WINDOW RELAY POWER DISTRIBUTION KYRON 2010.01...
  • Page 1021 03-8 8210-00 3) SB10 ~ SB11, CONDENSOR FAN RELAY (HI, LO) 4) SB12 ~ SB16, START RELAY, PTC RELAY POWER DISTRIBUTION KYRON 2010.01...
  • Page 1022 03-9 8210-00 5) Ef1, Ef2, Ef6, Ef7 6) Ef8 ~ Ef10, TAIL LAMP RELAY, FRT FOG LAMP RELAY POWER DISTRIBUTION KYRON 2010.01...
  • Page 1023 03-10 8210-00 7) Ef12 ~ Ef14, ENG MOUNT RELAY, COMPRESSOR RELAY 8) Ef15 ~ Ef23 POWER DISTRIBUTION KYRON 2010.01...
  • Page 1024 03-11 8210-00 9) WIPER MOTOR RELAY (HI, LO), WASHER RELAY (FRT, RR) POWER DISTRIBUTION KYRON 2010.01...

  • Page 1025: I/P - Lh Fuse / Relay Box Circuit

    03-12 8410-00 I/P - LH FUSE / RELAY BOX CIRCUIT 8410-00 1) F24 ~ F28 2) F29 ~ F34 POWER DISTRIBUTION KYRON 2010.01...
  • Page 1026 03-13 8410-00 3) F35 ~ F40, RR WIPER RELAY 4) F41 ~ F48 POWER DISTRIBUTION KYRON 2010.01...
  • Page 1027 03-14 8410-00 5) F49 ~ F51, RR FOG LAMP RELAY 6) F52 ~ F55, BURGLAR HORN RELAY, RR SEAT (LH/RH) WARMER RELAY POWER DISTRIBUTION KYRON 2010.01...
  • Page 1028 03-15 8410-00 7) F56 ~ F57, HDC RELAY, FLASHER UNIT POWER DISTRIBUTION KYRON 2010.01...

  • Page 1029: I/P - Rh Fuse / Relay Box Circuit

    03-16 8410-00 I/P - RH FUSE / RELAY BOX CIRCUIT 8410-00 1) F58 ~ F64, ENG MAIN RELAY 2) F65 ~ F71, SHIFT RELAY (4-A/T) POWER DISTRIBUTION KYRON 2010.01...
  • Page 1030 03-17 8410-00 ’ ’ 3) BLOWER RELAY, INJECTOR RELAY, SNR RELAY 4) FOLD G RELAY, UNFOLD G RELAY POWER DISTRIBUTION KYRON 2010.01...

  • Page 1031: Icm Relay Box Circuit

    03-18 8410-00 ICM RELAY BOX CIRCUIT 8410-00 1) DEICER RELAY, DR LOCK/UNLOCK RELAY 2) HAZARD RELAY, DRL SIGNAL POWER DISTRIBUTION KYRON 2010.01...
  • Page 1033 CIRCUIT 1461-01/2820-01/1491-01/1491-01/8210-01/3110-01/3410-01/4892-01/4620-12/8810-01/8010-01/7410-13/7410-02/7410-04/8510-52/8510-48/8710-02/7830-03/ 8510-05/8610-06/7632-16/7340-03/8310-01/8510-00/8320-01/8410-01/8210-01/8310-10/4810-01/7770-02/7770-10/8910-01/8930-01/8790-01/6810-15/6910-01/6810- CIRCUIT ELECTRIC ENGINE 8810-00 AIR-BAG (CURTAIN AIR-BAG)..1461-00 STARTING / CHARGING....7770-00 INTERIOR LAMP CIRCUIT... 8010-00 CLUSTER........2820-00 PREHEATING CIRCUIT....7770-00 AUTO DIMMING ROOM 7410-00 POWER SEAT - DRIVER 1491-00 ECU (ENGINE CONTROL MIRROR CIRCUIT......(W/ MEMORY)....... UNIT - D20/D27DT EU-IV)....
  • Page 1035 04-3 1461-00 STARTING / CHARGING (1) CONNECTOR INFORMATION 1461-00 5-AT, M/T (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1036 04-4 1461-00 6-A/T, 4-A/T (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1037 04-5 2820-00 PREHEATING CIRCUIT (1) CONNECTOR INFORMATION 2820-00 (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1038 ECU (ENGINE CONTROL UNIT - D20/D27DT EU-IV) ECU (ENGINE CONTRIV) (1) CONNECTOR INFORMATION 1491-00 ENG MAIN RELAY, INTAKE THROTTLE, A/CRUISE SW, VALVE (E-EGR, WASTE GATE, INLET METERING), SENSOR (HFM, PEDAL) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1039 04-7 1491-00 2) SENSOR (FUEL PRESSURE, CAM SHAFT, BOOSTER PRESSURE, (1) CONNECTOR INFORMATION CRANK SHAFT, KNOCK, FUEL TEMP, FUEL FILTER WARNING), PTC RELAY (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1040 INJECTOR, STOP LAMP, IMMOBILIZER, CLUSTER, PREHEATING UNIT, INJECTOR, STOP LAMP, IMMOBILIZER, CLUSTER, PREHEATING UNIT, (1) CONNECTOR INFORMATION SENSOR (EXHAUST GAS TEMP), TRIPPLE PRESSURE SW SENSOR (EXHAUST GAS TEMP), TRIPPLE PRESSURE SW (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1041 04-9 1491-00 ECU (ENGINE CONTROL UNIT - D20/D27DT) (1) CONNECTOR INFORMATION 1491-00 ENG MAIN RELAY, PEDAL SENSOR, HFM SENSOR, VALVE, CRUISE CONTROL SW, ENG MOUNT RELAY (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1042 04-10 1491-00 2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL (1) CONNECTOR INFORMATION PRESSURE, CAM SHAFT, BOOSTER PRESSURE, CRANK SHAFT, KNOCK, COOLANT TEMP., FUEL TEMP.) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1043 04-11 1491-00 3) INJECTOR, CAN LINE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1044 04-12 1490-00 ECU (ENGINE CONTROL UNIT - GSL G32) (1) CONNECTOR INFORMATION 1490-00 IGN COIL, INJECTOR, PEDAL MODULE, THROTTLE SENSOR (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...
  • Page 1045 04-13 1490-00 2) O2 SENSOR, CPS, KNOCK SENSOR, HFM SENSOR, CANISTER PURGE (1) CONNECTOR INFORMATION VALVE (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2010.01...

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