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SSANGYONG KYRON 2007.04 Manual

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Table of Contents

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GENERAL INFORMATION
0000-00
GENERAL INFORMATION
GENERAL INFORMATION
1. HOW TO READ ELECTRICAL WIRING
DIAGRAM...............................................
3

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Summary of Contents for SSANGYONG KYRON 2007.04

  • Page 1 GENERAL INFORMATION 0000-00 GENERAL INFORMATION GENERAL INFORMATION 1. HOW TO READ ELECTRICAL WIRING DIAGRAM..........
  • Page 3 0000-00 GENERAL INFORMATION 2) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT) 1. HOW TO READ ELECTRICAL WIRING DIAGRAM 1) HOW TO READ ELECTRICAL WIRING DIAGRAM Position Explanation - Upper horizontal lines : Power supply lines - Power supply lines : 30, 15, 15A, 15C, 58 - Ef20 or F2 : Fuse Number ·Ef20 : Fuse No #20 in engine room compartment ·F2 : Fuse No #2 in passenger room compartment...
  • Page 4 0000-00 5) WIRING HARNESS COLOR IDENTIFICATION 3) CIRCUIT IDENTIFICATION SYMBOL Identification Symbol Meaning Abbreviation Color Abbreviation Color Connector Brown Sky Blue Diode Green Fuse in engine room fuse & relay box Violet Blue Fuse in passenger room fuse box Pink Yellow Ground White...
  • Page 5 0000-00 7) PART LOCATION ACCORDING TO PART NUMBER 8) ELECTRIC SYMBOLS ▶ Ex.) C 1 0 2 C : Symbol character for connector Symbol Character Description Connector (Connecting part that connects two wiring harness) Diode Ground Splice pack (Joint connector that connects various wiring harness) 1 : Part location number Part number according to locating section Part Numbe...
  • Page 7 CONNECTOR/GROUND 8201-00/8210-00/8210-02/8210-03/8210-09/8210-10/8210-06/8210-07/8210-08 CONNECTOR/GROUND WIRING 8201-00 WIRING HARNESS, COMPONENTS LOCATION..CONNECTOR/GROUND 8210-00 W/H ENGINE ROOM..... 8210-02 W/H MAIN........8210-03 W/H FLOOR........8210-09 W/H ROOF........8210-10 W/H TAIL GATE......8210-06 W/H DRIVER DOOR...... 8210-07 W/H PASSENGER DOOR..... 8210-08 W/H RR DOOR......
  • Page 9 8201-00 WIRING HARNESS WIRING HARNESS, COMPONENTS LOCATION 8201-00 2) COMPONENTS LOCATION 1) WIRING HARNESS CONNECTOR/GROUND KYRON 2007.03...
  • Page 10 8201-00 3) CONNECTOR, GROUND & SPLICE PACK INFORMATION ▶ CONNECTOR CONNECTOR/GROUND KYRON 2007.03...
  • Page 11 8201-00 ▶ GROUND ▶ SPLICE PACK CONNECTOR/GROUND KYRON 2007.03...
  • Page 12 8201-00 4) SPLICE PACK CIRCUIT ▶ S203 (GND) ▶ S101 ▶ S201 ▶ S204 (ILL+) ▶ S202 (CAN) ▶ S205 (GND) CONNECTOR/GROUND KYRON 2007.03...
  • Page 13 8201-00 ▶ S303 ▶ S206 ▶ S301 (CAN) ▶ S302 CONNECTOR/GROUND KYRON 2007.03...
  • Page 14 8201-00 5) CONNECTOR ▶ ▶ WIRNING CONNECTOR WIRNING CONNECTOR ▶ WIRNING CONNECTOR ▶ MODE CONNECTOR CONNECTOR/GROUND KYRON 2007.03...
  • Page 15 8201-00 ▶ UNIT CONNECTOR ▶ SWITCH CONNECTOR ▶ LAMP CONNECTOR ▶ SENSOR CONNECTOR CONNECTOR/GROUND KYRON 2007.03...
  • Page 16 0-10 8201-00 ▶ ETC. CONNECTOR/GROUND KYRON 2007.03...

  • Page 17: Table Of Contents

    POWER DISTRIBUTION 8410-02/8410-04/8401-06 POWER DISTRIBUTION FUSE/RELAY 8410-02 ENGINE ROOM FUSE ＆ RELAY BOX......... 8410-04 I/P - LH FUSE ＆ RELAY BOX..8401-06 I/P - RH FUSE ＆ RELAY BOX..ELECTRICITY DIVIDE 8210-02 ENGINE ROOM FUSE ＆ RELAY BOX CIRCUIT....8410-04 I/P - LH FUSE ＆ RELAY BOX CIRCUIT....

  • Page 19: Fuse/Relay

    8410-02 FUSE ＆ RELAY 8410-02 ENGINE ROOM FUSE ＆ RELAY BOX 1) UPPER 3) ENGINE ROOM FUSE & RELAY BOX 2) LOW POWER DISTRIBUTION KYRON 2007.03...
  • Page 20 8410-02 5) ENGINE ROOM FUSE BOX CONNECTOR NUMBER 4) USAGE OF FUSE IN ENGINE ROOM FUSE BOX POWER DISTRIBUTION KYRON 2007.03...

  • Page 21: 8410-04 I/P - Lh Fuse ＆ Relay Box

    8410-04 8410-04 I/P - LH FUSE ＆ RELAY BOX 1) I/P - LH FUSE & RELAY BOX 2) POWER SUPPLY POWER DISTRIBUTION KYRON 2007.03...

  • Page 22: 8410-04 I/P - Lh Fuse ＆ Relay Box Circuit

    8410-06 8410-06 I/P - RH FUSE ＆ RELAY BOX 1) I/P - RH FUSE & RELAY BOX POWER DISTRIBUTION KYRON 2007.03...
  • Page 23 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 2007.04...
  • Page 24 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 2007.04...
  • Page 25 01-4 6810-20 2. VENTILATION SYSTEM COMPONENTS Locations of Vents ▶ ▶ Air Duct AIR CONDITIONER KYRON 2007.04...
  • Page 26 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 2007.04...
  • Page 27 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 2007.04...
  • Page 28 01-7 6810-15 3) Components AIR CONDITIONER KYRON 2007.04...
  • Page 29 01-8 6810-15 4. PTC HEATER AND FFH HEATER LAYOUT 1) PTC HEATER ASSEMBLY LAYOUT 2) FFH HEATER ASSEMBLY LAYOUT AIR CONDITIONER KYRON 2007.04...
  • Page 30 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 2007.04...
  • Page 31 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 2007.04...
  • Page 32 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 2007.04...
  • Page 33 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 2007.04...
  • Page 34 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 2007.04...
  • Page 35 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 2007.04...
  • Page 36 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 2007.04...
  • Page 37 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 2007.04...
  • Page 38 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 2007.04...
  • Page 39 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 2007.04...
  • Page 40 01-19 6810-15 (2) Exploded View AIR CONDITIONER KYRON 2007.04...
  • Page 41 01-20 6810-15 AIR CONDITIONER KYRON 2007.04...
  • Page 42 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 2007.04...
  • Page 43 01-22 6810-15 (3) SPECIFICATIONS AIR CONDITIONER KYRON 2007.04...
  • Page 44 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 2007.04...
  • Page 45 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 2007.04...
  • Page 46 01-25 6810-15 4) Circuit Diagram AIR CONDITIONER KYRON 2007.04...
  • Page 47 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 2007.04...
  • Page 48 01-27 6810-15 6) Specification - Water Pump 7) Characteristic Curve of Water Pump (12 V) AIR CONDITIONER KYRON 2007.04...
  • Page 49 01-28 6810-15 8) Function Diagram 9) Switching Diagram According to Temperature Changes AIR CONDITIONER KYRON 2007.04...
  • Page 50 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 2007.04...
  • Page 51 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 2007.04...
  • Page 52 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 2007.04...
  • Page 53 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 2007.04...
  • Page 55 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 2007.04...
  • Page 56 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 2007.04...
  • Page 57 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 2007.04...
  • Page 58 02-11 8810-03 AIR BAG KYRON 2007.04...
  • Page 59 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 2007.04...
  • Page 60 (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 2007.04...
  • Page 61 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 2007.04...
  • Page 62 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 2007.04...
  • Page 63 This holds the occupant more securely in the seat. Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side) Belt pretensioner (LH) Belt pretensioner (RH) Curtain air bag G sensor AIR BAG KYRON 2007.04...
  • Page 64 (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 2007.04...
  • Page 65 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 2007.04...
  • Page 66 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 Connector Signal Ground terminal AIR BAG KYRON 2007.04...
  • Page 67 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 2007.04...
  • Page 68 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 2007.04...
  • Page 69 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 2007.04...
  • Page 70 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 2007.04...
  • Page 71 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 2007.04...
  • Page 72 02-25 8810-03 8. AIR BAG ELECTRICAL WIRING DIAGRAM AIR BAG KYRON 2007.04...
  • Page 73 03-3 7410-01 7410 -01 SEAT AND SEAT BELT 1. SEAT OVERVIEW 1)FRONT SEAT (DRIVER'S SEAT) Lumbar support lever Reclining Motor SEAT KYRON 2007.04...
  • Page 74 1) Front Seat (Driver's Seat) Seat cushion up/ down bar (rear) Sliding rail Sliding rail Seat cushion up/ down bar (front) Sliding motor SPWM (Seat Position With Seat Cushion Motor Seat Cushion Motor Memory) Unit (Front) (Rear) SEAT KYRON 2007.04...
  • Page 75 03-5 7410-01 Reclining lever Seat cushion angle adjusting lever (rear) Seat height Seat cushion control switch angle adjusting lever (front) Sliding lever SEAT KYRON 2007.04...
  • Page 76 03-6 7410-01 ▶ Location of Seat Position With Memory Unit (Bottom of Driver Seat) SPWM unit SEAT KYRON 2007.04...
  • Page 77 03-7 7410-01 2) Front Seat (Passenger Seat) Reclining Motor Reclining lever Sliding rail Sliding rail Sliding lever (No seat height control function) Sliding motor SEAT KYRON 2007.04...
  • Page 78 2 Point type seat belt: center seat of second row seat. Pretensioner: Installed at front seats. The seat belt pretensioner rewinds the seat belt immediately to protect occupant's face and chest when a strong frontal collision occurs. SEAT KYRON 2007.04...
  • Page 79 O-ring Pre-tensioner Buckle of 3 point type seat belt Buckle of 2 point type seat belt 2) Seat Belt (2 Point Type) point type seat belt is installed only in the center seat of second row seat. SEAT KYRON 2007.04...
  • Page 80 04-3 7340-01 7340-01 SUNROOF SYSTEM 1. HAZARD (MANUAL) OPERATION The sunroof can be operated by rotating the motor operating hole on the sunroof motor with a proper tool. 1) Circuit Diagram Motor Connector (SCU) SCU Main Connector SUNROOF KYRON 2007.04...
  • Page 81 If the power supply system is in normal conditions, replace the sunroof motor or the sunroof control unit. Replace the sunroof control unit with new one and check if the sunroof operates properly before replacing the sunroof motor. SUNROOF KYRON 2007.04...
  • Page 82 04-5 7340-01 3. TROUBLE DIAGNOSIS SUNROOF KYRON 2007.04...
  • Page 83 04-6 7340-01 1. SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit (SCU) Sunroof Switch Sunroof Assembly SUNROOF KYRON 2007.04...
  • Page 84 Anti-Trap function automatically opens the sunroof when an object is trapped. However, if the force against the sunroof is less than the specified value, Anti-Trap function doesn't operate. Anti-trap function is built in SCU SUNROOF KYRON 2007.04...
  • Page 85 04-8 7340-01 3.SUNROOF CIRCUIT DIAGRAM SUNROOF KYRON 2007.04...
  • Page 86 NO DATA...
  • Page 87 NO DATA...
  • Page 88 0000-00 DIAGNOSIS 1. FFH............
  • Page 90 0000-00 0000-00 1. FFH KYRON 2007.04...
  • Page 91 0000-00 KYRON 2007.04...
  • Page 92 0000-00 KYRON 2007.04...
  • Page 93 0000-00 KYRON 2007.04...
  • Page 94 P/TRUNK 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK..........
  • Page 96 0000-00 0000-00 P/TRUNK 1. P/TRUNK P/TRUNK KYRON 2007.04...
  • Page 97 0000-00 P/TRUNK KYRON 2007.04...
  • Page 98 RAIN SENSOR 0000-00 RAIN SENSOR DIAGNOSIS 1. TROUBLE SHOOTING......
  • Page 100 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 2007.04...
  • Page 101 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 2007.04...
  • Page 102 STICS 0000-00 STICS DIAGNOSIS 1. STICS............
  • Page 104 0000-00 0000-00 STICS 1. STICS STICS KYRON 2007.04...
  • Page 105 0000-00 STICS KYRON 2007.04...
  • Page 106 0000-00 DIAGNOSIS 1. TC............
  • Page 108 0000-00 0000-00 1. TC KYRON 2007.04...
  • Page 109 0000-00 KYRON 2007.04...
  • Page 110 0000-00 KYRON 2007.04...
  • Page 111 0000-00 KYRON 2007.04...
  • Page 112 0000-00 DIAGNOSIS 1. TCU............
  • Page 114 0000-00 0000-00 1. TCU KYRON 2007.04...
  • Page 115 0000-00 KYRON 2007.04...
  • Page 116 0000-00 KYRON 2007.04...
  • Page 117 0000-00 KYRON 2007.04...
  • Page 118 0000-00 KYRON 2007.04...
  • Page 119 0000-00 KYRON 2007.04...
  • Page 120 0000-00 KYRON 2007.04...
  • Page 121 0-10 0000-00 KYRON 2007.04...
  • Page 122 0-11 0000-00 KYRON 2007.04...
  • Page 123 0-12 0000-00 KYRON 2007.04...
  • Page 124 0-13 0000-00 KYRON 2007.04...
  • Page 125 0-14 0000-00 KYRON 2007.04...
  • Page 126 0-15 0000-00 KYRON 2007.04...
  • Page 127 0-16 0000-00 KYRON 2007.04...
  • Page 128 0-17 0000-00 KYRON 2007.04...
  • Page 129 0-18 0000-00 KYRON 2007.04...
  • Page 130 0-19 0000-00 KYRON 2007.04...
  • Page 132 TGS LEVER 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER...........
  • Page 134 0000-00 0000-00 TGS LEVER 1. TGS LEVER TGS LEVER KYRON 2007.04...
  • Page 135 0000-00 TGS LEVER KYRON 2007.04...
  • Page 136 0000-00 TGS LEVER KYRON 2007.04...
  • Page 137 0000-00 TGS LEVER KYRON 2007.04...
  • Page 138 (It is also installed on the connection of the high pressure fuel supply line of the HP pump.) ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 139 Also, the engine ECU, HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely. Fuel high pressure pipe (HP pump → Common rail) ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 141 (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 pressure High pressure sensor fuel pipe ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 142 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) connector ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 143 02-8 1881-09 2. FUEL FLOW OF D20DT (EU-IV) ENGINE ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 144 Also, the improved HFM sensor (from HFM5.0 to HFM6.0) has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased. ENGINE INTAKE SYSTEM KYRON 2007.04...
  • Page 145 03-4 2321-01 2. INTAKE SYSTEM LAYOUT Uncompressed air Compressed air VGT Turbo Chargera Air cleaner Ambient air HFM Sensor (ver. 6.0) Temperature sensor Turbo coeaner charger Pretension graph ENGINE INTAKE SYSTEM KYRON 2007.04...
  • Page 146 To corresponding Coolant Supply power cylinders Ground port Output voltage Compress ed air EGR gas Throttle body Normal: flap open Engine stopped: flap closed Intake duct Intake duct Intercooler Intake manifold Turbo charger (Throttle body) ENGINE INTAKE SYSTEM KYRON 2007.04...
  • Page 147 Intake manifold Turbocharger intercooler (Intake compressed air) EGR gas (From EGR cooler) Exhaust manifold Throttle bod Turbocharger EGR pipe EGR pipe E-EGR valve EGR cooler Coolant E-EGR valve To EGR cooler Intake manifold Exhaust manifold ENGINE EXHAUST SYSTEM KYRON 2007.04...
  • Page 148 Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/closes due to pressure differences between the intake side and crankcase. ENGINE LUBRICATION SYSTEM KYRON 2007.04...
  • Page 149 If too much oil or particulate material is accumulated, check the followings: 1. Engine oil level 2. EGR valve (exhaust gas leak and operating condition) 3. Turbocharger (oil/gas leak and operating condition) 4. PCV oil separator (installation condition and leak) 5. PCV oil separator (some functions) ENGINE LUBRICATION SYSTEM KYRON 2007.04...
  • Page 150 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 151 06-2 2112-00 ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 152 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. 1) Cooling System for Engine ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 153 The capacity of water pump has been increased due to the EGR cooler, increased engine power and additional coolant port in the cylinder block. For D20DT (EURO4) engine For D20DT engine Port to EGR cooler ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 154 06-5 1520-00 1) Structure of Water Pump for D20DT Engine ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 156 The glow control relay (K-line communication with engine ECU) is deleted. The unit communicates via CAN communication with engine ECU. Also, the number of pins is increased as glow plug's performance has been improved (1000 C increase in approx. 2 ° seconds). ENGINE ELECTRICAL SYSTEM KYRON 2007.04...
  • Page 157 07-4 1491-01 2. D20DT (EU-IV)) ENGINE'S ECU CIRCUIT ENGINE ELECTRICAL SYSTEM KYRON 2007.04...
  • Page 158 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 2007.04...
  • Page 159 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 2007.04...
  • Page 160 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 161 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 2007.04...
  • Page 162 (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 2007.04...
  • Page 163 (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 2007.04...
  • Page 164 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 2007.04...
  • Page 165 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 166 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 168: Engine Assembly Layout

    01-3 0000-00 0000-00 ENGINE GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH Side View D20DT D27DT ENGINE D20DT KYRON 2007.04...
  • Page 169 01-4 0000-00 2) RH side view D20DT D27DT ENGINE D20DT KYRON 2007.04...
  • Page 170 01-5 0000-00 3) Front view D20DT D27DT ENGINE D20DT KYRON 2007.04...
  • Page 171 01-6 0000-00 4) Fan belt D20DT D27DT ENGINE D20DT KYRON 2007.04...

  • Page 172: Components In D20Dt Engine And D27Dt Engine

    01-7 0000-00 2. COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ENGINE D20DT KYRON 2007.04...
  • Page 173 01-8 0000-00 ENGINE D20DT KYRON 2007.04...
  • Page 174 01-9 0000-00 ENGINE D20DT KYRON 2007.04...
  • Page 175 01-10 0000-00 ENGINE D20DT KYRON 2007.04...

  • Page 176: Engine Controls Layout

    01-11 0000-00 3. ENGINE CONTROLS LAYOUT 1) Ecu related componets (1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 177 01-12 0000-00 (2) D27DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 178 01-13 0000-00 2) ENGINE AND SENSORS (1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 179 01-14 0000-00 (2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 180: Electrical Components And Preheating System

    01-15 0000-00 4. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 181 01-16 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 182: Intake System Layout

    01-17 0000-00 5. INTAKE SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 183 01-18 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 184: Exhaust System Layout

    01-19 0000-00 6. EXHAUST SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 185 01-20 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 186: Lubrication System Layout

    01-21 0000-00 7. LUBRICATION SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 187 01-22 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 188: Cooling System Layout

    01-23 0000-00 8. COOLING SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 189 01-24 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 190: Fuel System Layout

    01-25 0000-00 9. FUEL SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2007.04...
  • Page 191 01-26 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 192: Fuel Supply System

    Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE D20DT KYRON 2007.04...
  • Page 193 01-28 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2007.04...

  • Page 194: Cleanness

    The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. ENGINE D20DT KYRON 2007.04...
  • Page 195 At this point, thoroughly clean the related area in engine compartment. - Clean the engine compartment before starting service works. Tool kit for Took kit for low Removal tool box and high pressure line pressure line cap kits ENGINE D20DT KYRON 2007.04...
  • Page 196 If not, the injection point may be deviated from correct position, and it may cause engine disorder. Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components. ENGINE D20DT KYRON 2007.04...
  • Page 197 Do not crank engine before having filled pump. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. With SCAN-100, check if there are current faults and erase the history faults. ENGINE D20DT KYRON 2007.04...
  • Page 198 Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.) ENGINE D20DT KYRON 2007.04...

  • Page 200: Maintenance And Repair

    Using oils of any viscosity other than those viscosities recommended could result in engine damage. ▷ Cooling System Service Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section. ENGINE D20DT KYRON 2007.04...
  • Page 201 To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type) ENGINE D20DT KYRON 2007.04...

  • Page 202: Guidelines For Service Work Safety

    Notice means precautions on tool/device or part damages or personal injuries that can occur during service works. However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses. ENGINE D20DT KYRON 2007.04...
  • Page 203 LOCK position before work. Be careful not to touch hot components like catalytic converter, muffler and exhaust · pipe when the engine is running or just stopped. They may burn you badly. ENGINE D20DT KYRON 2007.04...
  • Page 204 While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. During service work of removal/installation, be sure to check each connected portions to engine not to make interference. ENGINE D20DT KYRON 2007.04...
  • Page 205 When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury. ENGINE D20DT KYRON 2007.04...

  • Page 206: During Service Work For Inspection

    Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work. Use recommended and specified tools to increase efficiency of service work. Use only genuine spare parts. ENGINE D20DT KYRON 2007.04...
  • Page 207 (Refer to cleanness.) If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new. ENGINE D20DT KYRON 2007.04...

  • Page 208: During Service Work For Electric Devices

    If lift up the vehicle with safety jack and stand, should be more careful during works. Never be under the vehicle if supported with only jack. If have to be under the vehicle, be sure to use safety block. Use wheel block in front and rear of every wheel. ENGINE D20DT KYRON 2007.04...

  • Page 209: Owner Inspections And Services

    ▶ Headlamp Aim Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed. ENGINE D20DT KYRON 2007.04...
  • Page 210 Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once. ENGINE D20DT KYRON 2007.04...
  • Page 211 ▶ Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly. ENGINE D20DT KYRON 2007.04...
  • Page 212 Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation. ENGINE D20DT KYRON 2007.04...

  • Page 213: Standard Bolts Specifications

    01-48 0000-00 17. STANDARD BOLTS SPECIFICATIONS *Diameter X pitch in millimeters ENGINE D20DT KYRON 2007.04...
  • Page 214 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. ENGINE D20DT KYRON 2007.04...
  • Page 216 It satisfies the strict emission regulation and provides improved output and maximum torque. 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 KYRON 2007.04...
  • Page 217 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 KYRON 2007.04...
  • Page 218 TVD (Torsional Vibration Damper) D27DT 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 ENGINE D20DT KYRON 2007.04...
  • Page 219 Cylinder head cover D27DT 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 ENGINE D20DT KYRON 2007.04...
  • Page 220 36. Oil dipstick 37. Exhaust manifold 29. Cylinder head D27DT 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 ENGINE D20DT KYRON 2007.04...
  • Page 221 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. EGR valve (Black) ENGINE D20DT KYRON 2007.04...
  • Page 222 02-9 1114-01 3. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE D20DT KYRON 2007.04...
  • Page 223 02-10 1114-01 2) Engine Performance Curve (1) Vehicle with A/T Output and Torque ▶ D20DT engine D27DT engine ENGINE D20DT KYRON 2007.04...
  • Page 224 02-11 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT KYRON 2007.04...
  • Page 225 02-12 1114-01 (2) Vehicle with M/T ▶ Output and Torque D20DT engine D27DT engine ENGINE D20DT KYRON 2007.04...
  • Page 226 02-13 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT KYRON 2007.04...
  • Page 227 02-14 1114-01 4. TIGHTENING TORQUE ENGINE D20DT KYRON 2007.04...
  • Page 228 02-15 1114-01 ENGINE D20DT KYRON 2007.04...
  • Page 229 02-16 1114-01 ENGINE D20DT KYRON 2007.04...
  • Page 230 5) Conditions for Using Priming Pump After run out of fuel After draining the water from fuel separator After replacing the fuel filter ENGINE D20DT KYRON 2007.04...
  • Page 231 When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes rigid before starting the engine. The water drain from fuel filter should be performed whenever changing the engine oil. ENGINE D20DT KYRON 2007.04...
  • Page 232 Start the engine and check the conditions. If the priming pump is not properly operated, air may get into the fuel line. It may cause starting problem or fuel system problem. Make sure to perform the job in step 4. ENGINE D20DT KYRON 2007.04...
  • Page 233 Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE D20DT KYRON 2007.04...
  • Page 234 ECU control section. Fuel Line System D20DT High pressure pipe Common rail Fuel pressure sensor Injector D20DT: 4 EA D27DT: 5 EA Priming pump Fuel filter Fuel pump (High pressure pump, transfer pump) Fuel route ENGINE D20DT KYRON 2007.04...
  • Page 235 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) ENGINE D20DT KYRON 2007.04...
  • Page 236 After run out of fuel After draining the water from fuel separator After replacing the fuel filter Press the priming pump until it becomes rigid before starting the engine. ENGINE D20DT KYRON 2007.04...
  • Page 237 Fuel filter purifies fuel before it reaches to high pressure pump help proper operations in high pressure pump. And more, it separates water from fuel to prevent water from getting into FIE system (high pressure line). ENGINE D20DT KYRON 2007.04...
  • Page 238 Fuel pressure is measured by rail pressure sensor. And the fuel pressure regulating valve (IMV, Inlet Metering Valve) included in high D27DT pressure pump housing keeps pressure to a desired level. ENGINE D20DT KYRON 2007.04...
  • Page 239 The transfer pump is included in the housing of the high pressure pump. The transfer pump is the volumetric blade type pump. To deliver continuously required fuel volume, the pump transfers fuel from the fuel tank to high pressure pump. ENGINE D20DT KYRON 2007.04...
  • Page 240 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 KYRON 2007.04...
  • Page 241 03-14 1881-01 7) Circuit Diagram ENGINE D20DT KYRON 2007.04...
  • Page 242 03-15 1881-01 ENGINE D20DT KYRON 2007.04...
  • Page 243 03-16 1881-01 ENGINE D20DT KYRON 2007.04...
  • Page 244 ­ If the vehicle is operated under severe condition (short distance driving, extensive ldling or driving in dusty condition): More frequent maintenance is required. 2) Special Tools and Equipment Special Tools and Equipment Application Y99220112B Installation of intake manifold Intake manifold guide pin ENGINE D20DT KYRON 2007.04...
  • Page 245 04-4 2321-01 1. ENGINE INTAKE COMPONENTS LOCATOR 1) D20DT Engine Air Cleaner Intake Manifold Cover Housing Elemen HFM Sensor Intercooler ENGINE D20DT KYRON 2007.04...
  • Page 246 04-5 2321-01 2) D27DT Engine Air Cleaner Intake Manifold Cover Element Housing HFM Sensor Intercooler ENGINE D20DT KYRON 2007.04...
  • Page 247 04-6 2321-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE D20DT KYRON 2007.04...
  • Page 248 The DI engine ECU receives feedback signal of change in amount of air being passed through the HFM sensor according to the opening amount of the EGR valve. ENGINE D20DT KYRON 2007.04...
  • Page 249 05-4 1913-01 D20DT D27DT HUBER EGR System for IDI Engine EGR System for DI Engine (Including the EGR Valve Potentiometer) ENGINE D20DT KYRON 2007.04...
  • Page 250 05-5 1913-01 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 KYRON 2007.04...
  • Page 251 05-6 1913-01 Exhaust Manifold EGR Valve Muffler Catalytic Converter Vacuum Modulator Turbo Charger EGR Pipe (DOC) ENGINE D20DT KYRON 2007.04...
  • Page 252 05-7 1913-01 2. EXHAUST GAS FLOWS ENGINE D20DT KYRON 2007.04...
  • Page 253 3. When operating in dusty, sandy and salty areas 4. In hilly or moutainous terrain 5. When doing frequent trailer towing ▶Oil Pressure Switch 1. Operating temperature: -40 ~ 140° 2. Operating pressure: 0.3 ~ 0.55 bar 3. Permissible pressure: 10 bar ENGINE D20DT KYRON 2007.04...
  • Page 254 06-4 1533-01 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 KYRON 2007.04...
  • Page 255 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 KYRON 2007.04...
  • Page 256 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 KYRON 2007.04...
  • Page 257 ※ 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 KYRON 2007.04...
  • Page 258 07-3 9210-05 9210-05 ENGINE COOLING SYSTEM 1. ENGINE COOLING SPECIFICATIONS ENGINE D20DT KYRON 2007.04...
  • Page 259 07-4 9210-05 1. COMPONENTS ENGINE COOLING 1) D20DT Engine Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor ENGINE D20DT KYRON 2007.04...
  • Page 260 07-5 9210-05 2) D27DT Engine Coolant Coolant Reservoir Temperature Sensor Radiator Water Pump Cooling Fan ENGINE D20DT KYRON 2007.04...
  • Page 261 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 KYRON 2007.04...
  • Page 262 It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5. In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to water pump with an additional pulley. ENGINE D20DT KYRON 2007.04...
  • Page 263 08-3 1461-01 1461-01 ENGINE ELECTRIC SYSTEM 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE D20DT KYRON 2007.04...
  • Page 264 08-4 1461-01 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 KYRON 2007.04...
  • Page 265 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 KYRON 2007.04...
  • Page 266 08-6 1461-01 2. COMPONENTS OF ELECTRIC DEVICES IN ENGIN 1) D20DT ENGINE Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE D20DT KYRON 2007.04...
  • Page 267 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 KYRON 2007.04...
  • Page 268 08-8 1461-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM ENGINE D20DT KYRON 2007.04...
  • Page 269 08-9 1461-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ENGINE D20DT KYRON 2007.04...
  • Page 270 1491-01 EGINE CONTROL SYSTEM 1. ENGINE ECU AND OTHER COMPONENTS 1) D20DT Engine ECU/Barometric Camshaft Position Fuel Filter Accelerator Pedal Sensor Sensor (Water Sensor) Sensor HFM Sensor / Intake Air Preheating Relay Main Relay Temperature Sensor ENGINE D20DT KYRON 2007.04...
  • Page 271 09-4 1491-01 2) D20DT Engine ECU/Barometric Camshaft Position Fuel Filter Accelerator Pedal Sensor Sensor (Water Sensor) Sensor HFM Sensor / Intake Air Preheating Relay Main Relay Temperature Sensor ENGINE D20DT KYRON 2007.04...
  • Page 272 09-5 1491-01 3) TOP VIEW (1) D20DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE D20DT KYRON 2007.04...
  • Page 273 09-6 1491-01 (2) D27DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors (5 EA) Glow Plugs (5) ENGINE D20DT KYRON 2007.04...
  • Page 274 09-7 1491-01 4) SIDE VIEW (1) D20DT Engine Coolant Temperature Knock Sensors (1 EA) Sensor Fuel Temperature Fuel Pressure Crankshaft Position Sensor Regulating Valve Sensor ENGINE D20DT KYRON 2007.04...
  • Page 275 09-8 1491-01 (2) D27DT Engine Coolant Temperature Knock Sensors (2 EA) Sensor Fuel Temperature Fuel Pressure Crankshaft Position Sensor Regulating Valve Sensor ENGINE D20DT KYRON 2007.04...
  • Page 276 (Water warning light, glow Accelerator sensor plug Vehicle speed sensor indicator light, engine warning Switch input signal light) (IG, brake, clutch, A/C signal, Preheater (auxiliary heater) A/C compressor) K - line CAN communication Self-diagnosis ENGINE D20DT KYRON 2007.04...
  • Page 277 Driving mode control If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm and the drive map will be used to match the drivers inputs with optimum engine power. ENGINE D20DT KYRON 2007.04...
  • Page 278 If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is increased. If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is reduced. ENGINE D20DT KYRON 2007.04...
  • Page 279 To do this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the water temperature. This requirement only concerns the starting phase, since once the engine has started the system must re-use the mapping and the corrections described previously. ENGINE D20DT KYRON 2007.04...
  • Page 280 This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude. During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant temperature. ENGINE D20DT KYRON 2007.04...
  • Page 281 The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed during transient conditions. This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined before each injection as a function of the instantaneous engine speed. ENGINE D20DT KYRON 2007.04...
  • Page 282 A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand. ENGINE D20DT KYRON 2007.04...
  • Page 283 The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver demand is then corrected according to the coolant temperature. This correction is added to the driver demand. ENGINE D20DT KYRON 2007.04...
  • Page 284 A correction depending on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool. ENGINE D20DT KYRON 2007.04...
  • Page 285 The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system. ENGINE D20DT KYRON 2007.04...
  • Page 286 The first MDP value is provided by the C2I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector. ENGINE D20DT KYRON 2007.04...
  • Page 287 The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. ENGINE D20DT KYRON 2007.04...
  • Page 288 The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of the injector. So, the pulse should be corrected according to characteristics of each injector. ENGINE D20DT KYRON 2007.04...
  • Page 289 When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when the accelerator pedal is depressed. C2I Number value (16 digits) For coding of C2I, refer to "Diagnosis" section ※ ENGINE D20DT KYRON 2007.04...
  • Page 290 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors. 1) Learning Conditions 2) Trouble Codes ENGINE D20DT KYRON 2007.04...
  • Page 292 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. ENGINE D20DT KYRON 2007.04...
  • Page 293 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. ENGINE D20DT KYRON 2007.04...
  • Page 294 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration ENGINE D20DT KYRON 2007.04...
  • Page 295 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. ENGINE D20DT KYRON 2007.04...
  • Page 296 (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. ENGINE D20DT KYRON 2007.04...
  • Page 297 (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. ENGINE D20DT KYRON 2007.04...
  • Page 298 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. ENGINE D20DT KYRON 2007.04...
  • Page 299 Ensure that the braking distance is maintained and use the brake pedal if needed. ENGINE D20DT KYRON 2007.04...
  • Page 300 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 302: Structure And Comparison

    01-3 0000-00 0000-00 ENGINE GENERAL 1. STRUCTURE AND COMPARISON ▶D27DT (EU IV) Engine - Front View ▶D27DT (EU IV) Engine - Top View ENGINE GENERAL KYRON 2007.04...
  • Page 303 01-4 0000-00 ▶D27DT (EU IV) Engine - Side View ▶D27DT (EU IV) Engine - Left Side View ENGINE GENERAL KYRON 2007.04...
  • Page 304 01-5 0000-00 ▶D27DT Engine (General) - Front View ▶D27DT Engine (General) - Top View ENGINE GENERAL KYRON 2007.04...
  • Page 305 01-6 0000-00 ▶D27DT Engine (General) - Side View ▶D27DT Engine (General) - Left Side View ENGINE GENERAL KYRON 2007.04...

  • Page 306: Engine Specifications And Performance Curve

    01-7 0000-00 2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE GENERAL KYRON 2007.04...
  • Page 307 01-8 0000-00 2) D27DT Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE GENERAL KYRON 2007.04...

  • Page 308: 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 KYRON 2007.04...
  • Page 309 01-10 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 310 01-11 0000-00 ENGINE GENERAL KYRON 2007.04...

  • Page 311: Major Changes In D27Dtp(Power Up) Engine(Compared To D27Dt)

    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 KYRON 2007.04...
  • Page 312 01-13 0000-00 2) Major Changes and Summary ENGINE GENERAL KYRON 2007.04...
  • Page 313 01-14 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 314 01-15 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 315 01-16 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 316 01-17 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 317 01-18 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 318 01-19 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 319 01-20 0000-00 ENGINE GENERAL KYRON 2007.04...

  • Page 320: Engine Compartment

    01-21 0000-00 1. ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows: ENGINE GENERAL KYRON 2007.04...
  • Page 321 01-22 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 322 Washer fluid filler cap Air cleaner housing Engine compartment fuse box 2Coolant surge tank PTC relay box ABS/ESP HECU (Including TPMS function: Battery optional) Vacuum modulator (for VGT turbo charger) Exhaust gas FRT Temp. sensor (T3) ENGINE GENERAL KYRON 2007.04...
  • Page 323 01-24 0000-00 ▶Major Sensors and Components ENGINE GENERAL KYRON 2007.04...

  • Page 324: System In Engine Compartment

    01-25 0000-00 2. SYSTEMS IN ENGINE COMPARTMENT 1) Engine Accessories Related to ECU ENGINE GENERAL KYRON 2007.04...
  • Page 325 01-26 0000-00 ENGINE GENERAL KYRON 2007.04...
  • Page 326 01-27 0000-00 2) Preheat System ENGINE GENERAL KYRON 2007.04...
  • Page 327 01-28 0000-00 3) Fuel System ENGINE GENERAL KYRON 2007.04...
  • Page 328 01-29 0000-00 ▶Fuel Supply System ENGINE GENERAL KYRON 2007.04...
  • Page 329 01-30 0000-00 4) Lubrication System ENGINE GENERAL KYRON 2007.04...
  • Page 330 01-31 0000-00 5) Cooling System ENGINE GENERAL KYRON 2007.04...
  • Page 331 01-32 0000-00 6) Intake System ENGINE GENERAL KYRON 2007.04...
  • Page 332 01-33 0000-00 7) Exhaust System ENGINE GENERAL KYRON 2007.04...
  • Page 333 D27DT injector to lift the nozzle) is leaned only when the engine is running. However, for the D27DTP engine, it is learned when the vehicle is in motion and the engine is at idle speed. ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 334 (It is also installed on the connection of the high pressure fuel supply line of the HP pump.) D27DT ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 335 * Fuel high pressure pipe (HP pump → 　 Common rail) D27DT * Fuel pipe (Common rail → Injector) * Fuel high pressure pipe (HP pump → Common rail) ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 336 02-6 1881-09 2. COMPONENTS OF FUEL SYSTEM ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 337 02-7 1881-09 ▶Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 338 Also, the improved HFM sensor (from HFM5.0 to HFM6.0) has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased. ENGINE INTAKE SYSTEM KYRON 2007.04...
  • Page 339 The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power. For more details, refer to the next description. The exhaust system for D27DTP (POWER UP) engine is as follows: ENGINE EXHAUST SYSTEM KYRON 2007.04...
  • Page 340 NO DATA...
  • Page 341 For the D27DT engine, the cooling system uses the fan clutch. ▶Cooling System for D27DTP (POWER UP) Engine ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 342 06-4 1520-01 ▶Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 343 NO DATA...
  • Page 344 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 2007.04...
  • Page 345 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 2007.04...
  • Page 346 08-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 347 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 2007.04...
  • Page 348 (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 2007.04...
  • Page 349 (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 2007.04...
  • Page 350 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 2007.04...
  • Page 351 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 352 NO DATA...
  • Page 353 ENGINE INFORMATION 0000-00 ENGINE INFORMATION GENERAL) 1. COMPONENT LOCATOR....... 2. DESCRIPTION AND OPERATION..
  • Page 356 01-4 0000-00 0000-00 ENGINE GENERAL 1. COMPONENT LOCATOR 1) Front View ENGINE INFORMATION KYRON 2007.04...
  • Page 357 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 2007.04...
  • Page 358 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 2007.04...
  • Page 359 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 2007.04...
  • Page 361 02-3 1113-01 1113-01 ENGINE ASSEMBLY 1. SPECIFICATIONS 1) ENGINE SPECIFICATIONS ENGINE ASSEMBLY KYRON 2007.04...
  • Page 362 02-4 1113-01 2) PERFORMANCE CURVE ENGINE ASSEMBLY KYRON 2007.04...
  • Page 363 02-5 1113-01 2. SPECIAL TOOLS AND EQUIPMENT ENGINE ASSEMBLY KYRON 2007.04...
  • Page 364 02-6 1113-01 ENGINE ASSEMBLY KYRON 2007.04...
  • Page 365 02-7 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin ENGINE ASSEMBLY KYRON 2007.04...
  • Page 366 02-8 1113-01 3. FASTENER TIGHTENING SPECIFICATIONS ENGINE ASSEMBLY KYRON 2007.04...
  • Page 367 02-9 1113-01 4. FASTENER TIGHTENING SPECIFICATIONS (CONT'D) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 368 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 2007.04...
  • Page 369 03-4 2211-22 ▶ temperature vs resistance ENGINE FUEL SYSTEM KYRON 2007.04...
  • Page 370 NO DATA...
  • Page 371 (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 2007.04...
  • Page 372 05-4 2420-01 4. FASTENER TIGHTENING SPECIFICATIONS ENGINE EXHAUST SYSTEM KYRON 2007.04...
  • Page 373 06-3 9210-01 9210-01 ENGINE LUBRICATION SYSTEM 1. OIL CIRCULATION LUBRICATION SYSTEM KYRON 2007.04...
  • Page 374 (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 2007.04...
  • Page 375 07-3 2110-01 2110-01 ENGINE COOLING SYSTEM 1. GENERAL SPECIFICATIONS COOLING SYSTEM KYRON 2007.04...
  • Page 376 07-4 2110-01 2. SPECIAL TOOLS AND EQUIPMENT COOLING SYSTEM KYRON 2007.04...
  • Page 377 07-5 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS COOLING SYSTEM KYRON 2007.04...
  • Page 378 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 2007.04...
  • Page 379 07-7 2110-01 2. COMPONENT LOCATOR COOLING SYSTEM KYRON 2007.04...
  • Page 380 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 2007.04...
  • Page 381 08-3 1452-01 1452-01 ENGINE ELECTRIC DEVICES 1. GENERAL SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2007.04...
  • Page 382 08-4 1452-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2007.04...
  • Page 383 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 2007.04...
  • Page 384 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 2007.04...
  • Page 385 08-7 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT ENGINE ELECTRIC DEVICES KYRON 2007.04...
  • Page 386 09-3 1522-16 1522-16 ENGINE CONTROL SYSTEM 1. ENGINE DATA DISPLAY TABLE ENGINE CONTROL SYSTEM KYRON 2007.04...
  • Page 387 09-4 1522-16 1) TEMPERATURE VS RESISTANCE 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE CONTROL SYSTEM KYRON 2007.04...
  • Page 388 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 2007.04...
  • Page 389 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 2007.04...
  • Page 390 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 391 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 2007.04...
  • Page 392 (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 2007.04...
  • Page 393 (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 2007.04...
  • Page 394 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 2007.04...
  • Page 395 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 396 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 2007.04...
  • Page 397 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 2007.04...
  • Page 398 01-5 1113-01 2. G23D ENGINE ASSEMBLY Front View Rear View ENGINE ASSEMBLY KYRON 2007.04...
  • Page 399 01-6 1113-01 LH Side View RH Side View ENGINE ASSEMBLY KYRON 2007.04...
  • Page 400 01-7 1113-01 3. G23D ENGINE STRUCTURE Front View Side View ENGINE ASSEMBLY KYRON 2007.04...
  • Page 401 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 2007.04...
  • Page 402 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 2007.04...
  • Page 403 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 2007.04...
  • Page 404 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 2007.04...
  • Page 405 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 2007.04...
  • Page 406 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 2007.04...
  • Page 407 01-14 1113-01 5. GENERAL DIAGNOSIS ENGINE ASSEMBLY KYRON 2007.04...
  • Page 408 01-15 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 409 01-16 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 410 01-17 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 411 01-18 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 412 01-19 1113-01 6. SPECIFICATIONS 1) Engine Specifications MSE : Engine Control Module 3.53D : 4 Cylinder Version ENGINE ASSEMBLY KYRON 2007.04...
  • Page 413 01-20 1113-01 2) Fastener Tightening Specifications ENGINE ASSEMBLY KYRON 2007.04...
  • Page 414 01-21 1113-01 ▶ Fastener Tightening Specifications (Cont'd) ENGINE ASSEMBLY KYRON 2007.04...
  • Page 415 01-22 1113-01 2) Performance Curve ENGINE ASSEMBLY KYRON 2007.04...
  • Page 417 02-3 1713-08 1713-08 ENGINE INTAKE SYSTEM 1. SPECIFICATIONS (1) Fastener Tightening Specifications ENGINE INTAKE SYSTEM KYRON 2007.04...
  • Page 418 03-3 2420-01 2420-01 ENGINE EXHAUST SYSTEM 1. SPECIFICATION (1) Fastener Tightening Specifications ENGINE EXHAUST SYSTEM KYRON 2007.04...
  • Page 419 000~500,000ft3. (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 2007.04...
  • Page 420 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 2007.04...
  • Page 421 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 2007.04...
  • Page 422 04-3 2110-01 2110-01 ENGINE COOLING SYSTEM 1. GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 423 04-4 2110-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE COOLING SYSTEM KYRON 2007.04...
  • Page 424 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 2007.04...
  • Page 425 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 2007.04...
  • Page 426 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 2007.04...
  • Page 427 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 2007.04...
  • Page 428 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 2007.04...
  • Page 429 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 2007.04...
  • Page 430 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 2007.04...
  • Page 431 05-3 1452-01 1452-01 ENGINE ELECTRIC DEVICES 1. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Ignition System ENGINE ELECTRICAL SYSTEM KYRON 2007.04...
  • Page 432 05-4 1452-01 2) Ignition System (Cont'd) ENGINE ELECTRICAL SYSTEM KYRON 2007.04...
  • Page 433 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 2007.04...
  • Page 434 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 2007.04...
  • Page 435 (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 2007.04...
  • Page 436 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 2007.04...
  • Page 437 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 2007.04...
  • Page 438 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 2007.04...
  • Page 439 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 2007.04...
  • Page 440 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 2007.04...
  • Page 441 06-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 442 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 2007.04...
  • Page 443 (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 2007.04...
  • Page 444 (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 2007.04...
  • Page 445 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 2007.04...
  • Page 446 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2007.04...
  • Page 447 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..........6.

  • Page 448: Locations Of Interior Units And Sensors

    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 2007.04...
  • Page 449 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 2007.04...

  • Page 450: 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 2007.04...
  • Page 451 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 2007.04...

  • Page 452: 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 2007.04...
  • Page 453 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 2007.04...

  • Page 454: 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 2007.04...
  • Page 455 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 2007.04...

  • Page 456: Electric Components And Layout

    01-10 0000-00 5. ELECTRIC COMPONENTS AND LAYOUT ▶ Wiring Harness Arrangement ELECTRIC SYSTEM KYRON 2007.04...
  • Page 457 01-11 0000-00 ▶ Components Locator ELECTRIC SYSTEM KYRON 2007.04...

  • Page 458: Fuse And Relay

    The designation and capacity of relays and fuses are shown on the fuse and relay box cover. ▶ Location of Fuses and Relays Engine compartment Instrument panel Fuse and relay box (LH) Fuse and relay box (RH) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 459 The labels on the fuse box indicate only major circuits connected. Therefore, some system may not be shown on the labels. For details about the fuse and relay connection, refer to "Power distribution diagram" in this section. ELECTRIC SYSTEM KYRON 2007.04...
  • Page 460 01-14 0000-00 Designation and capacity for fuses and relays in instrument panel ▶ Fuse and relay box (driver side) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 461 01-15 0000-00 Fuse and relay box (passenger side) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 462 01-16 0000-00 POWER DISTRIBUTION DIAGRAM Fuse and relay box in engine compartment ▶ Fuse and Relay Box in Engine Compartment I ELECTRIC SYSTEM KYRON 2007.04...
  • Page 463 01-17 0000-00 Fuse and relay box in engine compartment II ELECTRIC SYSTEM KYRON 2007.04...
  • Page 464 01-18 0000-00 Fuse and relay box in engine compartment III ELECTRIC SYSTEM KYRON 2007.04...
  • Page 465 01-19 0000-00 Interior fuse and relay box (driver side) ▶ Interior fuse and relay box (driver side) I ELECTRIC SYSTEM KYRON 2007.04...
  • Page 466 01-20 0000-00 Interior fuse and relay box (driver side) II ELECTRIC SYSTEM KYRON 2007.04...
  • Page 467 01-21 0000-00 Interior fuse and relay box (driver side) III ELECTRIC SYSTEM KYRON 2007.04...
  • Page 468 01-22 0000-00 Interior fuse and relay (passenger side) ▶ Interior fuse and relay (passenger side) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 469 Battery Open the box cover and unscrew box mounting nuts. Lift up the ruse and relay box assembly and disconnect the connector from behind the box. Then, remove the fuse and relay box assembly. ELECTRIC SYSTEM KYRON 2007.04...

  • Page 470: Fuse And Relay (G23D)

    The designation and capacity of relays and fuses is shown on the fuse and relay box cover. ▶ Engine Room (G23D) ▶ Interior (G23D) Fuse and relay box (LH) Fuse and relay box (RH) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 471 01-25 0000-00 2) DESIGNATION AND CAPACITY OF FUSES AND RELAYS IN ENGINE COMPARTMENT ELECTRIC SYSTEM KYRON 2007.04...
  • Page 472 01-26 0000-00 3) DESIGNATION AND CAPACITY OF INTERIOR FUSES AND RELAYS ▶ Fuse and Relay (G23D) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 473 01-27 0000-00 ▶ Fuse and Relay (RH)(G23D) ELECTRIC SYSTEM KYRON 2007.04...

  • Page 474: Interior Fuse Box

    01-28 0000-00 8. INTERIOR FUSE BOX Fuse and Relay Box (LH) Fuse and Relay Box (RH) ELECTRIC SYSTEM KYRON 2007.04...
  • Page 475 01-29 0000-00 1) Designation and Capacity Driver Side ▶ ELECTRIC SYSTEM KYRON 2007.04...
  • Page 476 01-30 0000-00 ▶ Passenger Side ELECTRIC SYSTEM KYRON 2007.04...
  • Page 477 1) Connection Between Scan-100 and Diagnostic Connector Scan-100 Diagnostic connector Additional cable for CAN module CAN module Connection of Scan-100 Additional Devices of Scan-100 (Including CAN Module and (Diagnosis: EAS, EPB Only) Additional Cable) CAN module CAN module connecting cable ELECTRIC SYSTEM KYRON 2007.04...
  • Page 478 01-32 0000-00 2) Pin Arrangement of Diagnostic Connector It is installed under the instrument panel and consists of 16 pins. The REKES key coding should be performed with Scan-100. 3) Functions of Terminal ELECTRIC SYSTEM KYRON 2007.04...
  • Page 479 01-33 0000-00 4) ELECTRICAL WIRING DIAGRAMS ELECTRIC SYSTEM KYRON 2007.04...
  • Page 481 (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 2007.04...
  • Page 482 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 2007.04...
  • Page 483 02-5 8710-01 ▶ Rated Load STICS KYRON 2007.04...
  • Page 484 02-6 8710-01 ▶ Input Signals STICS KYRON 2007.04...
  • Page 485 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 2007.04...
  • Page 487 ECU. Refer to the informationthat follows for specific functions and their descriptions. IMMO KYRON 2007.04...
  • Page 488 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 2007.04...
  • Page 490 (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 2007.04...
  • Page 491 1. SEAT POSITION WITH MEMORY COMPONENTS LH outside SPWM Unit rearviewmirror RH outside rearviewmirror Seat Position With Memory COMPONENTS Seat memory switch Outside rearview mirror folding switch Front cushion motor/sensor Rear cushion motor/sensor Seat adjusting switch Reclining motor/sensor Sliding motor/sensor SPWM Unit SPWM KYRON 2007.04...
  • Page 492 And then adjust "R": Passenger side mirror theselected mirror up, down, left, or rightby pressing the corresponding edgesof the switch to get the direct 2) Seat Position Control rearview. Seat Height Adjustment Seat Slide Adjustment Seat Tilt Adjustment SPWM KYRON 2007.04...
  • Page 493 Adjust the driver's seat and outside rearview mirrors to the desired positions. Press the "SET"button. The indicator on the button will come on. Within 5 seconds, press the buttons (1), (2) or (3) you want to set. The indicator on the set buttonblinks 3 times. SPWM KYRON 2007.04...
  • Page 494 In the vehicle equipped with manual transmission, the position memory recall is not · available if the parkingbrake is released. If the position memory recall is successfully completed the buzzer sounds twice. If it failed, · the buzzer soundsthree times. SPWM KYRON 2007.04...
  • Page 495 04-8 7410-13 3. SEAT POSITION WITH MEMORY INPUT/OUTPUT OF SPWM UNIT SPWM KYRON 2007.04...
  • Page 496 The buzzer sounds once if the memory set mode is activated. The buzzer sounds twice if the memory setting/recalling is completed. The buzzer sounds three times if an error is found in the sensor during the memory recall operation. SPWM KYRON 2007.04...
  • Page 497 When pressing the STOP button during the memory recall operation. · When adjusting the seat or outside rearview mirrors during the memory recall · operation. The seat will not move unless a position switch has a memory setting. Timing Chart ▶ SPWM KYRON 2007.04...
  • Page 498 The motor doesn't operate if the difference between the stored position and the current position is out of thespecified range · Sliding : 12 edges (6 pulses) Cushion height : 6 edges (3 pulses) · Reclining : 100 mV · SPWM KYRON 2007.04...
  • Page 499 Operating voltage : DC 9 ~ 16 V Current consumption : Max. 500 mA (not including the load) Operating temperature range : -30°C ~ 75°C Reserve temperature range : -40°C ~ 85°C Parasitic current : Max. 2 mA SPWM KYRON 2007.04...
  • Page 500 Rated voltage : DC 12 V Operating voltage : DC 9 ~ 16 V Current consumption : Max. 300 mA (not including the load) Operating temperature range : -30°C ~ 75°C Reserve temperature range : -40°C ~ 85°C SPWM KYRON 2007.04...
  • Page 501 05-3 8010-01 8010-01 CLUSTER 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 2007.04...
  • Page 502 05-4 8010-01 CLUSTER KYRON 2007.04...
  • Page 504 05-6 8010-01 2.WARNING / INDICATOR PANEL CLUSTER KYRON 2007.04...
  • Page 505 05-7 8010-01 CLUSTER KYRON 2007.04...
  • Page 506 05-8 8010-01 1. CLUSTER CONFIGURATION Front View Rear View Main Connector Sub Connector CLUSTER KYRON 2007.04...
  • Page 507 High beam (-) M/T N (Neutral) input RH indicator lamp (+) M/T P (Parking) input High beam (+) CAN Low LH indicator lamp (+) CAN High Oil pressure AGND (Fuel -) Parking brake signal input MGND (Micom -) (STICS) CLUSTER KYRON 2007.04...
  • Page 508 If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectivesin tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer,connect a scanner and then compare the value on tachometer with the reading from scanner. CLUSTER KYRON 2007.04...
  • Page 509 Check if the speedometer pointer is shaking and the abnormal noise sounds. Eliminate the hysteresis by tapping the speedometer. The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range. CLUSTER KYRON 2007.04...
  • Page 510 Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, thedifferences that can be occurred by the road conditions and fuel fluctuations are ignored. CLUSTER KYRON 2007.04...
  • Page 511 80°C - 321W±5 % 100°C - 12W±5 % When the resistance value by coolant temperature is within the specified range, check thermostat, waterpump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectorsfor proper connection. CLUSTER KYRON 2007.04...
  • Page 512 5) TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter Odometer/Trip Odometer When pressing the TRIP/RESET switch on the cen-ter panel, the odometer/trip odometer is convertedand the meter resets to 0.0 km in Trip A and Trip B. CLUSTER KYRON 2007.04...
  • Page 513 Basically, the brake system's basic functions can work even when there are problems with the HDC system.As given in the table above, the HDC warning lamp comes on when: Initial ignition ON · HDC system error occurs · Brake system overheat · CLUSTER KYRON 2007.04...
  • Page 514 ESP warning lamp is turned on by pressing the ESP OFF switch.When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And thebasic ABS system will operate. CLUSTER KYRON 2007.04...
  • Page 515 150 ms, theESP OFF mode and the ESP warning lamp will not be changed. · When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP systemwill not be turned on. CLUSTER KYRON 2007.04...
  • Page 516 ESP OFF switch is pushed (for over 150 ms) andthen goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESPunit resets the ESP OFF switch for approx. 3.5 seconds. CLUSTER KYRON 2007.04...
  • Page 517 The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function)is working. When the driver presses the brake pedal during the ESP OFF mode, the yaw control is · performed to compen-sate the vehicle stability (posture) during ESP operation. CLUSTER KYRON 2007.04...
  • Page 518 ECU. The engine ECU receives the N switch signal, the vehicle speed, the clutch operating conditions,and the engine coolant temperature and raises the engine speed by 100-200 rpm. This helps the vehicle startsmoothly during gear shifting. N Switch Outside Inside CLUSTER KYRON 2007.04...
  • Page 519 There isno separate unit to process the wheel speed sensor signal. 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. CLUSTER KYRON 2007.04...
  • Page 520 05-22 8010-01 5. CLUSTER ELECTRICAL WIRING DIAGRAMS ▶ Gauge (Speed, RPM, Fuel, Temp), Warning Lamp (Fuel, Fuel Filter, ABS/ESP, Brake, HDC, 4WD, EPB, EAS, TPMS) CLUSTER KYRON 2007.04...
  • Page 521 05-23 8010-01 ▶ Warning Lamp (EAS, EPB, Auto Park's, TPMS, Grobal), Easy Load'g, TPMS Display CLUSTER KYRON 2007.04...
  • Page 522 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 2007.04...
  • Page 523 06-3 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 2007.04...
  • Page 524 06-4 8310-01 ▶ BULB SPECIFICATIONS LAMP KYRON 2007.04...
  • Page 526 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 2007.04...
  • Page 527 (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 2007.04...
  • Page 528 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 2007.04...
  • Page 529 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 2007.04...
  • Page 530 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 2007.04...
  • Page 531 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 2007.04...
  • Page 532 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 2007.04...
  • Page 533 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 2007.04...
  • Page 534 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 2007.04...
  • Page 535 08-8 7810-01 2. WIPER / WASHER RELATED FUNCTION AND SPECIFICATION 1) Wiper and Washer Fluid Switch Operation WIPER KYRON 2007.04...
  • Page 536 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 2007.04...
  • Page 537 It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. WIPER KYRON 2007.04...
  • Page 538 "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 2007.04...
  • Page 539 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 2007.04...
  • Page 540 08-13 7810-01 3. WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS WIPER KYRON 2007.04...
  • Page 541 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 2007.04...
  • Page 542 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 2007.04...
  • Page 543 "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 2007.04...
  • Page 544 "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 2007.04...
  • Page 545 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 2007.04...
  • Page 546 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 2007.04...
  • Page 547 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 2007.04...
  • Page 548 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 2007.04...
  • Page 549 09-11 8610-09 3. ELECTRICAL WIRING DIAGRAM RAIN SENSOR KYRON 2007.04...
  • Page 550 PAS(PARKING AID SYSTEM) 8790-03/8790-01/8790-00 PAS(PARKING AID SYSTEM) GENERAL 1. COMPONENT SPECIFICATIONS... OVERVIEW AND OPERATION PROCESS 1. SYSTEM CONFIGURATION....2. ALARM INTERVAL AND TROUBLE SHOOTING......3. CAUTIONS ON PARKING AID SYSTEM 4. CIRCUIT DIAGRAM........ REMOVAL AND INSTALLATION 8790-03 PARKING AID SENSOR....8790-01 PARKING AID UNIT......

  • Page 552: Component Specifications

    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 2007.04...

  • Page 553: System Configuration

    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 2007.04...

  • Page 554: Alarm Interval And Trouble Shooting

    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 2007.04...
  • Page 555 10-6 8790-00 ▶ When failed KYRON 2007.04...

  • Page 556: Cautions On Parking Aid System

    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 2007.04...

  • Page 557: Circuit Diagram

    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 2007.04...
  • Page 558 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 2007.04...
  • Page 559 11-4 8930-14 1. AV SYSTEM CONFIGURATION AV System (DVD Head Unit + DVD Changer) ▶ ▶ Audio System - 6 Speakers KYRON 2007.04...
  • Page 560 11-5 8930-14 6 DISC changer + TAPE + RADIO CD + RADIO DISC changer CD slot Tape KYRON 2007.04...
  • Page 561 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 2007.04...
  • Page 562 11-7 8930-14 KYRON 2007.04...
  • Page 563 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 2007.04...
  • Page 564 11-9 8930-14 4. AV SYSTEM SPECIFICATIONS AND CONTROL KYRON 2007.04...
  • Page 565 11-10 8930-14 ▶ Function Settings on Touch Panel (Example) KYRON 2007.04...
  • Page 566 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 2007.04...
  • Page 567 01-3 3410-01 3410-01 ION 4-SPEED 1. SPECIFICATIONS ION 4-SPEED KYRON 2007.04...
  • Page 568 01-4 3410-01 2. FASTENER TIGHTENING SPECIFICATIONS ION 4-SPEED KYRON 2007.04...
  • Page 569 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 2007.04...
  • Page 570 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 2007.04...
  • Page 571 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 2007.04...
  • Page 572 1 - Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. ION 4-SPEED KYRON 2007.04...
  • Page 573 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 2007.04...
  • Page 574 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 2007.04...
  • Page 575 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 2007.04...
  • Page 576 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 2007.04...
  • Page 577 01-13 3410-01 ION 4-SPEED KYRON 2007.04...
  • Page 578 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 2007.04...
  • Page 579 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 2007.04...
  • Page 580 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 2007.04...
  • Page 581 01-17 3410-01 ▶ Solenoid Operation during Gearshifts ION 4-SPEED KYRON 2007.04...
  • Page 582 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 2007.04...
  • Page 583 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 2007.04...
  • Page 584 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 2007.04...
  • Page 585 01-21 3410-01 1) Hydraulic Control Circuit ION 4-SPEED KYRON 2007.04...
  • Page 586 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 2007.04...
  • Page 587 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 2007.04...
  • Page 588 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 2007.04...
  • Page 589 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 2007.04...
  • Page 590 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 2007.04...
  • Page 591 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 2007.04...
  • Page 592 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 2007.04...
  • Page 593 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 2007.04...
  • Page 594 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 2007.04...
  • Page 595 01-31 3410-01 ION 4-SPEED KYRON 2007.04...
  • Page 596 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 2007.04...
  • Page 597 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 2007.04...
  • Page 598 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 2007.04...
  • Page 599 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 2007.04...
  • Page 600 01-36 3410-01 1) Park and Neutral ION 4-SPEED KYRON 2007.04...
  • Page 601 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 2007.04...
  • Page 602 01-38 3410-01 2) Reverse ION 4-SPEED KYRON 2007.04...
  • Page 603 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 2007.04...
  • Page 604 01-40 3410-01 3) Manual 1 ION 4-SPEED KYRON 2007.04...
  • Page 605 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 2007.04...
  • Page 606 01-42 3410-01 4) Drive 1 ION 4-SPEED KYRON 2007.04...
  • Page 607 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 2007.04...
  • Page 608 01-44 3410-01 5) Drive 2 and Manual 2 ION 4-SPEED KYRON 2007.04...
  • Page 609 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 2007.04...
  • Page 610 01-46 3410-01 6) Drive 3 and Manual 3 ION 4-SPEED KYRON 2007.04...
  • Page 611 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 2007.04...
  • Page 612 01-48 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 3 and Manual 3 ION 4-SPEED KYRON 2007.04...
  • Page 613 01-49 3410-01 7) Drive 3 Lock Up and Manual 3 Lock Up ION 4-SPEED KYRON 2007.04...
  • Page 614 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 2007.04...
  • Page 615 01-51 3410-01 8) Drive 4 (Overdrive) ION 4-SPEED KYRON 2007.04...
  • Page 616 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 2007.04...
  • Page 617 01-53 3410-01 ELEMENTS ENGAGED Gear State CLUTCH Drive 4 Overdrive ION 4-SPEED KYRON 2007.04...
  • Page 618 01-54 3410-01 9) Drive 4 Lock Up ION 4-SPEED KYRON 2007.04...
  • Page 619 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 2007.04...
  • Page 620 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 2007.04...
  • Page 621 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 2007.04...
  • Page 622 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 2007.04...
  • Page 623 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 2007.04...
  • Page 624 02-8 3650-01 ▶ Specifications DC 5-SPEED KYRON 2007.04...
  • Page 625 02-9 3650-01 DC 5-SPEED KYRON 2007.04...
  • Page 626 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 2007.04...
  • Page 627 (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 2007.04...
  • Page 628 02-12 3650-01 ▶ General Characteristics DC 5-SPEED KYRON 2007.04...
  • Page 629 02-13 3650-01 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 2007.04...
  • Page 630 02-14 3650-01 ▶ Shifting Elements ※ 1) Selector program switch: S mode 2) Selector program switch: W mode 3) Overrun DC 5-SPEED KYRON 2007.04...
  • Page 631 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 2007.04...
  • Page 632 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 2007.04...
  • Page 633 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 2007.04...
  • Page 634 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 2007.04...
  • Page 635 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 2007.04...
  • Page 636 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 2007.04...
  • Page 637 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 2007.04...
  • Page 638 2. LOCATIONS AND COMPONENTS Tip switch (-) Tip switch (+) TGS lever knob Tip switch TGS lever TGS LEVER KYRON 2007.04...
  • Page 639 "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 2007.04...
  • Page 640 04-3 3170-01 3170-01 T/M LEVER 1. CIRCUIT OF ION 4-SPEED AUTOMATIC T/M T/M LEVER KYRON 2007.04...
  • Page 641 04-4 3170-01 2. CIRCUIT OF SHIFT INTER LOCK T/M LEVER KYRON 2007.04...
  • Page 642 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 2007.04...
  • Page 643 05-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications 2) Tightening Torque KYRON 2007.04...
  • Page 644 05-5 3170-01 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch N (Neutral) Switch Outside N Switch Inside N Switch KYRON 2007.04...
  • Page 645 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 2007.04...
  • Page 646 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 2007.04...
  • Page 647 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 2007.04...
  • Page 648 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 2007.04...
  • Page 649 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 2007.04...
  • Page 651 06-3 3010-01 1. CLUTCH SPECIFICATIONS 2. TIGHTTENING TORQUE CLUTCH KYRON 2007.04...
  • Page 652 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 2007.04...
  • Page 653 06-5 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH KYRON 2007.04...
  • Page 654 06-6 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 2007.04...
  • Page 655 07-3 4120-01 1. AXLE SPECIFICATIONS Specification Torque Gear ratio ← ← Type ← → → ← Size Offset ← Housing ← Specification ← Capacity Length ← ← Width Weight ← AXLE KYRON 2007.04...
  • Page 656 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 2007.04...
  • Page 657 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 2007.04...
  • Page 658 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 2007.04...
  • Page 659 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 2007.04...
  • Page 660 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 2007.04...
  • Page 661 09-4 3240-01 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 2007.04...
  • Page 662 (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 2007.04...
  • Page 663 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 2007.04...
  • Page 664 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 2007.04...
  • Page 665 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 2007.04...
  • Page 666 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 2007.04...
  • Page 667 09-10 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 2007.04...
  • Page 668 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 2007.04...
  • Page 669 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 2007.04...
  • Page 670 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 672 10-3 3310-00 3310-00 PROPELLER SHAFT 1. SPECIFICATION PROPELLER SHAFT KYRON 2007.04...
  • Page 673 The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration. PROPELLER SHAFT KYRON 2007.04...
  • Page 674 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 2007.04...
  • Page 675 10-6 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 2007.04...
  • Page 676 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 2007.04...
  • Page 677 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 2007.04...
  • Page 678 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 2007.04...
  • Page 679 10-10 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 2007.04...
  • Page 680 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 2007.04...
  • Page 681 10-12 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 2007.04...
  • Page 682 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 2007.04...
  • Page 683 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 2007.04...
  • Page 684 11-3 4411-01 4411-01 SUSPENSION 1. FRONT SUSPENSION SPECIFICATIONS 2. REAR SUSPENSION SPECIFICATIONS SUSPENSION KYRON 2007.04...
  • Page 685 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 2007.04...
  • Page 686 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 2007.04...
  • Page 687 12-5 4890-01 3) SECTIONAL DRAWING Front Disc Brake Rear Disc Brake KYRON 2007.04...
  • Page 688 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 2007.04...
  • Page 689 12-7 4890-01 2. BRAKE SYSTEM SPECIFICATIONS KYRON 2007.04...
  • Page 690 It is also a physical phenomenon and has no relation with the brake performance. KYRON 2007.04...
  • Page 691 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 2007.04...
  • Page 692 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 2007.04...
  • Page 693 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 2007.04...
  • Page 694 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 2007.04...
  • Page 695 12-13 4890-01 [New T/C] Without speed sensor KYRON 2007.04...
  • Page 696 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 2007.04...
  • Page 697 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2007.04...
  • Page 698 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 2007.04...
  • Page 700 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 2007.04...
  • Page 701 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 2007.04...
  • Page 702 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 2007.04...
  • Page 703 (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 2007.04...
  • Page 704 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 2007.04...
  • Page 705 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 2007.04...
  • Page 706 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 2007.04...
  • Page 707 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 2007.04...
  • Page 708 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 2007.04...
  • Page 710 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 2007.04...
  • Page 711 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 2007.04...
  • Page 712 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 2007.04...
  • Page 713 12-31 4890-01 4) Input/Output Signals for HDC Operation KYRON 2007.04...
  • Page 714 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 2007.04...
  • Page 716 12-34 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 2007.04...
  • Page 717 12-35 4890-01 ▶ Comparison with ABS System Active Wheel Speed Sensor HDC Switch HDC Indicator ESP OFF Switch ABS / ESP Indicator KYRON 2007.04...
  • Page 718 12-36 4890-01 7. INPUT/OUTPUT SIGNALS FOR HDC OPERATION ▶ Input/Output of ESP System KYRON 2007.04...
  • Page 719 12-37 4890-01 8. ESP HYDRAULIC CIRCUIT DIAGRAM KYRON 2007.04...
  • Page 720 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 2007.04...
  • Page 721 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 2007.04...
  • Page 722 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 2007.04...
  • Page 723 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 2007.04...
  • Page 724 12-42 4890-01 New Transfer Case Without Speed Sensor KYRON 2007.04...
  • Page 725 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 2007.04...
  • Page 726 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2007.04...
  • Page 727 12-45 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 2007.04...
  • Page 728 12-46 4890-01 13. INPUT AND OUTPUT DIAGRAM OF ABS ▶ Input/Output of ABS (without TPMS) KYRON 2007.04...
  • Page 729 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 2007.04...
  • Page 730 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 2007.04...
  • Page 731 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 2007.04...
  • Page 732 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 2007.04...
  • Page 733 Feed pipe nut 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 2007.04...
  • Page 734 13-5 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 2007.04...
  • Page 735 13-6 4610-00 Pipe bracket bolt (10 mm) Pipe bracket bolt (10 mm) Gear box mounting bolt Pipe mounting nut Installation Drawing of SSPS STEERING KYRON 2007.04...
  • Page 736 13-7 4610-00 ▶ Components Steering wheel Column shaft Lower shaft Tie rod end Steering gear box STEERING KYRON 2007.04...
  • Page 737 13-8 4610-00 Steering wheel Lower shaft Column shaft Steering gear box STEERING KYRON 2007.04...
  • Page 738 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 2007.04...
  • Page 739 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 2007.04...
  • Page 740 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 2007.04...
  • Page 741 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 2007.04...
  • Page 742 333 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 2007.04...
  • Page 743 13-14 4610-00 3) CIRCUIT DIAGRAM STEERING KYRON 2007.04...
  • Page 744 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 2007.04...
  • Page 745 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 2007.04...

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