SSANGYONG KYRON 2006.03 Manual
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SSANGYONG KYRON 2006.03 Manual

SSANGYONG KYRON 2006.03 Manual

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Table of Contents

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GENERAL INFORMATION
1. HOW TO READ ELECTRICAL WIRING
DIAGRAM...............................................
2. LAYOUT OF ELECTRICAL SYSTEM.....
GENERAL INFORMATION
GENERAL INFORMATION
3
6
0000-00

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Summary of Contents for SSANGYONG KYRON 2006.03

  • Page 1 GENERAL INFORMATION 0000-00 GENERAL INFORMATION GENERAL INFORMATION 1. HOW TO READ ELECTRICAL WIRING DIAGRAM..........2. LAYOUT OF ELECTRICAL SYSTEM..
  • Page 3 - Internal circuit of component (Switch) (Component Name, Terminal Number and Connecting Wiring Circuit) - Lower horizontal line : Ground line ·Ground position (G101 ~ G402) ·B : Body Ground ·Refer to Major Ground Position (Section2) GENERAL INFORMATION KYRON 2006.03...
  • Page 4 Battery Voltage (B+) supply in Ignition Switch “ON” and “ACC” Battery Voltage (B+) supply directly regardless of Ignition Switch Ground connected to battery (-) Battery Voltage (B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit) GENERAL INFORMATION KYRON 2006.03...
  • Page 5 Underbody In the locating section, the assignment for part number startsfrom left bottom and proceeds clockwise. In the fuse and relay box or the instrument panel, the partnumber is assigned from left top to light bottom. GENERAL INFORMATION KYRON 2006.03...
  • Page 6 TV ANT AMP DVD Changer Buzzer STICS PAS Unit Curtain DSP AMP Air-Bag Sensor TV Tuner Woofer Driver Seat Memory SW TCCU / TCU ENG ECU / SSPS Unit Incar Sensor SSPS Unit TCCU (Under the ENG ECU) GENERAL INFORMATION KYRON 2006.03...
  • Page 7 Tripple Pressure SW IWE Solenoid Valve (4WD) Horn (RH) (Under the BATT TRAY) Horn (LH) Burglar Horn AQS Sensor/ Fuse & Relay Box (Under the BATT) Ambient Temp Sensor (FFH) Ambient Temp Sensor (FFH) AQS/ AmbientSensor GENERAL INFORMATION KYRON 2006.03...
  • Page 8 TRIP SW Mirror SW Deicer SW ESP OFF RR Fog Lamp SW Center Fascia SW 4WD SW Driver Seat Driver Seat Memory SW P/Window Main SW (Driver) Passenger P/Window SW Warmer SW Passenger Seat Warmer SW GENERAL INFORMATION KYRON 2006.03...
  • Page 9 Position: Upper the G/Box panel TV ANT AMP (RH) DVD Changer Audio Remocon DVD + Tape Radio ANT AMP Woofer Etc Audio Head Unit AV SYSTEM 6pcs INDASH CD+TAPE+RADIO CD+RAIDIO DSP/AMP 6pcs Indash CD Insert Tuner Tape GENERAL INFORMATION KYRON 2006.03...
  • Page 10 Manual A/C Intake Sensor W/H A/Con Blower Unit W/H Main Control Unit Sun Sensor Receiver Dryer (LH) (Upper the IP LH) AQS/Ambient ENG ECU AQS Mode SW Compressor Coolant Temp Sensor Temp Sensor Sensor Ambient Temp Sensor GENERAL INFORMATION KYRON 2006.03...
  • Page 11 0000-00 ▶ AIR-DUCT LAY-OUT ▶ W/H A/CON MODULE A/Con Wiring Setting Coolant Temp Sensor Mode Actuator Intake Actuator Power TR W/H Main Air-Mix Connector Actuator Intake Air Temp. Sensor Blower Motor Incar Sensor A/Con Control Unit GENERAL INFORMATION KYRON 2006.03...

  • Page 13: Table Of Contents

    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 15: Wiring Harness, Components Location

    8201-00 WIRING HARNESS WIRING HARNESS, COMPONENTS LOCATION 8201-00 2) COMPONENTS LOCATION 1) WIRING HARNESS CONNECTOR/GROUND KYRON 2006.03...

  • Page 16: Connector/Ground

    8201-00 3) CONNECTOR, GROUND & SPLICE PACK INFORMATION ▶ CONNECTOR CONNECTOR/GROUND KYRON 2006.03...
  • Page 17 8201-00 ▶ GROUND ▶ SPLICE PACK CONNECTOR/GROUND KYRON 2006.03...
  • Page 18 8201-00 4) SPLICE PACK CIRCUIT ▶ S203 (GND) ▶ S101 ▶ S201 ▶ S204 (ILL+) ▶ S202 (CAN) ▶ S205 (GND) CONNECTOR/GROUND KYRON 2006.03...
  • Page 19 8201-00 ▶ S303 ▶ S206 ▶ S301 (CAN) ▶ S302 CONNECTOR/GROUND KYRON 2006.03...
  • Page 20 8201-00 5) CONNECTOR ▶ C101 ▶ C104 ▶ C105 ▶ C102 ▶ C103 ▶ C106 CONNECTOR/GROUND KYRON 2006.03...
  • Page 21 8201-00 ▶ C107 ▶ C111 ▶ C112 D27DT/GSL D20DT ▶ C108 C113 ▶ ▶ C110 ▶ C114 CONNECTOR/GROUND KYRON 2006.03...
  • Page 22 0-10 8201-00 ▶ C115 ▶ C115 (DSL) (GSL) ▶ C116 CONNECTOR/GROUND KYRON 2006.03...
  • Page 23 0-11 8201-00 ▶ C201 ▶ C202 ▶ C203 ▶ C204 CONNECTOR/GROUND KYRON 2006.03...
  • Page 24 0-12 8201-00 ▶ C205 ▶ C206 (Curtain A/Bag) ▶ C207 CONNECTOR/GROUND KYRON 2006.03...
  • Page 25 0-13 8201-00 ▶ C208 ▶ C212 (DSL) ▶ C209 ▶ C210 (GSL) C211 ▶ (Curtain A/Bag) CONNECTOR/GROUND KYRON 2006.03...
  • Page 26 0-14 8201-00 ▶ C213 ▶ C301 (Power Seat, W/ Memory) ▶ C214 (Manual Seat, W/O Memory) CONNECTOR/GROUND KYRON 2006.03...
  • Page 27 0-15 8201-00 ▶ C302 ▶ C361 ▶ C351 ▶ C371 CONNECTOR/GROUND KYRON 2006.03...
  • Page 28 0-16 8201-00 ▶ C381 ▶ C901 (Auto T/M) (Manual T/M) ▶ C401 ▶ C902 (DSL) (GSL) ▶ C402 C904 ▶ CONNECTOR/GROUND KYRON 2006.03...
  • Page 29 0-17 8201-00 ▶ WIRNING CONNECTOR ▶ MODE CONNECTOR ▶ UNIT CONNECTOR CONNECTOR/GROUND KYRON 2006.03...
  • Page 30 0-18 8201-00 ▶ SWITCH CONNECTOR ▶ ETC. ▶ LAMP CONNECTOR ▶ SENSOR CONNECTOR CONNECTOR/GROUND KYRON 2006.03...

  • Page 31: W/H Engine Room

    0-19 8210-00 CONNECTOR W/H ENGINE ROOM 8210-00 CONNECTOR/GROUND KYRON 2006.03...

  • Page 32: W/H Main

    0-20 8210-02 W/H MAIN 8210-02 CONNECTOR/GROUND KYRON 2006.03...

  • Page 33: W/H Floor

    0-21 8210-03 W/H FLOOR 8210-03 CONNECTOR/GROUND KYRON 2006.03...
  • Page 34 0-22 8210-10 CONNECTOR/GROUND KYRON 2006.03...

  • Page 35: W/H Roof

    0-23 8210-09 W/H ROOF 8210-09 W/H TAIL GATE 8210-10 CONNECTOR/GROUND KYRON 2006.03...

  • Page 36: W/H Driver Door

    0-24 8210-07 W/H DRIVER DOOR W/H PASSENGER DOOR 8210-06 8210-07 CONNECTOR/GROUND KYRON 2006.03...

  • Page 37: W/H Rr Door

    0-25 8210-08 W/H RR DOOR 8210-08 CONNECTOR/GROUND KYRON 2006.03...
  • Page 39 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 41: 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 2006.03...
  • Page 42 8410-02 5) ENGINE ROOM FUSE BOX CONNECTOR NUMBER 4) USAGE OF FUSE IN ENGINE ROOM FUSE BOX POWER DISTRIBUTION KYRON 2006.03...

  • Page 43: 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 2006.03...

  • Page 44: I/P - Rh Fuse & Relay Box

    8410-06 8410-06 I/P - RH FUSE ＆ RELAY BOX 1) I/P - RH FUSE & RELAY BOX POWER DISTRIBUTION KYRON 2006.03...

  • Page 45: Electricity Divide

    8210-02 ELECTRICITY DIVIDE 8210-02 ENGINE ROOM FUSE ＆ RELAY BOX CIRCUIT (1) SB5, SB6, Ef4, Ef5, Ef11, HORN RELAY, HEAD LAMP RELAY (HI, LO) (2) SB2 ~ SB4, SB7 ~ SB9, Ef3, P/WINDOW RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 46 8410-02 (3) SB10 ~ SB11, CONDENSOR FAN RELAY (HI, LO) (4) SB12 ~ SB16, START RELAY, PTC RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 47 8410-02 (5) Ef1, Ef2, Ef6, Ef7 (6) Ef8 ~ Ef10, TAIL LAMP RELAY, FRT FOG LAMP RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 48 0-10 8410-02 (7) Ef12 ~ Ef15, Ef18 ~ Ef23, COMPRESSOR RELAY (8) WIPER MOTOR RELAY (HI, LO), WASHER RELAY (FRT, RR) POWER DISTRIBUTION KYRON 2006.03...

  • Page 49: I/P - Lh Fuse ＆ Relay Box Circuit

    0-11 8410-04 8410-04 I/P - LH FUSE ＆ RELAY BOX CIRCUIT (1) F24 ~ F28 (2) F29 ~ F34 POWER DISTRIBUTION KYRON 2006.03...
  • Page 50 0-12 8410-04 (3) F35 ~ F40, RR WIPER RELAY (4) F41 ~ F48 POWER DISTRIBUTION KYRON 2006.03...
  • Page 51 0-13 8410-04 (5) F49 ~ F51, DRL RELAY, RR FOG LAMP RELAY (6) F52 ~ F55, BURGLAR HORN RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 52 0-14 8410-04 (7) F56 ~ F57, HDC RELAY, FLASHER UNIT POWER DISTRIBUTION KYRON 2006.03...

  • Page 53: I/P - Rh Fuse ＆ Relay Box Circuit

    0-15 8410-06 8410-06 I/P - RH FUSE ＆ RELAY BOX CIRCUIT (1) F58 ~ F64, ENG MAIN RELAY (2) F65 ~ F71, HAZARD RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 54 0-16 8410-06 (3) BLOWER RELAY, P/OUTLET RELAY, INJECTOR RELAY, SNR RELAY POWER DISTRIBUTION KYRON 2006.03...
  • Page 55 CIRCUIT 1461-01/2820-01/1491-01/1491-01/8210-01/3110-01/3410-01/4892-01/4620-12/8810-01/8010-01/7410-13/7410-02/7410-04/8510-52/8510-48/8710-02/7830-03/ 8510-05/8610-06/7632-16/7340-03/8310-01/8510-00/8320-01/8410-01/8210-01/8310-10/4810-01/7770-02/7770-10/8910-01/8930-01/8790-01/6810-15/6910-01/6810- CIRCUIT ENGINE 1461-01 STARTING ＆ CHARGING.... 8510-48 SEAT WARMER......2820-01 PREHEATING CIRCUIT....8710-02 STICS.......... 1491-01 ECU (ENGINE CONTROL 7830-03 RR WIPER CIRCUIT..... UNIT - DSL)........8510-05 POWER WINDOW CIRCUIT..1491-01 ECU (ENGINE CONTROL 8610-06 HORN........... UNIT - GSL G32)......7632-16 CIGAR LIGHTER ＆...

  • Page 57: Starting ＆ Charging

    1461-01 1461-01 STARTING ＆ CHARGING 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 58: Preheating Circuit

    2820-01 PREHEATING CIRCUIT 2820-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 59 Senses engine temperature and controls the preheating/post heating time. Preheating warning light. ▶ K-LINE for information exchanges between preheating unit and ECU Transmits preheating unit self-diagnosis results to ECU. Transmits glow plug diagnosis results and operating status to ECU. CIRCUIT KYRON 2006.03...

  • Page 60: Ecu (Engine Control Unit - Dsl)

    1491-01 ECU (ENGINE CONTROL UNIT - DSL) 1491-01 ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, (1) CONNECTOR INFORMATION CRUISE CONTROL SW (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 61 1491-01 2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (1) CONNECTOR INFORMATION CIRCUIT (FUEL PRESSURE, SHAFT, BOOSTER PRESSURE, CRANK SHAFT, KNOCK, COOLANT TEMP., FUEL TEMP.) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 62 1491-01 3) INJECTOR, CAN LINE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 63 ECU to generate necessary current during injector drive stages. Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-current-phase and then the injectors should work very correctly under every working condition. CIRCUIT KYRON 2006.03...

  • Page 64: Ecu (Engine Control Unit - Gsl G32)

    0-10 1491-01 ECU (ENGINE CONTROL UNIT - GSL G32) 1491-01 1) IGN COIL, INJECTOR, PEDAL MODULE, THROTTLE SENSOR (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 65 0-11 1491-01 2) O₂SENSOR, CPS, KNOCK SENSOR, HFM SENSOR, CANISTER PURGE VALVE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 66 0-12 1491-01 3) S/AIR PUMP, STOP LAMP, CRUISE CONTROL SW, FUEL PUMP, IMMOBILIZER (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 67: Diagnosis Circuit

    0-13 8210-01 DIAGNOSIS CIRCUIT 8210-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 68: Tcu (Dc5 - A/T)

    0-14 3110-01 TCU (DC5 - A/T) 3110-01 (1) CONNECTOR INFORMATION 1) START MOTOR, TGS LEVER, CAN LINE (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 69 0-15 3110-01 2) SOLENOID, OIL TEMP SENSOR, SPEED SENSOR (N2, N3) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 70 This closes the electrical circuit to the starter in selector lever positions “P” and “N” via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the contact is closed and the starter cannot be operated. CIRCUIT KYRON 2006.03...
  • Page 71 This valve activates and releases the lockup clutch by adjusting the current to solenoid valve according to engine throttle opening value and output shaft speed. The lockup clutch operates in 3rd, 4th and 5th gear with steps to reduce shift shocks. CIRCUIT KYRON 2006.03...
  • Page 72 0-18 3110-01 K. DTC (DIAGNOSIS TROUBLE CODE) OF DC5AT CIRCUIT KYRON 2006.03...
  • Page 73 0-19 3110-01 CIRCUIT KYRON 2006.03...
  • Page 74 0-20 3110-01 CIRCUIT KYRON 2006.03...
  • Page 75 0-21 3110-01 CIRCUIT KYRON 2006.03...

  • Page 76: Tccu

    0-22 3410-01 TCCU 3410-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 77 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. CIRCUIT KYRON 2006.03...
  • Page 78 (5) SHIFT MOTOR CONNECTOR When selecting a position in the 4WD switch (2H, 4H, 4L), TOD control unit exactly changes the motor position to 2H, 4H and 4L by detecting the electric signals from position encoder that monitors motor position. CIRCUIT KYRON 2006.03...
  • Page 79 0-25 3410-01 (8) DIAGNOSTIC TROUBLE CODE CIRCUIT KYRON 2006.03...

  • Page 80: Abs/Esp

    0-26 4892-01 ABS/ESP 4892-01 W/SPEED SENSOR, STOP LAMP SW, DIAGNOSIS, WARNING LAMP (ABS/ESP), HDC (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 81 0-27 4892-01 PRESSURE SENSOR, S.W.A SENSOR, SENSOR CLUSTER, ESP OFF SW (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 82 In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but The HBA System increases the braking force under urgent situations to enhance the inputted this is a normal condition due to HDC operation. braking force from the driver. CIRCUIT KYRON 2006.03...
  • Page 83 This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to under-steering or over-steering during cornering. CIRCUIT KYRON 2006.03...
  • Page 84 Even when the ESP is operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds and the buzzer sounds for at least 1.4 seconds with 100 ms interval. CIRCUIT KYRON 2006.03...
  • Page 85 0-31 4892-01 N. ABS/ESP TROUBLE DIAGNOSIS CIRCUIT KYRON 2006.03...
  • Page 86 0-32 4892-01 CIRCUIT KYRON 2006.03...
  • Page 87 0-33 4892-01 CIRCUIT KYRON 2006.03...
  • Page 88 0-34 4620-12 S.S.P.S (SPEED SENSITIVE POWER STEERING 4620-12 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 89: Speed Sensitive Power Steering)

    This device increases the steerability effect by binding the input shaft with supplied hydraulic ignition is “ON”. pressure from PCV. When a trouble occurs in the system, the SSPS control unit generates a trouble code using fail safe function. CIRCUIT KYRON 2006.03...

  • Page 90: Air-Bag (Curtain Air-Bag)

    0-36 8810-01 AIR-BAG (CURTAIN AIR-BAG) 8810-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 91 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. CIRCUIT KYRON 2006.03...
  • Page 92 When the Air Bag Unit Receives Any Malfunction Signals from the 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. CIRCUIT KYRON 2006.03...
  • Page 93 0-39 8810-01 CIRCUIT KYRON 2006.03...
  • Page 94 0-40 8810-01 CIRCUIT KYRON 2006.03...

  • Page 95: Cluster

    0-41 8010-01 CLUSTER 8010-01 1) GAUGE (SPEED, RPM, FUEL, TEMP), WARNING LAMP (FUEL, (1) CONNECTOR INFORMATION FUEL FILTER, ABS/ESP, BRAKE, HDC, 4WD) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 96 0-42 8010-01 2) WARNING LAMP (BATT CHARGE, OIL, HOOD, DOOR, ENG CHECK, AIR BAG, SSPS, SEAT BELT), TURN SIGNAL, FOG LAMP, HAZARD (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 97 13. Low fuel level warning light 30. Glow indicator 14. Winter mode indicator 31. Engine check warning light 15. ESP warning light 32. Engine oil pressure warning light 16. 4WD HIGH indicator 33. Auto cruise indicator 17. Battery charge warning light CIRCUIT KYRON 2006.03...
  • Page 98 Resistance value by coolant temperature: 20℃ - 2449W ± 5 % 50℃ - 826W ± 5 % 80℃ - 321W ± 5 % 100℃ - 12W ± 5 % CIRCUIT KYRON 2006.03...
  • Page 99 The HDC switch is a push & self return type switch - when you press it once, it starts to · HDC system error occurs operate and when you press it again, it stops the operation. Brake system overheat · CIRCUIT KYRON 2006.03...

  • Page 100: Power Seat - Driver (W/ Memory)

    0-46 7410-13 POWER SEAT - DRIVER (W/ MEMORY) 7410-13 1) DRIVER POWER SEAT & SEAT MEMORY (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 101 0-47 7410-13 2) ELECTRIC OUTSIDE MIRROR & FOLDING CIRCUIT (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 102 Press the “SET” button. The indicator on the button will come on. Within 5 seconds, press the buttons ( ), ( ) or ( ) you want to set. The indicator on the set button blinks 3 times. CIRCUIT KYRON 2006.03...
  • Page 103 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. ▷ CIRCUIT KYRON 2006.03...
  • Page 104 Current consumption: Max. 300 mA (not including the load) Relay Protection ▷ Operating temperature range: -30°C ~ 75°C Once the relay is turned on, it will not be turned off within 60 ms. Reserve temperature range: -40 ~ 85°C CIRCUIT KYRON 2006.03...
  • Page 105 The outside rearview mirrors can be folded and unfolded within 30 ± 6 seconds even after turning off the ignition switch. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is extended 13 seconds when pressing the switch again. CIRCUIT KYRON 2006.03...

  • Page 106: Power Seat - Driver (W/O Memory)

    0-52 7410-02 POWER SEAT - DRIVER (W/O MEMORY) 7410-02 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 107: Power Seat - Passenger

    0-53 7410-04 POWER SEAT - PASSENGER 7410-04 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 108: Electric Outside Mirror

    0-54 8510-52 null ELECTRIC OUTSIDE MIRROR & FOLDING 8510-52 (W/O MEMORY) 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 109: Seat Warmer

    0-55 8510-48 SEAT WARMER 8510-48 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 110: Stics

    0-56 8710-02 STICS 8710-02 (1) CONNECTOR INFORMATION 1) POWER/GROUND, CHIME BELL, BUZZER WARNING LAMP (BRAKE, SEAT BELT, DR OPEN) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 111 0-57 8710-02 2) CENTRAL DOOR LOCK CIRCUIT (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 112 0-58 8710-02 3) TAIL LAMP, HAZARD, POWER WINDOW (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 113 0-59 8710-02 4) DEFOGGER (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 114 0-60 8710-02 5) PANIC, AUTO LIGHT & RAIN SENSING, ROOM LAMP (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 115 0-61 8710-02 6) FRT WIPER/WASHER & RR WASHER (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 116 Receiving distance: Approx. 10 ~ 15 m (In case there are not obstacles around the It cannot be activated while the front washer switch or the auto washer and wiper system)em) (AFW: Advanced Fast Washer) is in operation. CIRCUIT KYRON 2006.03...
  • Page 117 The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation. When the auto INT switch input is received during the auto washer operation, the auto washer operation stops and the auto INT operation is activated. CIRCUIT KYRON 2006.03...
  • Page 118 2 seconds, then continuously outputs the small amount of rain drops. Therefore, change the knob to the low sensitivity. parking signal of current sensitivity. The wiper motor runs only when the rain sensor requires. · CIRCUIT KYRON 2006.03...
  • Page 119 If the key is in the key cylinder, the ignition key reminder the INT switch positioned to “ON”. function is activated. · Intermittent interval (at 0 km/h): 3 ± 0.5 ~ 19 ± 2 seconds This function does not work if the vehicle speed is over 10 km/h. CIRCUIT KYRON 2006.03...
  • Page 120 The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch is pressed. CIRCUIT KYRON 2006.03...
  • Page 121 10 minutes after completion of output for 12 minutes. This can be done The door unlock relay output is “ON” for 0.5 seconds when receiving the only once. remote control unlock signal. The output is “OFF” when the IGN 2 switch is “OFF”. CIRCUIT KYRON 2006.03...
  • Page 122 “ON” position. · If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is canceled immediately and the warning buzzer stops after 27 seconds (remaining time). CIRCUIT KYRON 2006.03...
  • Page 123 It the door is not opened within 30 seconds after unlocking the door with remote control control key sends the coded control message to the CPU in receiver to control the vehicle. key, the system outputs “LOCK” signal and activates the armed mode (Relock function). CIRCUIT KYRON 2006.03...
  • Page 124 0-70 8710-02 F. DIAGNOSIS TROUBLE CODE AND HELP TIPS CIRCUIT KYRON 2006.03...

  • Page 125: Rr Wiper Circuit

    0-71 7830-03 RR WIPER CIRCUIT 7830-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 126: Power Window Circuit

    0-72 8510-05 POWER WINDOW CIRCUIT 8510-05 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 127 30 seconds (T2) just for once when opening the door during its extended operation period of 30 seconds (T1). The power window relay is turned “OFF” when closing the door during its extended operation period of 30 seconds (T2). CIRCUIT KYRON 2006.03...

  • Page 128: Horn

    0-74 8610-06 HORN 8610-06 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 129: Cigar Lighter ＆ Power Outlet Circuit

    0-75 7632-16 7632-16 CIGAR LIGHTER ＆ POWER OUTLET CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 130: Sun Roof Circuit

    0-76 7340-03 SUN ROOF CIRCUIT 7340-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 131 However, if the force against the sunroof is less than the specified value, the Anti-Trap power supply system is in normal conditions, check if the ground circuit of switch is function doesn't operate. securely tightened and reset the sunroof system again. CIRCUIT KYRON 2006.03...
  • Page 132 0-78 7340-03 E. TROUBLE DIAGNOSIS CIRCUIT KYRON 2006.03...

  • Page 133: Head Lamp ＆ Drl

    0-79 8310-01 HEAD LAMP & DRL HEAD LAMP ＆ DRL 8310-01 (DAY TIME RUNNING LIGHT) UNIT CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 134: Hlld (Head Lamp Level'gdevice) Circuit

    0-80 8510-00 8510-00 HLLD (HEAD LAMP LEVEL’G DEVICE) CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 135: Tail Lamp Circuit

    0-81 8320-01 TAIL LAMP CIRCUIT 8320-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 136 Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door while the ignition key is removed and the tail lamp is turned on. CIRCUIT KYRON 2006.03...

  • Page 137: Turn Signal ＆ Hazard Lamp Circuit

    0-83 8410-01 8410-01 TURN SIGNAL ＆ HAZARD LAMP CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 138: Trailer Lamp Circuit

    0-84 8210-01 TRAILER LAMP CIRCUIT 8210-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 139: Fog Lamp Circuit

    0-85 8310-10 FOG LAMP CIRCUIT 8310-10 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 140: Stop ＆ Back-Up Lamp Circuit

    0-86 4810-01 4810-01 STOP ＆ BACK-UP LAMP CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 141: Interior Lamp Circuit

    0-87 7770-02 INTERIOR LAMP CIRCUIT 7770-02 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 142 When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2. The room lamp output stops immediately after receiving the lock signal from driver’s door and passenger’s door lock switch while the driver’s door and passenger’s door are closed. CIRCUIT KYRON 2006.03...

  • Page 143: Auto Dimming Room Mirror Circuit

    0-89 7770-10 AUTO DIMMING ROOM MIRROR CIRCUIT 7770-10 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 144: Audio ＆ Clock Circuit

    0-90 8910-01 8910-01 AUDIO ＆ CLOCK CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 145: A/V System

    0-91 8930-01 A/V SYSTEM 8930-01 1) A/V HEAD UNIT, TUNER UNIT, DSP UNIT, DVD CHANGER, (1) CONNECTOR INFORMATION GLS ANT AMP (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 146 0-92 8930-01 2) DSP UNIT, SPEAKER (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...

  • Page 147: Parking Aid Circuit

    0-93 8790-01 PARKING AID CIRCUIT 8790-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 148 Frequency: 40 KHz ± 2 KHz Detecting range (13.5 V) · Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm · Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm CIRCUIT KYRON 2006.03...
  • Page 149 When the sensing portion is covered by rain, water drops, snow or mud. (operates normally after cleaned) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). When a high-power radio is turned on. CIRCUIT KYRON 2006.03...

  • Page 150: Ptc Heater (Positive Temperature Coefficient)

    0-96 6810-15 PTC HEATER 6810-15 (POSITIVE TEMPERATURE COEFFICIENT) 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 151 60°C and ambient temperature ≤ 0°C ~ 5°C, PTC operates (ON) ▶ PTC “OFF” CONDITION Airconditioner blower switch OFF Ambient temperature sensor error (wiring short or open) When engine craking Battery voltage is lower than 11V When preheating the engine (Glow indicator “ON”) CIRCUIT KYRON 2006.03...

  • Page 152: Ffh (Fuel Fired Heater)

    0-98 6910-01 FFH (FUEL FIRED HEATER) 6910-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 153 It is possible to diagnose the system by connecting the diagnostic device to controller. For details, refer to the “Diagnosis Procedures” section. Emergency shutdown 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. CIRCUIT KYRON 2006.03...
  • Page 154 0-100 6910-01 CIRCUIT KYRON 2006.03...
  • Page 155 0-101 6910-01 (4) RAL TROUBLE CAUSES AND REMEDIES CIRCUIT KYRON 2006.03...
  • Page 156 0-102 6810-20 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT 6810-20 1) CONDENSOR FAN, AIR MIX MOTOR, SUN SENSOR, WATER (1) CONNECTOR INFORMATION TEMP SENSOR (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 157 0-103 6810-20 2) BLOWER, ACTUATOR (MODE, INTAKE), AQS SENSOR (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 158 The symbol "-" in front of step number "2" means a short circuit of the blinking sensor. Short-circuit ambient First sensor failure Second sensor failure air temperature sensor code blinks twice code blinks twice ▶ Trouble Code CIRCUIT KYRON 2006.03...
  • Page 159 1. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 1. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4 2. Indication of Step 2. 3. Sensor failure Starting self diagnosis code blinking (30: no failure) ▶ Trouble Code CIRCUIT KYRON 2006.03...
  • Page 160 When engine speed is below 650 rpm ▶ Canceling the trouble diagnosis When engine speed is over 4,500 rpm During abrupt acceleration for the vehicle equipped with manual transmission Turn the AUTO switch ON or turn the ignition key OFF. CIRCUIT KYRON 2006.03...
  • Page 161 FATC controller. Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller. CIRCUIT KYRON 2006.03...
  • Page 162 When pressing the AQS switch again, the self diagnosis and preheating mode of AQS operates only for the remaining time. CIRCUIT KYRON 2006.03...
  • Page 163 A/C switch operation. At this mode, the AQS system operates according to the AQS switch operation. If the ignition switch is turned off with AQS ON, the AQS is turned on when turning the ignition switch on again. CIRCUIT KYRON 2006.03...
  • Page 164 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. CIRCUIT KYRON 2006.03...
  • Page 165 Separate the mode door actuator and remove the mode door link assembly. Make sure that the mode door link mounted on the air conditioner module assembly. When installing, if the location of the mode door link is not correct, may not operate properly. CIRCUIT KYRON 2006.03...

  • Page 166: Fatc

    Disconnect the negative battery cable and then remove the instrument panel FATC. assembly. Remove the driver’s instrument lower panel and then disconnect the connection connector of the mode door actuator and the mounting screws (2EA). Remove the in/ex air door actuator. CIRCUIT KYRON 2006.03...
  • Page 167 FATC. assembly. With the instrument panel assembly removed as shown in the above figure, disconnect the air mix door actuator and unscrew two mounting screws to remove the air mix door actuator. CIRCUIT KYRON 2006.03...
  • Page 168 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. CIRCUIT KYRON 2006.03...
  • Page 169 Disconnect the negative battery cable and remove the instrument panel assembly. Unscrew three mounting bolts (10 mm) on air conditioner module assembly and remove the sensor wire of air conditioner module. Separate the blower unit from the heater unit. CIRCUIT KYRON 2006.03...

  • Page 170: Air-Con (Manual) Circuit

    0-116 6810-20 AIR-CON (MANUAL) CIRCUIT 6810-20 (1) CONNECTOR INFORMATION 1) COMPRESSOR, MOTOR (MODE, INTAKE, AIR MIX) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 171 0-117 6810-20 2) BLOWER (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT KYRON 2006.03...
  • Page 173 GENERAL 0000-00 GENERAL GENERAL 1. DIMENSIONS........2. SPECIFICATIONS......... 3. VEHICLE IDENTIFICATION....4. MAINTENANCE INTERVAL....5. RECOMMENDED FLUIDS AND LUBRICANTS........6. JACK-UP POINTS ........ 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR........8. ELECTRIC COMPONENTS AND LAYOUT..........9. STANDARD BOLTS SPECIFICATIONS.
  • Page 174 01-2 0000-00 GENERAL KYRON 2006.03...

  • Page 175: Dimensions

    01-3 0000-00 0000-00 GENERAL GENERAL 1. DIMENSIONS Unit: mm GENERAL KYRON 2006.03...

  • Page 176: Specifications

    01-4 0000-00 2. SPECIFICATIONS * ( ) Optional GENERAL KYRON 2006.03...
  • Page 177 01-5 0000-00 * ( ) Optional GENERAL KYRON 2006.03...

  • Page 178: Vehicle Identification

    3. Certification Label The certification label is located on the driver's door sill. Diesel Engine: The engine number is stamped on the lower area of cylinder block behind the Intake manifold. GENERAL KYRON 2006.03...

  • Page 179: Maintenance Interval

    0000-00 4. MAINTENANCE INTERVAL 1) Diesel Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
  • Page 180 01-8 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 181 01-9 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 182 01-10 0000-00 2) Gasoline Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
  • Page 183 01-11 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
  • Page 184 01-12 0000-00 * Use only approved Ssangyong genuine parts. * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.

  • Page 185: Recommended Fluids And Lubricants

    01-13 0000-00 5. RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants. Keep the specified levels when adding or replacing the fluids. Do not mix any different types or brands of oils or fluids. This may cause damages.

  • Page 186: Jack-Up Points

    01-14 0000-00 6. JACK-UP POINTS 1) IRS - Lifting Point (Dotted Circles) GENERAL KYRON 2006.03...
  • Page 187 01-15 0000-00 2) 5 Link System - Lifting Point (Dotted Circles) GENERAL KYRON 2006.03...

  • Page 188: Pin Arrangement Of Diagnostic Connector

    01-16 0000-00 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR It is installed under the instrument panel and consists of 16 pins. 1) Functions of Terminal GENERAL KYRON 2006.03...

  • Page 189: Electric Components And Layout

    01-17 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement GENERAL KYRON 2006.03...
  • Page 190 01-18 0000-00 2) Components Locator GENERAL KYRON 2006.03...

  • Page 191: Standard Bolts Specifications

    01-19 0000-00 9. STANDARD BOLTS SPECIFICATIONS *Diameter X pitch in millimeters GENERAL KYRON 2006.03...
  • Page 192 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. GENERAL KYRON 2006.03...
  • Page 193 ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT....2. ENGINE CONTROLS LAYOUT....3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM....4. INTAKE SYSTEM LAYOUT....5. EXHAUST SYSTEM LAYOUT....6. LUBRICATION SYSTEM LAYOUT..7. COOLING SYSTEM LAYOUT....8. FUEL SYSTEM LAYOUT....... 9.

  • Page 195: General

    01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH SIDE VIEW 2) RH SIDE VIEW ENGINE GENERAL KYRON 2006.03...
  • Page 196 01-4 0000-00 3) FRONT VIEW 4) FAN BELT ENGINE GENERAL KYRON 2006.03...

  • Page 197: Engine Controls Layout

    Engine oil filler cap Vacuum pump PWM electric fan & fan shroud EGR valve Power steering oil reservoir Vacuum modulator Fuel filter & priming pump Brake fluid reservoir Battery ABS/ESP modulator Fuse box Air cleaner assembly Washer fluid reservoir ENGINE GENERAL KYRON 2006.03...
  • Page 198 01-6 0000-00 2) Engine And Sensors Camshaft Position Sensor Injector Glow Plug Fuel Pressure Sensor Booster Pressure Sensor Common Rail (Common Rail) ENGINE GENERAL KYRON 2006.03...
  • Page 199 01-7 0000-00 HP Pump Knock Sensor (1 EA) & Crankshaft Vacuum Modulator Water Temperature Sensor Position Sensor Water temp. sensor Knock sensor ENGINE GENERAL KYRON 2006.03...
  • Page 200 01-8 0000-00 3) Engine Accessories Related to ECU IP Interior Fuse Box (Passenger Side) Installed Engine ECU main relay Hazard warning lamp VGT & EGR vacuum modulators, HFM HP pumpIMV Engine ECU Mounting Location ENGINE GENERAL KYRON 2006.03...
  • Page 201 Pump Filter Service Interval (Fuel Filter) Replace every 30,000 km (Draining water from fuel filter: Only whenever replacing the engine oil) Replace every 25,000 km General (Draining water from fuel filter: whenever replacing the engine oil) ENGINE GENERAL KYRON 2006.03...

  • Page 202: Electrical Components And Preheating System

    01-10 0000-00 3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM Battery Preheat Warning Lamp Glow Plug (Cluster) Engine compartment Alternator Starter motor fuse box PTC / FFH: 12V - 2.2kw 12V - 115A ENGINE GENERAL KYRON 2006.03...
  • Page 203 No G5 for 4 cylinders (Without D20DT) IG1 power supply terminal Glow plug control signal (ECU113) Ground terminal Battery main wire Preheat completion transmit terminal : No use for vehicle without remote engine start K-line (ECU 34) ENGINE GENERAL KYRON 2006.03...

  • Page 204: Intake System Layout

    0000-00 4. INTAKE SYSTEM LAYOUT Intake outlet hose Air cleaner Front air duct Terbocharger intercooler Supplying Compressed Air with Intake Manifold Turbocharger's Operation To corresponding cylinders Coolant port Air cleaner Inter cooler Turbo charger From intercooler ENGINE GENERAL KYRON 2006.03...
  • Page 205 01-13 0000-00 Recirculation of Exhaust Gas when Turbocharger Intercooler EGR Valve Operates EGR valve Intake com pressed air Exhaust gas HFM Sensor Plug-in sensor Temperature Pretension Air cleaner Turbo - charger - Sensor graph ENGINE GENERAL KYRON 2006.03...

  • Page 206: Exhaust System Layout

    01-14 0000-00 5. EXHAUST SYSTEM LAYOUT EEGR Pipe Passage for recirculation of exhaust gas DOC (Diesel Catalytic Converter) Exhaust Manifold To turbo - To EGR charger pipe From cylinders ENGINE GENERAL KYRON 2006.03...
  • Page 207 IP interior fuse duct hose valve that Engine ECU box (RH) opens/closes due to pressure differences (No. 95) No.63(7.5A) between the intake side and crankcase. ENGINE GENERAL KYRON 2006.03...

  • Page 208: Lubrication System Layout

    01-16 0000-00 6. LUBRICATION SYSTEM LAYOUT Oil dipstick gauge Cylinder Head Cover Oil Pressure Warning Lamp (Cluster) Oil Pan and Baffle Plate (Integrated Type) Oil Strainer ENGINE GENERAL KYRON 2006.03...
  • Page 209 Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through duct hose valve that opens/closes due to pressure differences between the intake side and crankcase. ENGINE GENERAL KYRON 2006.03...

  • Page 210: Cooling System Layout

    Coolant inlet hose Return hose Coolant outlet hose PWM electric Radiator Coolant Port Water Pump & Pipe Thermostat (inside) Coolant - Cylinder outlet port Radiator block Reservoir (Coolant inlet hose) Radiator Assembly Cooling Fan and Fan Clutch ENGINE GENERAL KYRON 2006.03...
  • Page 211 01-19 0000-00 Engine Oil Filter & Cooler Oil filter cap Oil cooler cooler filter Oil pressure switch ENGINE GENERAL KYRON 2006.03...

  • Page 212: Fuel System Layout

    Fuel filter Connector HP Pump Fuel return port Fuel return port Fuel tempera - ture sensor Venturi IMV connector IMV valve High pres - sure fuel supply port Low pres - sure fuel supply port ENGINE GENERAL KYRON 2006.03...
  • Page 213 01-21 0000-00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ENGINE GENERAL KYRON 2006.03...

  • Page 214: Fuel Supply System

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

  • Page 215: Cleanness

    The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise. ENGINE GENERAL KYRON 2006.03...
  • Page 216 At this point, thoroughly clean the related area in engine compartment. Clean the engine compartment before starting service works. Tool kit for Took kit for low Removal tool box and high pressure line pressure line cap kits ENGINE GENERAL KYRON 2006.03...
  • Page 217 If not, the injection point may be deviated from correct position, and it may cause engine disorder. Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components. ENGINE GENERAL KYRON 2006.03...
  • Page 218 Priming pump filled pump. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status. With SCAN-100, check if there are current faults and erase the history faults. ENGINE GENERAL KYRON 2006.03...
  • Page 219 Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.) ENGINE GENERAL KYRON 2006.03...

  • Page 220: Maintenance And Repair

    Using oils of any viscosity other than those viscosities recommended could result in engine damage. ▷ Cooling System Service Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section. ENGINE GENERAL KYRON 2006.03...
  • Page 221 Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type) ENGINE GENERAL KYRON 2006.03...

  • Page 222: Guidelines For Service Work Safety

    Notice means precautions on tool/device or part damages or personal injuries that can occur during service works. However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses. ENGINE GENERAL KYRON 2006.03...
  • Page 223 LOCK position before work. · Be careful not to touch hot components like catalytic converter, muffler and exhaust pipe when the engine is running or just stopped. They may burn you badly. ENGINE GENERAL KYRON 2006.03...
  • Page 224 While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. During service work of removal/installation, be sure to check each connected portions to engine not to make interference. ENGINE GENERAL KYRON 2006.03...
  • Page 225 When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury. ENGINE GENERAL KYRON 2006.03...

  • Page 226: During Service Work For Inspection

    Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work. Use recommended and specified tools to increase efficiency of service work. Use only genuine spare parts. ENGINE GENERAL KYRON 2006.03...
  • Page 227 (Refer to cleanness.) If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new. ENGINE GENERAL KYRON 2006.03...

  • Page 228: During Service Work For Electric Devices

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

  • Page 229: Owner Inspections And Services

    ▶ Headlamp Aim Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed. ENGINE GENERAL KYRON 2006.03...
  • Page 230 Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once. ENGINE GENERAL KYRON 2006.03...
  • Page 231 ▶ Hood Latch Operation When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly. ENGINE GENERAL KYRON 2006.03...
  • Page 232 Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation. ENGINE GENERAL KYRON 2006.03...

  • Page 233: Standard Bolts Specifications

    01-41 0000-00 16. STANDARD BOLTS SPECIFICATIONS ENGINE GENERAL KYRON 2006.03...
  • Page 234 Determine extra proper tightening torque if tightens with washer or packing. If tightens bolts on the below materials, be sure to determine the proper torque. Aluminum alloy: Tighten to 80 % of above torque table. Plastics: Tighten to 20 % of above torque table. ENGINE GENERAL KYRON 2006.03...
  • Page 235 It satisfies the strict emission regulation and provides improved output and maximum torque. Oil separator Coolant (PCV valve) reservoir Engine oil Vacuum dipstick pump Air cleaner assembly Engine oil filler cap VGT Turbo sensor charger Engine ENGINE ASSEMBLY KYRON 2006.03...
  • Page 236 02-3 1212-01 Vacuum modulator ABS/ESP Brake fluid modulator EGR valve reservoir Battery Fuel filter & priming pump Washer fluid reservoir Power steering oil PWM electric reservoir fan & fan shroud ENGINE ASSEMBLY KYRON 2006.03...
  • Page 237 Oil separator (with PCV) VGT Turbo charger EGR pipe Water pump pulley Alternator Crankshaft pulley Oil pan Auto tensioner Air conditioner compressor Auto tensioner pulley Power steering pump pulley Power steering pump EGR valve Idle pulley Viscos clutch pulley ENGINE ASSEMBLY KYRON 2006.03...
  • Page 238 Water outlet port EGR valve Oil filler Booster pressure sensor 10 ± 1.0 Nm Common rail (25 ± 2.5 Nm) Vacuum pump (10 ± 1.0 Nm) Glow plug (15 ± 3 Nm) Cylinder head cover VGT Turbo charger ENGINE ASSEMBLY KYRON 2006.03...
  • Page 239 Vacuum modulator for VGT turbocharger actuator Flywheel Crank position sensor 0.8 ± 0.4 Nm Gap: 0.7 ~ 1.5 mm Vacuum modulator for EGR valve Oil filter & oil cooler Vacuum pump Booster pressure sensor Intake manifold ENGINE ASSEMBLY KYRON 2006.03...
  • Page 240 02-7 1212-01 Left Side View Cylinder head jack valve screw VGT Turbo charger assembly Cylinder block assembly Engine mounting bracket Oil pan Alternator Water pump EGR pipe Oil dipstick gauge Oil separator (with PCV) ENGINE ASSEMBLY KYRON 2006.03...
  • Page 241 02-8 1212-01 2. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE ASSEMBLY KYRON 2006.03...
  • Page 242 02-9 1212-01 2) Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE ASSEMBLY KYRON 2006.03...
  • Page 243 02-10 1212-01 3. TIGHTENING TORQUE ENGINE ASSEMBLY KYRON 2006.03...
  • Page 244 02-11 1212-01 ENGINE ASSEMBLY KYRON 2006.03...
  • Page 245 02-12 1212-01 ENGINE ASSEMBLY KYRON 2006.03...
  • Page 246 5) Conditions for Using Priming Pump After run out of fuel After draining the water from fuel separator After replacing the fuel filter ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 247 When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes rigid before starting the engine. The water drain from fuel filter should be performed whenever changing the engine oil. ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 248 Start the engine and check the conditions. If the priming pump is not properly operated, air may get into the fuel line. It may cause starting problem or fuel system problem. Make sure to perform the job in step 4. ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 249 Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables. ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 250 ECU control section. Fuel Line System common rail High pressure pipe Common rail Fuel pressure sensor Injector D20DT: 4 EA D27DT: 5 EA Priming pump Fuel filter Fuel pump (High pressure pump, transfer pump) Fuel route ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 251 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) High pressure supply line Transfer pressure supply line Return line ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 252 After run out of fuel After draining the water from fuel separator After replacing the fuel filter Press the priming pump until it becomes rigid before starting the engine. ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 253 Fuel filter purifies fuel before it reaches to high pressure pump help proper operations in high pressure pump. And more, it separates water from fuel to prevent water from getting into FIE system (high pressure line). ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 254 Fuel pressure is measured by rail pressure sensor. And the fuel pressure regulating valve (IMV, Inlet Metering Valve) included in high pressure pump housing keeps pressure to a desired level. ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 255 6) Fuel Filter Replacement Fuel filter change interval: every 30,000 km Water separation interval: every 10,000 km (same with engine oil change interval) Never reuse the removed fuel filter ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 256 03-13 1881-01 6. CIRCUIT DIAGRAM ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 257 03-14 1881-01 ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 258 03-15 1881-01 ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 260 - Initial cleaning: 5,000 km, Clean or change every 10,000 km as required. However, change every 30,000 km. Service Interval - If the vehicle is operated under severe condition (short distance driving, extensive ldling or driving in dusty condition): More frequent maintenance is required. ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 261 1. Plug-in sensor 2. Cylinder housing 3. Protection grid Plug-in sensor 4. Hybrid cover 5. Measuring duct cover 6. Housing 7. Hybrid 8. Sensor 9. Mounting plate Temperature 10. O-ring Protection grid sensor 11. Temperature sensor ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 262 Turbocharger Intercooler The charging efficiency may be lowered or the knocking may happen as the intake air is heated and the density of air is lowered. The intercooler is the device which cools the supercharged air. ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 263 04-6 2321-01 2) Layout ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 264 The inlet port and coolant outlet port is integrated together. Therefore, be careful not to let the residual coolant in the manifold enter the inlet port when removing the intake manifold. Also, replace the gasket with a new one and tighten it to the specified torque (25 ± 2.5 Nm). ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 265 Intake air Intake air Exhaust gas 1. EGR pipe (RH) 5. Exhaust gas 2. EGR pipe (center) 6. EGR pipe (LH) 3. Coolant emission port 7. Vacuum modulator to the EGR valve 4. Intake air (intercooler) ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 266 Thus, more air is entered the cylinder than the engine only with the turbocharger to give more power. Intercooler For removal and installation procedures, refer to the "Cooling system" section in DI engine service manual. ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 267 04-10 2321-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE INTAKE SYSTEM KYRON 2006.03...
  • Page 268 The DI engine ECU receives feedback signal of change in amount of air being passed through the HFM sensor according to the opening amount of the EGR valve. ENGINE EXHAUST SYSTEM KYRON 2006.03...
  • Page 269 Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is used to control the booster pressure valve in turbo charger. ENGINE EXHAUST SYSTEM KYRON 2006.03...
  • Page 270 EGR Valve and Installation Location Intake air Intake (intercooler) manifold Intake Intake manifold manifold EGR pipe EGR pipe (LH) Exhaust Manifold Exhaust manifold To turbo- To EGR EGR pipe (RH) charger valve Diesel catalytic converter → Muffler ENGINE EXHAUST SYSTEM KYRON 2006.03...
  • Page 271 05-6 1913-01 2) Exhaust Gas Flows ENGINE EXHAUST SYSTEM KYRON 2006.03...
  • Page 272 When operating in dusty, sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing 2. OIL PRESSURE SWITCH Operating temperature: -40 ~ 140°C Operating pressure: 0.3 ~ 0.55 bar Permissible pressure: 10 bar LUBRICATION SYSTEM KYRON 2006.03...
  • Page 273 Blow-by gas again after entering the combustion chamber (air duct hose) through air duct hose via PCV valve that Inlet port opens/closes due to pressure differences between the intake side and crankcase. Oil (oil gauge pipe) LUBRICATION SYSTEM KYRON 2006.03...
  • Page 274 06-5 1533-01 Oil pressure Warning Lamp Cylinder Head Cover (Cluster) Oil Pan and Baffle Plate Oil Strainer Oil Filter & Oil Cooler (Integrated Type) cooler filter LUBRICATION SYSTEM KYRON 2006.03...
  • Page 275 Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 Return hole: φ 14 Chain nozzle: φ 1 HP pump bearing: φ 6 Cylinder Block LUBRICATION SYSTEM KYRON 2006.03...
  • Page 276 2. LUBRICATION DIAGRAM Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of cylinder head LUBRICATION SYSTEM KYRON 2006.03...
  • Page 277 07-3 9210-05 9210-05 ENGINE COOLING SYSTEM GENERAL 1. ENGINE COOLING SPECIFICATIONS COOLING SYSTEM KYRON 2006.03...
  • Page 278 07-4 9210-05 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS ENGINE COOLING Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor COOLING SYSTEM KYRON 2006.03...
  • Page 279 Cylinder block side · Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump Cylinder head side · Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump COOLING SYSTEM KYRON 2006.03...
  • Page 280 It prevents cooling efficiency from decreasing due to coolant separation between · cylinder #4 and #5. In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to water pump with an additional pulley. COOLING SYSTEM KYRON 2006.03...
  • Page 281 08-3 1461-01 1461-01 ENGINE ELECTRICAL SYSTEM GENERAL 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 282 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ELECTRIC IN ENGINE Fuel Pressure Camshaft Position Coolant Temperature Fuel Temperature Sensor Sensor Sensor Sensor Booster Pressure Oil Pressure Switch Crankshaft Position Knock Sensor Sensor Sensor (1 EA) ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 283 08-5 1461-01 2. COMPONENTS OF ELECTRIC DEVICES IN ENGIN Alternator Glow Plug Capacity PTC equipped vehicle : 12V - 140A FFH equipped vehicle : 12V - 115A Air Conditioner Compressor Starter ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 284 08-6 1461-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1) Preheating ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 285 08-7 1461-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1) Starting & Charging ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 286 Water Pump and Pipe Coolant Port Thermostat (inside) Cylinder block Coolant outlet Radiator port Reservior (coolant inlet hose) Engine Oil Filter and Cooler Oil Filter cap Oil cooler Oil cooler Oil filter Oil pressure switch ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 287 09-4 1491-01 2. TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors (4 EA) Glow Plugs (4 EA) ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 288 09-5 1491-01 3. SIDE VIEW Coolant Temperature Knock Sensors (1 EA) Sensor Fuel Temperature Sensor Fuel Pressure Crankshaft Position Regulating Valve Sensor ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 289 (Water warning light, glow Accelerator sensor plug Vehicle speed sensor indicator light, engine warning Switch input signal light) (IG, brake, clutch, A/C signal, Preheater (auxiliary heater) A/C compressor) K - line CAN communication Self-diagnosis ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 290 Driving mode control If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm and the drive map will be used to match the drivers inputs with optimum engine power. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 291 If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is increased. If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is reduced. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 292 To do this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the water temperature. This requirement only concerns the starting phase, since once the engine has started the system must re-use the mapping and the corrections described previously. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 293 This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude. During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant temperature. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 294 This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined before each injection as a function of the instantaneous engine speed. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 295 A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 296 The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver demand is then corrected according to the coolant temperature. This correction is added to the driver demand. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 297 A correction depending on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 298 The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 299 The first MDP value is provided by the C2I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 300 The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 301 The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of the injector. So, the pulse should be corrected according to characteristics of each injector. ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 302 When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when the accelerator pedal is depressed. C2I Number value (16 digits) For coding of C2I, refer to "Diagnosis" section ※ ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 303 1 ~ 2 mm/str, so precise control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors. 1) Learning Conditions 2) Trouble Codes ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 304 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 2006.03...
  • Page 305 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 2006.03...
  • Page 306 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2006.03...
  • Page 307 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 2006.03...
  • Page 308 (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 2006.03...
  • Page 309 (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 2006.03...
  • Page 310 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 2006.03...
  • Page 311 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2006.03...
  • Page 312 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 314: General

    01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. ENGINE ASSEMBLY LAYOUT 1) LH Side View D20DT D27DT ENGINE D20DT KYRON 2006.03...
  • Page 315 01-4 0000-00 2) RH side view D20DT D27DT ENGINE D20DT KYRON 2006.03...
  • Page 316 01-5 0000-00 3) Front view D20DT D27DT ENGINE D20DT KYRON 2006.03...
  • Page 317 01-6 0000-00 4) Fan belt D20DT D27DT ENGINE D20DT KYRON 2006.03...

  • Page 318: Components In D20Dt Engine And D27Dt Engine

    01-7 0000-00 2. COMPONENTS IN D20DT ENGINE AND D27DT ENGINE ENGINE D20DT KYRON 2006.03...
  • Page 319 01-8 0000-00 ENGINE D20DT KYRON 2006.03...
  • Page 320 01-9 0000-00 ENGINE D20DT KYRON 2006.03...
  • Page 321 01-10 0000-00 ENGINE D20DT KYRON 2006.03...

  • Page 322: Engine Controls Layout

    01-11 0000-00 3. ENGINE CONTROLS LAYOUT 1) Ecu related componets (1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 323 01-12 0000-00 (2) D27DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 324 01-13 0000-00 2) ENGINE AND SENSORS (1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 325 01-14 0000-00 (2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 326: Electrical Components And Preheating System

    01-15 0000-00 4. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 327 01-16 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 328: Intake System Layout

    01-17 0000-00 5. INTAKE SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 329 01-18 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 330: Exhaust System Layout

    01-19 0000-00 6. EXHAUST SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 331 01-20 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 332: Lubrication System Layout

    01-21 0000-00 7. LUBRICATION SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 333 01-22 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 334: Cooling System Layout

    01-23 0000-00 8. COOLING SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 335 01-24 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 336: Fuel System Layout

    01-25 0000-00 9. FUEL SYSTEM LAYOUT 1) D20DT Engine ENGINE D20DT KYRON 2006.03...
  • Page 337 01-26 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 338: 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 2006.03...
  • Page 339 01-28 0000-00 2) D27DT Engine ENGINE D20DT KYRON 2006.03...

  • Page 340: 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 2006.03...
  • Page 341 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 2006.03...
  • Page 342 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 2006.03...
  • Page 343 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 2006.03...
  • Page 344 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 2006.03...

  • Page 346: 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 2006.03...
  • Page 347 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 2006.03...

  • Page 348: 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 2006.03...
  • Page 349 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 2006.03...
  • Page 350 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 2006.03...
  • Page 351 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 2006.03...

  • Page 352: 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 2006.03...
  • Page 353 (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 2006.03...

  • Page 354: 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 2006.03...

  • Page 355: 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 2006.03...
  • Page 356 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 2006.03...
  • Page 357 ▶ 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 2006.03...
  • Page 358 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 2006.03...

  • Page 359: Standard Bolts Specifications

    01-48 0000-00 17. STANDARD BOLTS SPECIFICATIONS *Diameter X pitch in millimeters ENGINE D20DT KYRON 2006.03...
  • Page 360 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 2006.03...
  • Page 362 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 2006.03...
  • Page 363 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 2006.03...
  • Page 364 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 2006.03...
  • Page 365 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 2006.03...
  • Page 366 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 2006.03...
  • Page 367 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 2006.03...
  • Page 368 02-9 1114-01 3. SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE D20DT KYRON 2006.03...
  • Page 369 02-10 1114-01 2) Engine Performance Curve (1) Vehicle with A/T Output and Torque ▶ D20DT engine D27DT engine ENGINE D20DT KYRON 2006.03...
  • Page 370 02-11 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT KYRON 2006.03...
  • Page 371 02-12 1114-01 (2) Vehicle with M/T ▶ Output and Torque D20DT engine D27DT engine ENGINE D20DT KYRON 2006.03...
  • Page 372 02-13 1114-01 ▶ Oil Temperature/Pressure and Boost Pressure D20DT engine D27DT engine ENGINE D20DT KYRON 2006.03...
  • Page 373 02-14 1114-01 4. TIGHTENING TORQUE ENGINE D20DT KYRON 2006.03...
  • Page 374 02-15 1114-01 ENGINE D20DT KYRON 2006.03...
  • Page 375 02-16 1114-01 ENGINE D20DT KYRON 2006.03...
  • Page 376 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 2006.03...
  • Page 377 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 2006.03...
  • Page 378 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 2006.03...
  • Page 379 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 2006.03...
  • Page 380 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 2006.03...
  • Page 381 03-8 1881-01 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE) ENGINE D20DT KYRON 2006.03...
  • Page 382 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 2006.03...
  • Page 383 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 2006.03...
  • Page 384 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 2006.03...
  • Page 385 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 2006.03...
  • Page 386 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 2006.03...
  • Page 387 03-14 1881-01 7) Circuit Diagram ENGINE D20DT KYRON 2006.03...
  • Page 388 03-15 1881-01 ENGINE D20DT KYRON 2006.03...
  • Page 389 03-16 1881-01 ENGINE D20DT KYRON 2006.03...
  • Page 390 ­ 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 2006.03...
  • Page 391 04-4 2321-01 OVERVIEW AND OPERATION PROCESS 1. ENGINE INTAKE COMPONENTS LOCATOR 1) D20DT Engine Air Cleaner Intake Manifold Cover Housing Elemen HFM Sensor Intercooler ENGINE D20DT KYRON 2006.03...
  • Page 392 04-5 2321-01 2) D27DT Engine Air Cleaner Intake Manifold Cover Element Housing HFM Sensor Intercooler ENGINE D20DT KYRON 2006.03...
  • Page 393 04-6 2321-01 2. AIR FLOWS 1) Work Flow of Intake System ENGINE D20DT KYRON 2006.03...
  • Page 394 (160°C). Control unit computes intake air volume based on voltage changes of heating resistance. Intake air temperature is measured by NTC integrated in the sensor. ENGINE D20DT KYRON 2006.03...
  • Page 395 CI type HFM sensor: The air flowing the sensor does not directs toward sensing section but flows along with lower wall after passing protection grid to enhance durability of the sensor. Oil, water and dust less damage the sensor. <Structure of CI type HFM Sensor> ENGINE D20DT KYRON 2006.03...
  • Page 396 04-9 2321-01 <Circuit Diagram of HFM Sensor> ENGINE D20DT KYRON 2006.03...
  • Page 397 The intercooler is the device which cools (50 ~ 60°C) the air entering the engine. Cold air has more oxygen molecules than warm air. Thus cooler air gives more power and better fuel economy. 1. Intercooler ENGINE D20DT KYRON 2006.03...
  • Page 398 3. Maximized intake efficiency with helical and tangential inlet port 1) Improving the swirl ratio in low and mid operating range 2) Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range 4. Integrated inlet port and coolant outlet port ENGINE D20DT KYRON 2006.03...
  • Page 399 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 2006.03...
  • Page 400 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 2006.03...
  • Page 401 05-5 1913-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS LOCATOR OF EXHAUST SYSTEM 1) D20DT ENGINE Exhaust Manifold EGR Valve Muffler Catalytic Converter Vacuum Modulator Turbo Charger EGR Pipe (DOC) ENGINE D20DT KYRON 2006.03...
  • Page 402 05-6 1913-01 Exhaust Manifold EGR Valve Muffler Catalytic Converter Vacuum Modulator Turbo Charger EGR Pipe (DOC) ENGINE D20DT KYRON 2006.03...
  • Page 403 05-7 1913-01 2. EXHAUST GAS FLOWS ENGINE D20DT KYRON 2006.03...
  • Page 404 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 2006.03...
  • Page 405 06-4 1533-01 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF LUBRICATION SYSTEM 1)D20DT ENGINE Cylinder Head Cover Oil Dipstick Oil Separator Oil Filter Oil Pump Oil Pan Oil Cooler Oil Pressure Switch ENGINE D20DT KYRON 2006.03...
  • Page 406 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 2006.03...
  • Page 407 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 2006.03...
  • Page 408 ※ 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 2006.03...
  • Page 409 07-3 9210-05 9210-05 ENGINE COOLING SYSTEM GENERAL 1. ENGINE COOLING SPECIFICATIONS ENGINE D20DT KYRON 2006.03...
  • Page 410 07-4 9210-05 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ENGINE COOLING 1) D20DT Engine Coolant Reservoir Water Pump Cooling Fan and Coolant Radiator Assembly Fan Clutch Temperature Sensor ENGINE D20DT KYRON 2006.03...
  • Page 411 07-5 9210-05 2) D27DT Engine Coolant Coolant Reservoir Temperature Sensor Radiator Water Pump Cooling Fan ENGINE D20DT KYRON 2006.03...
  • Page 412 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 2006.03...
  • Page 413 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 2006.03...
  • Page 414 08-3 1461-01 1461-01 ENGINE ELECTRIC SYSTEM GENERAL 1.SPECIFICATIONS OF ENGINE ELECTRIC ENGINE D20DT KYRON 2006.03...
  • Page 415 OVERVIEW AND OPERATION PROCESS 1. COMPONENTS OF ELECTRIC IN ENGINE 1) D20DT ENGINE Fuel Pressure Camshaft Position Coolant Temperature Fuel Temperature Sensor Sensor Sensor Sensor Booster Pressure Oil Pressure Switch Crankshaft Position Knock Sensor (1 Sensor Sensor ENGINE D20DT KYRON 2006.03...
  • Page 416 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 2006.03...
  • Page 417 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 2006.03...
  • Page 418 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 2006.03...
  • Page 419 08-8 1461-01 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM ENGINE D20DT KYRON 2006.03...
  • Page 420 08-9 1461-01 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ENGINE D20DT KYRON 2006.03...
  • Page 421 EGINE CONTROL SYSTEM GENERAL 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 2006.03...
  • Page 422 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 2006.03...
  • Page 423 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 2006.03...
  • Page 424 09-6 1491-01 (2) D27DT Engine Fuel Pressure Sensor Booster Pressure Sensor Injectors (5 EA) Glow Plugs (5) ENGINE D20DT KYRON 2006.03...
  • Page 425 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 2006.03...
  • Page 426 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 2006.03...
  • Page 427 (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 2006.03...
  • Page 428 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 2006.03...
  • Page 429 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 2006.03...
  • Page 430 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 2006.03...
  • Page 431 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 2006.03...
  • Page 432 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 2006.03...
  • Page 433 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 2006.03...
  • Page 434 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 2006.03...
  • Page 435 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 2006.03...
  • Page 436 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 2006.03...
  • Page 437 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 2006.03...
  • Page 438 The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. ENGINE D20DT KYRON 2006.03...
  • Page 439 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 2006.03...
  • Page 440 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 2006.03...
  • Page 441 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 2006.03...
  • Page 443 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 2006.03...
  • Page 444 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 2006.03...
  • Page 445 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration ENGINE D20DT KYRON 2006.03...
  • Page 446 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 2006.03...
  • Page 447 (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 2006.03...
  • Page 448 (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 2006.03...
  • Page 449 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 2006.03...
  • Page 450 Ensure that the braking distance is maintained and use the brake pedal if needed. ENGINE D20DT KYRON 2006.03...
  • Page 451 ENGINE INFORMATION 0000-00 ENGINE INFORMATION GENERAL) 1. COMPONENT LOCATOR....... 2. DESCRIPTION AND OPERATION..
  • Page 454 01-4 0000-00 0000-00 ENGINE GENERAL GENERAL 1. COMPONENT LOCATOR 1) Front View ENGINE INFORMATION KYRON 2006.03...
  • Page 455 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 2006.03...
  • Page 456 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 2006.03...
  • Page 457 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 2006.03...
  • Page 459 02-3 1113-01 1113-01 ENGINE ASSEMBLY GENERAL 1. SPECIFICATIONS 1) ENGINE SPECIFICATIONS ENGINE ASSEMBLY KYRON 2006.03...
  • Page 460 02-4 1113-01 2) PERFORMANCE CURVE ENGINE ASSEMBLY KYRON 2006.03...
  • Page 461 02-5 1113-01 2. SPECIAL TOOLS AND EQUIPMENT ENGINE ASSEMBLY KYRON 2006.03...
  • Page 462 02-6 1113-01 ENGINE ASSEMBLY KYRON 2006.03...
  • Page 463 02-7 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin ENGINE ASSEMBLY KYRON 2006.03...
  • Page 464 02-8 1113-01 3. FASTENER TIGHTENING SPECIFICATIONS ENGINE ASSEMBLY KYRON 2006.03...
  • Page 465 02-9 1113-01 4. FASTENER TIGHTENING SPECIFICATIONS (CONT ' D) ENGINE ASSEMBLY KYRON 2006.03...
  • Page 466 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 2006.03...
  • Page 467 03-4 2211-22 ▶ temperature vs resistance ENGINE FUEL SYSTEM KYRON 2006.03...
  • Page 468 NO DATA...
  • Page 469 (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 2006.03...
  • Page 470 05-4 2420-01 4. FASTENER TIGHTENING SPECIFICATIONS ENGINE EXHAUST SYSTEM KYRON 2006.03...
  • Page 471 06-3 9210-01 9210-01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1. OIL CIRCULATION LUBRICATION SYSTEM KYRON 2006.03...
  • Page 472 (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 2006.03...
  • Page 473 07-3 2110-01 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS COOLING SYSTEM KYRON 2006.03...
  • Page 474 07-4 2110-01 2. SPECIAL TOOLS AND EQUIPMENT COOLING SYSTEM KYRON 2006.03...
  • Page 475 07-5 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS COOLING SYSTEM KYRON 2006.03...
  • Page 476 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 2006.03...
  • Page 477 07-7 2110-01 2. COMPONENT LOCATOR COOLING SYSTEM KYRON 2006.03...
  • Page 478 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 2006.03...
  • Page 479 08-3 1452-01 1452-01 ENGINE ELECTRIC DEVICES GENERAL 1. GENERAL SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 480 08-4 1452-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 481 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 2006.03...
  • Page 482 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 2006.03...
  • Page 483 08-7 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT ENGINE ELECTRIC DEVICES KYRON 2006.03...
  • Page 484 09-3 1522-16 1522-16 ENGINE CONTROL SYSTEM GENERAL 1. ENGINE DATA DISPLAY TABLE ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 485 09-4 1522-16 1) TEMPERATURE VS RESISTANCE 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE CONTROL SYSTEM KYRON 2006.03...
  • Page 486 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 2006.03...
  • Page 487 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 2006.03...
  • Page 488 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM KYRON 2006.03...
  • Page 489 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 2006.03...
  • Page 490 (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 2006.03...
  • Page 491 (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 2006.03...
  • Page 492 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 2006.03...
  • Page 493 Ensure that the braking distance is maintained and use the brake pedal if needed. CRUISE CONTROL SYSTEM KYRON 2006.03...
  • Page 494 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 495: Electric General

    Steering Wheel Angular Sensor / Immobilizer Immobilizer Steering wheel angular sensor Door lock relay Chime bell Curtain air bag module Sun sensor Buzzer for PAS TV antenna amplifier RK STICS PAS Unit TCCU and TCU Driver Seat Memory Switch TCCU ELECTRIC SYSTEM KYRON 2006.03...
  • Page 496 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 2006.03...

  • Page 497: Switches, Units And Sensors In Engine Compartment

    2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT FFH Assembly Receiver Drier and Triple Pressure Switch Horn (RH) AQS Sensor and FFH Ambient Temperature Sensor FFH ambient temperature sensor AQS sensor (ambient temperature sensor integrated type) ELECTRIC SYSTEM KYRON 2006.03...
  • Page 498 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 2006.03...

  • Page 499: 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 2006.03...
  • Page 500 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 2006.03...

  • Page 501: 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 2006.03...
  • Page 502 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 2006.03...

  • Page 503: Electric Components And Layout

    01-10 0000-00 5. ELECTRIC COMPONENTS AND LAYOUT ▶ Wiring Harness Arrangement ELECTRIC SYSTEM KYRON 2006.03...
  • Page 504 01-11 0000-00 ▶ Components Locator ELECTRIC SYSTEM KYRON 2006.03...

  • Page 505: Fuses And Relays

    There are three fuse and relay boxes in this vehicle (one at each side of instrument panel and one in enginecompartment). The designation and capacity of relays and fuses is shown on the fuse and relay box cover. 1) Fuse and Relay Box in Engine Compartment Fuses and Relays Connector Arrangement ELECTRIC SYSTEM KYRON 2006.03...
  • Page 506 01-13 0000-00 ▶ Connector ELECTRIC SYSTEM KYRON 2006.03...
  • Page 507 Disconnect the negative battery cable, open the fuse and relay box cover in engine compartment, and unscrew the mounting nuts. Lift the fuse and relay box assembly and disconnect connectors behind the assembly. Remove the fuse and relay box assembly. ELECTRIC SYSTEM KYRON 2006.03...

  • Page 508: Interior Fuse Box

    01-15 0000-00 7. INTERIOR FUSE BOX Fuse and Relay Box (LH) Fuse and Relay Box (RH) ELECTRIC SYSTEM KYRON 2006.03...
  • Page 509 01-16 0000-00 1) Designation and Capacity ▶ Driver Side ELECTRIC SYSTEM KYRON 2006.03...
  • Page 510 01-17 0000-00 ▶ Passenger Side ELECTRIC SYSTEM KYRON 2006.03...
  • Page 511 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 2006.03...
  • Page 512 01-19 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 2006.03...
  • Page 513 01-20 0000-00 4) ELECTRICAL WIRING DIAGRAMS ELECTRIC SYSTEM KYRON 2006.03...
  • Page 514 (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 2006.03...
  • Page 515 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 2006.03...
  • Page 516 Front washer motor DC 12 V 1.5 A Rear washer motor relay DC 12 V 500 mA (Inducted load) Headlamp relay DC 12 V 750 mA (Inducted load) Front defogger relay DC 12 V 200 mA (Inducted load) STICS KYRON 2006.03...
  • Page 517 02-6 8710-01 ▶ Input Signals STICS KYRON 2006.03...
  • Page 518 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 2006.03...
  • Page 520 ECU. Refer to the informationthat follows for Transponder specific functions and their descriptions. Battery IMMO KYRON 2006.03...
  • Page 521 1. Engine start 2. Door lock/unlock PANIC button PANIC function (with ignition key in)Theft deterrent horn sounds approx. 27 seconds. The doors cannot be locked by remote control if they are not closed. Specification CR 2032 Quantity IMMO KYRON 2006.03...
  • Page 523 (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 2006.03...
  • Page 524 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 2006.03...
  • Page 525 "R": Passenger side mirror then adjust theselected mirror up, down, left, or rightby pressing corresponding edgesof the switch to get the direct rearview. 2) Seat Position Control Seat Height Adjustment Seat Slide Adjustment Seat Tilt Adjustment SPWM KYRON 2006.03...
  • Page 526 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 2006.03...
  • Page 527 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 2006.03...
  • Page 528 04-8 7410-13 3. SEAT POSITION WITH MEMORY INPUT/OUTPUT OF SPWM UNIT SPWM KYRON 2006.03...
  • Page 529 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 2006.03...
  • Page 530 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 2006.03...
  • Page 531 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 2006.03...
  • Page 532 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 2006.03...
  • Page 533 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 2006.03...
  • Page 534 The outside rearview mirrors can be folded and unfolded within 30 ± 6 seconds even after turning off the ignitionswitch. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is extended13 seconds when pressing the switch again. ▶ Timing Chart SPWM KYRON 2006.03...
  • Page 535 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 2006.03...
  • Page 536 05-4 8010-01 2.WARNING / INDICATOR PANE CLUSTER KYRON 2006.03...
  • Page 537 05-5 8010-01 CLUSTER KYRON 2006.03...
  • Page 538 05-6 8010-01 1. CLUSTER CONFIGURATION Front View Rear View Main Connector Sub Connector CLUSTER KYRON 2006.03...
  • Page 539 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 2006.03...
  • Page 540 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 2006.03...
  • Page 541 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 2006.03...
  • Page 542 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 2006.03...
  • Page 543 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 2006.03...
  • Page 544 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 2006.03...
  • Page 545 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 2006.03...
  • Page 546 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 2006.03...
  • Page 547 150 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 2006.03...
  • Page 548 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 2006.03...
  • Page 549 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 2006.03...
  • Page 550 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 2006.03...
  • Page 551 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 2006.03...
  • Page 552 05-20 8010-01 5. CLUSTER ELECTRICAL WIRING DIAGRAMS ▶ Gauge (speed, RPM, fuel, temp), Warning Lamp (fuel, fuel filter, ABS/ESP, brake, HDC, 4WD) CLUSTER KYRON 2006.03...
  • Page 553 05-21 8010-01 ▶ Warning Lamp (batt charge, oil, hood, door, eng check, air bag, ssps,seat belt), Turn Signal, Fog Lamp, Hazard CLUSTER KYRON 2006.03...
  • Page 554 (12V / 55W) High Beam one at each side (12V/55W) Position Lamp EU: one at each side (12V/W5W) Position lamp and Turn Signal Lamp General: one at each side (12V/28W/8W) EU: one at each side (12V/P21W) LAMP KYRON 2006.03...
  • Page 555 8310-01 Fog Lamp Assembly Fog Lamp Fog lamp General: one at each side (12V/27W) angle adjustment EU: one at each side (12V/H27W) Side Repeater Assembly General: one at each side (12V/5W) EU: one at each side (12V/W5W) LAMP KYRON 2006.03...
  • Page 556 General: LH-1 (12V/27W/8W) EU: LH-1 (12V/P21W/5W) Turn Signal Lamp General: one at each side (12V/27W) EU: one at each side (12V/PY21W) License Plate Reflector Lamp Assembly Assembly General: one at each side (12V/5W) EU: one at each side (12V/W5W LAMP KYRON 2006.03...
  • Page 557 Assembly Tail Lamp General: one at each side (12V/27W/8W) EU: one at each side (12V/P21W/5W) Reversing Lamp General: one at each side (12V/16W) Rear Fog Lamp General: one at each side (12V/P21W) High Mounted Stop Lamp Assembly LAMP KYRON 2006.03...
  • Page 558 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 2006.03...
  • Page 559 (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 2006.03...
  • Page 560 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 2006.03...
  • Page 561 Sun roof switch Audio Remote Control Switch Main room lamp switch Room lamp operating switch T/C Control Switch POWER Driver's Seat Warmer Switch MODER MUTER ▲ ▲ Passenger's Seat SEEK Warmer Switch SEEK ▼ ▼ SWITCH KYRON 2006.03...
  • Page 562 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 2006.03...
  • Page 563 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 2006.03...
  • Page 564 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 2006.03...
  • Page 565 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 2006.03...
  • Page 566 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 2006.03...
  • Page 567 "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 2006.03...
  • Page 568 "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 2006.03...
  • Page 569 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 2006.03...
  • Page 570 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 2006.03...
  • Page 571 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 2006.03...
  • Page 572 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 2006.03...
  • Page 573 09-11 8610-09 3. ELECTRICAL WIRING DIAGRAM RAIN SENSOR KYRON 2006.03...
  • Page 574 40 KHz ± 2 KHz Detecting range (13.5 V) ▶ ▶ Horizontal Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm ▶ Vertical Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm KYRON 2006.03...
  • Page 575 When placing the gear selector lever to "R" position, the designated unit (PAS unit) activates the parking aid sensors to measure the distance to obstacles. Gear Selector Lever (R Position) STICS PAS piezoelectric buzzer PAS buzzer KYRON 2006.03...
  • Page 576 10-5 8790-03 Left/Right/Center Sensor Location Center sensor Parking Aid Unit Left sensor Center sensor Connector Right sensor KYRON 2006.03...
  • Page 577 When the sensing portion is covered by rain, water drops, snow or mud. When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). When a high-power radio is turned on. When some accessories are attached in detecting ranges KYRON 2006.03...
  • Page 578 (conditions for warning beep due to failure) Sensor failure conditions (conditions for warning beep due tofailure) Open in sending circuit Back sonar (LH) Back sonar (RH) Open in receiving circuit Open in power circuit (+, -) Back sonar (center) ▶ Warning beeps KYRON 2006.03...
  • Page 579 10-8 8790-03 3. PAS CIRCUIT DIAGRAM KYRON 2006.03...
  • Page 580 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 2006.03...
  • Page 581 11-4 8930-14 1. AV SYSTEM CONFIGURATION AV System (DVD Head Unit + DVD Changer) ▶ ▶ Audio System - 6 Speakers KYRON 2006.03...
  • Page 582 11-5 8930-14 6 DISC changer + TAPE + RADIO CD + RADIO DISC changer CD slot Tape KYRON 2006.03...
  • Page 583 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 2006.03...
  • Page 584 11-7 8930-14 KYRON 2006.03...
  • Page 585 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 2006.03...
  • Page 586 11-9 8930-14 4. AV SYSTEM SPECIFICATIONS AND CONTROL KYRON 2006.03...
  • Page 587 11-10 8930-14 ▶ Function Settings on Touch Panel (Example) KYRON 2006.03...
  • Page 588 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 2006.03...
  • Page 589 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 2006.03...
  • Page 590 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 2006.03...
  • Page 591 01-6 3650-01 2. AUTOMATIC TRANSMISSION (DC 5-SPEED) APPEARANCE Left Side Without Torque Rear View With Torque Converter Converter DC 5-SPEED KYRON 2006.03...
  • Page 592 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 2006.03...
  • Page 593 01-8 3650-01 ▶ Specifications DC 5-SPEED KYRON 2006.03...
  • Page 594 01-9 3650-01 DC 5-SPEED KYRON 2006.03...
  • Page 595 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 2006.03...
  • Page 596 (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 2006.03...
  • Page 597 01-12 3650-01 ▶ General Characteristics DC 5-SPEED KYRON 2006.03...
  • Page 598 01-13 3650-01 OVERVIEW AND OPERATION PROCESS 1. POWER FLOW Brake B1(disk) Brake B3 (disk) Brake B2 (disk) assembly assembly assembly C1 (Disk clutch) C2 (Disk clutch) C3 (Disk clutch) assembly assembly assembly DC 5-SPEED KYRON 2006.03...
  • Page 599 01-14 3650-01 ▶ Shifting Elements ※ 1) Selector program switch: S mode 2) Selector program switch: W mode 3) Overrun DC 5-SPEED KYRON 2006.03...
  • Page 600 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 2006.03...
  • Page 601 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 2006.03...
  • Page 602 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 2006.03...
  • Page 603 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 2006.03...
  • Page 604 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 2006.03...
  • Page 605 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 2006.03...
  • Page 606 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 2006.03...
  • Page 607 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 2006.03...
  • Page 608 02-4 3170-01 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1) Specifications 2) Tightening Torque KYRON 2006.03...
  • Page 609 02-5 3170-01 1. MANUAL TRANSMISSION SYSTEM 1) Neutral Switch N (Neutral) Switch Outside N Switch Inside N Switch KYRON 2006.03...
  • Page 610 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 2006.03...
  • Page 611 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 2006.03...
  • Page 612 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 2006.03...
  • Page 613 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 2006.03...
  • Page 614 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 2006.03...
  • Page 616 03-3 3010-01 1. CLUTCH SPECIFICATIONS 2. TIGHTTENING TORQUE CLUTCH KYRON 2006.03...
  • Page 617 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 2006.03...
  • Page 618 03-5 3010-01 3) Functions Components of Clutch Assembly Adapter/Pipe Assembly Clutch Assembly Concentric Slave Cylinder CLUTCH KYRON 2006.03...
  • Page 619 03-6 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 2006.03...
  • Page 620 04-3 4120-01 1. AXLE SPECIFICATIONS Specification Torque Gear ratio ← ← Type ← → → ← Size Offset ← Housing ← Specification ← Capacity Length ← ← Width Weight ← AXLE KYRON 2006.03...
  • Page 621 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 2006.03...
  • Page 622 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 2006.03...
  • Page 623 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 2006.03...
  • Page 624 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 2006.03...
  • Page 625 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 2006.03...
  • Page 626 06-4 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 2006.03...
  • Page 627 (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 2006.03...
  • Page 628 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 2006.03...
  • Page 629 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 2006.03...
  • Page 630 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 2006.03...
  • Page 631 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 2006.03...
  • Page 632 06-10 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 2006.03...
  • Page 633 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 2006.03...
  • Page 634 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 2006.03...
  • Page 635 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 637: Specification

    07-3 3310-00 3310-00 PROPELLER SHAFT 1. SPECIFICATION PROPELLER SHAFT KYRON 2006.03...

  • Page 638: Overview

    The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration. PROPELLER SHAFT KYRON 2006.03...

  • Page 639: Component Locator

    8. Split washer 2. Journal bearing cap 9. Slip tube shaft 3. Spider journal 10. Tube 4. Slip yoke assembly 11. Tube yoke 5. Grease nipple 12. Flange yoke 6. Dust cap 13. Center bearing 7. Oil seal PROPELLER SHAFT KYRON 2006.03...
  • Page 640 07-6 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 2006.03...
  • Page 641 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 2006.03...
  • Page 642 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 2006.03...
  • Page 643 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 2006.03...
  • Page 644 07-10 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 2006.03...

  • Page 645: Shaft

    Remove the other bearings with same manner. If it cannot be removed, hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer. PROPELLER SHAFT KYRON 2006.03...
  • Page 646 07-12 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 2006.03...
  • Page 647 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 2006.03...
  • Page 648 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 2006.03...
  • Page 649 08-3 4411-01 4411-01 SUSPENSION 1. FRONT SUSPENSION SPECIFICATIONS 2. REAR SUSPENSION SPECIFICATIONS SUSPENSION KYRON 2006.03...
  • Page 650 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 2006.03...
  • Page 651 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 2006.03...
  • Page 652 09-5 4890-01 3) SECTIONAL DRAWING Front Disc Brake Rear Disc Brake KYRON 2006.03...
  • Page 653 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 2006.03...
  • Page 654 09-7 4890-01 2. BRAKE SYSTEM SPECIFICATIONS KYRON 2006.03...
  • Page 655 It is also a physical phenomenon and has no relation with the brake performance. KYRON 2006.03...
  • Page 656 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 2006.03...
  • Page 657 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 2006.03...
  • Page 658 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 2006.03...
  • Page 659 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 2006.03...
  • Page 660 09-13 4890-01 [New T/C] Without speed sensor KYRON 2006.03...
  • Page 661 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 2006.03...
  • Page 662 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2006.03...
  • Page 663 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 2006.03...
  • Page 665 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 2006.03...
  • Page 666 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 2006.03...
  • Page 667 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 2006.03...
  • Page 668 (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 2006.03...
  • Page 669 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 2006.03...
  • Page 670 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 2006.03...
  • Page 671 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 2006.03...
  • Page 672 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 2006.03...
  • Page 673 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 2006.03...
  • Page 675 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 2006.03...
  • Page 676 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 2006.03...
  • Page 677 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 2006.03...
  • Page 678 09-31 4890-01 4) Input/Output Signals for HDC Operation KYRON 2006.03...
  • Page 679 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 2006.03...
  • Page 681 09-34 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 2006.03...
  • Page 682 09-35 4890-01 ▶ Comparison with ABS System Active Wheel Speed Sensor HDC Switch HDC Indicator ESP OFF Switch ABS / ESP Indicator KYRON 2006.03...
  • Page 683 09-36 4890-01 7. INPUT/OUTPUT SIGNALS FOR HDC OPERATION ▶ Input/Output of ESP System KYRON 2006.03...
  • Page 684 09-37 4890-01 8. ESP HYDRAULIC CIRCUIT DIAGRAM KYRON 2006.03...
  • Page 685 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 2006.03...
  • Page 686 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 2006.03...
  • Page 687 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 2006.03...
  • Page 688 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 2006.03...
  • Page 689 09-42 4890-01 New Transfer Case Without Speed Sensor KYRON 2006.03...
  • Page 690 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 2006.03...
  • Page 691 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. KYRON 2006.03...
  • Page 692 09-45 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 2006.03...
  • Page 693 09-46 4890-01 13. INPUT AND OUTPUT DIAGRAM OF ABS ▶ Input/Output of ABS (without TPMS) KYRON 2006.03...
  • Page 694 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 2006.03...
  • Page 695 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 2006.03...
  • Page 696 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 2006.03...
  • Page 697 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 2006.03...
  • Page 698 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 2006.03...
  • Page 699 10-5 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 2006.03...
  • Page 700 10-6 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 2006.03...
  • Page 701 10-7 4610-00 ▶ Components Steering wheel Column shaft Lower shaft Tie rod end Steering gear box STEERING KYRON 2006.03...
  • Page 702 10-8 4610-00 Steering wheel Lower shaft Column shaft Steering gear box STEERING KYRON 2006.03...
  • Page 703 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 2006.03...
  • Page 704 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 2006.03...
  • Page 705 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 2006.03...
  • Page 706 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 2006.03...
  • Page 707 333 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 2006.03...
  • Page 708 10-14 4610-00 3) CIRCUIT DIAGRAM STEERING KYRON 2006.03...
  • Page 709 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 2006.03...
  • Page 710 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 2006.03...
  • Page 711 AQS sensor Ambient temperature sensor A function that turns on/off the This sensor is installed at the air source selection and air front bottom engine quality system. compartment. This changes source mode detecting the air pollution. AIR CONDITIONER KYRON 2006.03...
  • Page 712 Sensor (On Engine) Absorbs moisture Detects A/C switch position, A sensor that detects coolant refrigerant 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 2006.03...
  • Page 713 01-4 6810-15 1. VENTILATION SYSTEM COMPONENTS ▶ Locations of Vents ▶ Air Duct AIR CONDITIONER KYRON 2006.03...
  • Page 714 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 2006.03...
  • Page 715 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 2006.03...
  • Page 716 01-7 6810-15 2) Components AIR CONDITIONER KYRON 2006.03...
  • Page 717 01-8 6810-15 4. PTC HEATER AND FFH HEATER LAYOUT 1) PTC HEATER ASSEMBLY LAYOUT 2) FFH HEATER ASSEMBLY LAYOUT AIR CONDITIONER KYRON 2006.03...
  • Page 718 Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected through AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears. Press the AUTO switch AIR CONDITIONER KYRON 2006.03...
  • Page 719 When pressing DEF switch during in this process, the AQS indicator goes out and the air source selection is changed to fresh air mode from recirculation mode. When pressing the AQS switch again, the self diagnosis and preheating mode of AQS operates only for the remaining time. AIR CONDITIONER KYRON 2006.03...
  • Page 720 OFF, the AQS stops its operation and the indicator goes out and the display window shows the initial screen. If the AQS switch is pressed in, the AQS function works regardless of air conditioner controller operation. AIR CONDITIONER KYRON 2006.03...
  • Page 721 If the ignition switch is turned off with AQS ON, the AQS is turned on when turning the ignition switch on again. 6. The AQS is turned off: When pressing the defroster switch When pressing the recirculation mode switch AIR CONDITIONER KYRON 2006.03...
  • Page 722 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 2006.03...
  • Page 723 FATC controller. Humidity sensor ▶ This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller. AIR CONDITIONER KYRON 2006.03...
  • Page 724 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 2006.03...
  • Page 725 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 2006.03...
  • Page 726 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 2006.03...
  • Page 727 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 2006.03...
  • Page 728 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 2006.03...
  • Page 729 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 2006.03...
  • Page 730 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 2006.03...
  • Page 731 01-22 6810-15 (2) Exploded View AIR CONDITIONER KYRON 2006.03...
  • Page 732 01-23 6810-15 AIR CONDITIONER KYRON 2006.03...
  • Page 733 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 2006.03...
  • Page 734 01-25 6810-15 (3) SPECIFICATIONS AIR CONDITIONER KYRON 2006.03...
  • Page 735 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 2006.03...
  • Page 736 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 2006.03...
  • Page 737 01-28 6810-15 4) Circuit Diagram AIR CONDITIONER KYRON 2006.03...
  • Page 738 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 2006.03...
  • Page 739 01-30 6810-15 6) Specification - Water Pump 7) Characteristic Curve of Water Pump (12 V) AIR CONDITIONER KYRON 2006.03...
  • Page 740 01-31 6810-15 8) Function Diagram 9) Switching Diagram According to Temperature Changes AIR CONDITIONER KYRON 2006.03...
  • Page 741 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 2006.03...
  • Page 742 (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 2006.03...
  • Page 743 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 2006.03...
  • Page 744 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 2006.03...
  • Page 746 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 2006.03...
  • Page 747 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 2006.03...
  • Page 748 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 2006.03...
  • Page 749 02-11 8810-03 AIR BAG KYRON 2006.03...
  • Page 750 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 2006.03...
  • Page 751 (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 2006.03...
  • Page 752 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 2006.03...
  • Page 753 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 2006.03...
  • Page 754 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 2006.03...
  • Page 755 (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 2006.03...
  • Page 756 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 2006.03...
  • Page 757 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 2006.03...
  • Page 758 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 2006.03...
  • Page 759 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 2006.03...
  • Page 760 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 2006.03...
  • Page 761 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 2006.03...
  • Page 762 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 2006.03...
  • Page 763 02-25 8810-03 8. AIR BAG ELECTRICAL WIRING DIAGRAM AIR BAG KYRON 2006.03...
  • Page 764 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 2006.03...
  • Page 765 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 2006.03...
  • Page 766 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 2006.03...
  • Page 767 03-6 7410-01 ▶ Location of Seat Position With Memory Unit (Bottom of Driver Seat) SPWM unit SEAT KYRON 2006.03...
  • Page 768 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 2006.03...
  • Page 769 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 2006.03...
  • Page 770 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 2006.03...
  • Page 771 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 2006.03...
  • Page 772 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 2006.03...
  • Page 773 04-5 7340-01 3. TROUBLE DIAGNOSIS SUNROOF KYRON 2006.03...
  • Page 774 04-6 7340-01 1. SUNROOF COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit (SCU) Sunroof Switch Sunroof Assembly SUNROOF KYRON 2006.03...
  • Page 775 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 2006.03...
  • Page 776 04-8 7340-01 3.SUNROOF CIRCUIT DIAGRAM SUNROOF KYRON 2006.03...
  • Page 777 NO DATA...
  • Page 778 NO DATA...
  • Page 779 07-3 4110-01 4110-01 BODY REPAIR 1. DIMENSIONS BODY REPAIR KYRON 2006.03...
  • Page 780 07-4 4110-01 2. JACK-UP POINTS 1) IRS - Lifting Point (Dotted Circles) BODY REPAIR KYRON 2006.03...
  • Page 781 07-5 4110-01 2) 5 Link System - Lifting Point (Dotted Circles) BODY REPAIR KYRON 2006.03...
  • Page 782 Blocks the noise from engine and transmission and improves the reinforcement of vehicle body. Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility engine retreat when collision. BODY REPAIR KYRON 2006.03...
  • Page 783 BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise. Door impact beam BPR sealer reinforcement to reinforce the body to reinforce the door panel and reduce the impact beam noise Door impact beam to protect the passengers in case of side collision BODY REPAIR KYRON 2006.03...
  • Page 784 BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise. The foaming pads are applied to the symmetry surface of the vehicle. Thus, totally 6 foaming pad are applied to the vehicle body. BODY REPAIR KYRON 2006.03...
  • Page 785 07-9 4110-01 5) Applied the Asphalt to the Body Panel (Improved Anti-Vibration) BODY REPAIR KYRON 2006.03...
  • Page 786 ECU-GASOLINE 0000-00 ECU-GASOLINE 1. ECU-GASOLINE........
  • Page 788 0000-00 0000-00 ECU-GASOLINE 1. ECU-GASOLINE ECU-GASOLINE KYRON 2006.03...
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  • Page 834 ECU-DIESEL 0000-00 ECU-DIESEL DIAGNOSIS 1. ECU-DIESEL..........
  • Page 836 0000-00 0000-00 ECU-DIESEL 1. ECU-DIESEL ECU-DIESEL KYRON 2006.03...
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  • Page 911 0-78 0000-00 ECU-DIESEL KYRON 2006.03...
  • Page 912 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
  • Page 914 0000-00 0000-00 BRAKE 1. BRAKE BRAKE KYRON 2006.03...
  • Page 915 0000-00 BRAKE KYRON 2006.03...
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  • Page 924 AIR-BAG 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG..........
  • Page 926 0000-00 0000-00 AIR-BAG 1. AIR-BAG AIR-BAG KYRON 2006.03...
  • Page 927 0000-00 AIR-BAG KYRON 2006.03...
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  • Page 934 CCCS 0000-00 CCCS DIAGNOSIS 1. CCCS.............
  • Page 936 0000-00 0000-00 CCCS 1. CCCS CCCS KYRON 2006.03...
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  • Page 962 FATC 0000-00 FATC DIAGNOSIS 1. SELF DIAGNOSIS........
  • Page 964 1) Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds. Check LED segments on the vacuum fluorescent display (VFD). Press OFF switch more than 5 seconds. FATC KYRON 2006.03...
  • Page 965 If any failure exists, the appropriate trouble code is displayed as below. The symbol "-" in front of step number "2" means a short circuit of the blinking sensor. Short-circuit in the ambient air temperature sensor Trouble Code FATC KYRON 2006.03...
  • Page 966 Slightly turn the TEMP switch in step 3 until "41" is displayed on the display window. When pressing DEF switch , mode changes as shown below in turns to check each function. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4 FATC KYRON 2006.03...
  • Page 967 (other than TEMP switch) in step 5. Starts the trouble Compensates the diagnosis step 6 temperature turning turning TEMP speed dial. dial. Min. temperature Max. temperature Step 6 compensation value compensation value FATC KYRON 2006.03...
  • Page 968 0000-00 DIAGNOSIS 1. FFH............
  • Page 970 0000-00 0000-00 1. FFH KYRON 2006.03...
  • Page 971 0000-00 KYRON 2006.03...
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  • Page 973 0000-00 KYRON 2006.03...
  • Page 974 P/TRUNK 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK..........
  • Page 976 0000-00 0000-00 P/TRUNK 1. P/TRUNK P/TRUNK KYRON 2006.03...
  • Page 977 0000-00 P/TRUNK KYRON 2006.03...
  • Page 978 RAIN SENSOR 0000-00 RAIN SENSOR DIAGNOSIS 1. TROUBLE SHOOTING......
  • Page 980 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 2006.03...
  • Page 981 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 2006.03...
  • Page 982 STICS 0000-00 STICS DIAGNOSIS 1. STICS............
  • Page 984 0000-00 0000-00 STICS 1. STICS STICS KYRON 2006.03...
  • Page 985 0000-00 STICS KYRON 2006.03...
  • Page 986 0000-00 DIAGNOSIS 1. TCU............
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  • Page 1006 TGS LEVER 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER...........
  • Page 1008 0000-00 0000-00 TGS LEVER 1. TGS LEVER TGS LEVER KYRON 2006.03...
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