SSANGYONG Rexton W 2012.06 Manual
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SSANGYONG Rexton W 2012.06 Manual

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Table of Contents

VEHICLE GENERAL
1. DIMENSIONS........................................
2. SPECIFICATIONS.................................
3. VEHICLE IDENTIFICATION...................
4. MAINTENANCE ....................................
LUBRICANTS........................................
6. JACK POINTS.......................................
CONNECTOR........................................
LAYOUT................................................
STANDARD BOLTS...............................
3
4
6
7
19
20
21
22
24

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Summary of Contents for SSANGYONG Rexton W 2012.06

  • Page 1: Table Of Contents

    VEHICLE GENERAL 1. DIMENSIONS........2. SPECIFICATIONS......... 3. VEHICLE IDENTIFICATION....4. MAINTENANCE ........5. RECOMMENDED FLUIDS AND LUBRICANTS........6. JACK POINTS........7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR........8. ELECTRIC COMPONENTS AND LAYOUT..........9. TIGHTENING TORQUE OF STANDARD BOLTS.......

  • Page 3: Dimensions

    01-3 0000-00 1. DIMENSIONS Unit: mm Top view Side view Front view Rear view...

  • Page 4: Specifications

    01-4 2. SPECIFICATIONS * ( ): Optional, [ ]: 2WD, < >: DPF D20DTR: Diesel 2.0 (EU5), D20DT: Diesel 2.0, D27DTP: Diesel 2.7 Power-Up, D27DT: Diesel 2.7, G32D: Gasoline...
  • Page 5 01-5 0000-00 ▶Specifications (Cont'd)

  • Page 6: Vehicle Identification

    01-6 3. VEHICLE IDENTIFICATION Engine Number Vin Label Chassis Number Gasoline Engine: The The chassis number is engine number is stamped stamped on the frame on the lower area of behind the front right tire. cylinder block in exhaust manifold side. Certification Label The certification label is located on the driver’s door...

  • Page 7: Maintenance

    01-7 0000-00 4. MAINTENANCE 1) Scheduled Maintenance Services (EU) - Diesel Engine (D20DTR)
  • Page 8 01-8...
  • Page 9 01-9 0000-00...
  • Page 10 01-10 2) Scheduled Maintenance Services (GEN) - Diesel Engine (D20DTR)
  • Page 11 01-11 0000-00...
  • Page 12 01-12...
  • Page 13 01-13 0000-00 3) Scheduled Maintenance Services (GEN) - Diesel Engine (D27DT/D27DTP)
  • Page 14 01-14...
  • Page 15 01-15 0000-00...
  • Page 16 01-16 4) Scheduled Maintenance Services (Gasoline Engine)
  • Page 17 01-17 0000-00...
  • Page 18 01-18...

  • Page 19: Recommended Fluids And Lubricants

    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 20: Jack Points

    01-20 6. JACK POINTS Front: Double wishbone Rear: 5-link...

  • Page 21: Pin Arrangement Of Diagnostic Connector

    01-21 0000-00 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR The diagnostic connector is located at bottom of instrument panel. It consists of 16 pins. The REKES key should be coded by the scan tool. Diagnostic connector ▶ Connector Pin Pin No. Function CAN HI S203 "18"...

  • Page 22: Electric Components And Layout

    01-22 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement...
  • Page 23 01-23 0000-00 2) Components Locator...

  • Page 24: Tightening Torque Of Standard Bolts

    01-24 9. TIGHTENING TORQUE OF STANDARD BOLTS ▶ Tightening Torque By Bolt Specification Metric bolt strength is embossed on the Determine extra proper tightening torque if head of each bolt. The strength of bolt can tightens with washer or packing. be classified as 4T, 7T, 8.8T, 10.9T, 11T If tightens bolts on the below materials, be and 12.9T in general.
  • Page 25 02-2 1. EXTERIOR ▶ Font Side 8310-01 Head Lamp Head lamp - Head lamp - Low beam Low beam Head lamp - Head lamp - High beam High beam Turn signal/Position lamp Position lamp (LED) - Changed the head lamp design and functions. - Turn signal lamp integrated with front fog lamp 7910-01 Radiator Grille...
  • Page 26 02-3 0000-00 7810-04 Windshield Wiper Blade - Changed the aero-blade material (from steel to rubber). 7850-11 Outside Rearview Mirror Outside turn signal lamp - Introduced the turn signal lamp on outside rearview mirror. 8310-23 Front Combination Lamp Front fog lamp 6110-01 Hood Panel Front fog...
  • Page 27 02-4 ▶ Side 5720-03 Fender Panel & 7110-10 Door Outside Handle Side Repeater Lamp Side repeater lamp - Changed the door outside handle design. - Changed the fender panel design according to the changes of head lamp and front bumper. - Moved the side repeater lamp to the outside rearview mirror.
  • Page 28 02-5 0000-00 5210-18 Side Outer Rear Panel - Changed the side outer rear panel design according to the changes of rear combination lamp. 7931-09 Rear Wheel Arch Garnish - Changed the rear wheel arch garnish design. 4170-34 Wheel Sputtering type Diamond cut type 7931-01 Side Sill Garnish...
  • Page 29 02-6 ▶ Rear Side 8912-26 Audio Antenna - Changed the antenna type from shark type to pole type. 7950-39 Quarter Badge - Installed the brand logo on LH rear quarter panel (Rexton W). 7881-01 Rear Bumper and Rear PAS Sensor Rear PAS sensor Rear PAS sensor - Changed the rear bumper design.
  • Page 30 02-7 0000-00 7940-02 Spoiler - Added the wing type rear spoiler. 8320-01 Rear Combination Lamp Back-up Tail lamp lamp Tail/Stop lamp Stop lamp Tail lamp Turn signal Back-up Stop Turn signal lamp lamp lamp lamp - Changed the rear combination lamp design and functions. - Changed the stop lamp and tail lamp to LED type.
  • Page 31 02-8 2. INTERIOR 7610-01 Steering Wheel and Center Fascia Panel Center fascia upper panel Center fascia upper panel Center fascia Center fascia Steering wheel lower panel Steering wheel lower panel - Changed the center fascia panel design. - Changed the color of steering wheel wood grain. 8511-50 Center Fascia Switch and Bezel Multi station switch...
  • Page 32 02-9 0000-00 7632-00 Console Upper Fascia & Console Armrest Console upper fascia Console armrest - Changed the color of console upper fascia and console armrest wood grain. 8510-30 Power Outlet Socket AV type Audio type - For audio type, the power outlet is added on the top of center fascia panel.
  • Page 33 02-10 7410-03 Front Seat - Changed the seatback and seat cushion design. 7410-12 Front Headrest - Changed the front headrest design. - Changed the tilting type from swing type to sliding type. 7115-01 Door Panel - Changed the front headrest design. - Changed the color of front/rear door panel wood grain.
  • Page 34 02-11 0000-00 7510-05 Rear Center Armrest - Changed the rear armrest design. 7410-24 Front Seat Back-board - Changed the seat back-board and seatback pocket design. 7410-05 Front Seat Cover Shield - Changed the front seat cover shield from integrated type to split type.
  • Page 35 02-12 3. ELECTRIC SYSTEM 8010-01 Instrument Cluster - Added TPMS related warning lamp and indicator. 8410-32 ICM Box - Deleted the hazard lamp relay and added some relays (rear side seat warmer, blower, rear washer/wiper) 7010-03 Blanking Key - Changed mechanical key design.
  • Page 36 02-13 0000-00 8790-03 PAS Sensor - Changed the locking type from spring type to holder type. 8790-01 PAS Unit - Changed the PAS sensor operating voltage (12V→8V) and added one PAS sensor (rear center).
  • Page 37 02-14 4. ENGINE AND CHASSIS 1491-01 Engine Control Unit - Changed the logic according to introduction of TPMS. 4190-06 Wheel Module 4190-13 TPMS Unit - Added the wheel module in each - Installed TPMS unit with antenna wheel according to introduction of according to introduction of TPMS.
  • Page 38 02-15 0000-00 1990-00 Engine Mounting Insulator Rear Rear - Adopted the optimized engine mounting insulators based on system analysis and on-board test.
  • Page 40 01-3 0000-00 1. LOCATION OF MAJOR SENSORS ON ENGINE ▶ Major sensors and devices Injector Glow plug Common rail Injector Boost pressure sensor Camshaft position sensor Turbocharger vacuum Fuel rail sensor (common modulator rail) Common rail Knock sensor (one) and water temperature sensor Crankshaft position sensor...
  • Page 41 01-4 2. ENGINE ACCESSORIES RELATED TO ECU Engine ECU Location HFM sensor (HFM 6.0) To control the engine more precisely, new functions such as digital signal for intake air mass have been introduced.
  • Page 42 01-5 0000-00 Accelerator pedal module Fuse PPS (integrated two pedal position sensors) Pre-glow and immobilizer Relay Engine main relay 4 Engine main relay 4 Priming pump Fuel filter...
  • Page 43 01-6 3. LAYOUT OF PRE-GLOW SYSTEM Pre-glow indicator (on instrument Fuse cluster) Pre-glow Glow plug Pre-glow control unit Pre-glow control Power (D20DT: N/A) signal Ground Pre-glow complete Glow plug K-Line signal terminals...
  • Page 44 01-7 0000-00 4. LAYOUT OF INTAKE SYSTEM Turbocharger Intake manifold Coolant port To respective cylinder VGT control actuator Exhaust gas Air cleaner Turbocharger Turbocharger From Supplying the compressed air by turbocharger intercooler Boost pressure sensor Power Ground Air cleaner Voltage output Turbocharger intercooler HFM sensor (HFM 6.0) Throttle body...
  • Page 45 01-8 5. LAYOUT OF EXHAUST SYSTEM PCV oil separator Cylinder head cover (oil + gas) Blow-by gas (air duct hose) Inlet port Oil (oil gauge pipe) The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover.
  • Page 46 01-9 0000-00 CDPF Turbocharger vacuum modulator Throttle body EGR cooler Coolant Intercooler port Exhaust Intake manifold To water pump EGR pipe: Exhaust gas passage for recirculating the exhaust gas Intake manifold...
  • Page 47 01-10 6. LAYOUT OF COOLING SYSTEM Coolant reservoir tank Return hose Radiator Water pump and pipe Thermostat (internal) From heater Radiator EGR cooler Reservoir (coolant inlet hose) EEGR cooler Coolant port From heater Radiator Reservoir Water pump (coolant inlet hose)
  • Page 48 01-11 0000-00 Oil cooler Oil cooler Oil filter cap Oil pressure switch Oil cooler Oil filter Coolant port Coolant outlet port Radiator EGR cooler PWM electric fan Fan shroud PWM electric fan unit Cylinder head Cylinder head Radiator upper hose EGR cooler Flap door Electric fan...
  • Page 49 01-12 7. LAYOUT OF LUBRICATION SYSTEM Heavy-duty PCV oil separator Cylinder head Intake air cover (oil + gas) duct hose (blow-by gas) Oil gauge pipe The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover.
  • Page 50 01-13 0000-00 Cylinder head cover Low oil pressure warning lamp (on instrument cluster) Oil filter and oil cooler filter cooler...
  • Page 51 01-14 8. LAYOUT OF FUEL SYSTEM ▶ Components Injector Fuel filter and priming pump Fuel filter Priming pump Connector Returned fuel Fuel filter from HP pump Fuel tank HP pump Fuel tank HP pump Fuel return port IMV connector Venturi IMV connector Low pressure fuel supply port Fuel pipe...
  • Page 52 01-15 0000-00 ▶ Schematic Diagram...
  • Page 54 02-3 0000-00 1. SPECIFICATIONS...
  • Page 55 02-4 2) Engine Performance Curve ▶ Output and Torque...
  • Page 56 02-5 0000-00 ▶ Oil Temperature/Pressure and Boost Pressure...
  • Page 57 02-6 2. SPECIAL SERVICE TOOLS 1) Using the Special Service Tools on Engine Injector washer puller Glow plug socket Injector puller Sealing caps (fuel line) Cylinder head bolt wrench High pressure pipe HP remover/installer remover/installer...
  • Page 58 02-7 0000-00 3. TIGHTENING TORQUE...
  • Page 59 02-8...
  • Page 60 02-9 0000-00...
  • Page 61 02-10 4. CAUTION WHEN SERVICING THE ENGINE 1) Cleaness Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces when assemblying the components.
  • Page 62 02-11 0000-00 (4) Lubrication system Prolonged exposure to the engine oil make cause a skin cancer or an irritation. Used engine cotains the hazardous material that may cause the skin cancer. Do not allow the used engine to make contact with your skin. Make sure to wear the protection gloves and goggle when handling the engine oil.
  • Page 63 02-12 5. MAJOR CHANGES IN D20DT (EU-IV) ENGINE (COMPARED TO D20DT) 1) Engine Assembly D20DT Engine EU IV D27DTP Engine Front view Left side view Right side view...
  • Page 64 02-13 0000-00 2) Major Changes and Summary D20DT Engine Remarks ECU version 3.2 in D20DT engine has two connectors. Engine ECU - Version 3.2 1. E-EGR valve system 2. Throttle body system 3. C3I injector system * Injection nozzle (hole): 7 Injector * Injector label and coding - D27DTP, D20DT...
  • Page 65 02-14 D20DT Engine Remarks HFM 6.0 HFM 6-ID (Added digital signal function) ECU controls the EGR valve directly. Electrically controlled E-EGR valve It provides precise EGR control by transmitting the electric signal of EGR valve operating position. The vacuum modulator for controlling Vacuum modulator EGR valve has been deleted.
  • Page 66 02-15 0000-00 D20DT Engine Remarks EGR cooler To enhance the EGR performance by making the temperature of exhaust gas into the intake manifold down, the Coolant EGR Gas EGR cooler has been introduced. Intake manifold Boost pressure sensor The throttle body and boost pressure sensor have been installed on the intake manifold.
  • Page 67 03-3 0000-00 1. FUEL SYSTEM - K2006 The C3I injector system is used in D20DT engine. ▶ Injector Injector (7-way Injection and C3I Coding) C3I Code Fuel nozzle Fuel nozzle holes (7) holes (7) Two nozzle holes are added (currently 7) to the tip of the injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power.
  • Page 68 03-4 1. FUEL FLOW OF D20DT (EURO 4) ENGINE According to input signals from various sensors, engine ECU calculates driver's demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives the signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals.
  • Page 69 03-5 0000-00 2. COMPONENTS OF FUEL SYSTEM Injector (7-way Injection and C3I Coding) Fuel filter Priming Pump Fuel nozzle Fuel filter holes (7) Priming pump Connector Fuel filter Fuel from HP pump Fuel tank HP pump Fuel tank Common Rail Fuel Line HP Pump Injector...
  • Page 70 03-6 3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE)
  • Page 71 04-3 0000-00 1. TIGHTENINF TORQUE The hose clamps and fasteners should be tightened to the specified tightening torque when installing/removing the engine and/or components for intake system. 1. Hose between air cleaner and 2. Hose between turbocharger and turbocharger intercooler 4.
  • Page 72 04-4 1. INTAKE SYSTEM LAYOUT The intake system is equipped with an electric throttle body which includes a flap. This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off. And, the improved HFM sensor has been adopted to control the intake air volume more precisely.
  • Page 73 04-5 0000-00 Booster Pressure Sensor Intake Manifold To corresponding Supply power Coolant Ground cylinders port Output voltage Compressed EGR gas Throttle body Normal: flap open Engine stopped: flap closed Intake duct Intake duct Intercooler Intake manifold (Throttle body) Turbo charger...
  • Page 74 05-3 0000-00 1. TURBO CHARGER CHECK FOR VGT The turbocharger is sensitive to excessive vibration coming from external impact. When exposed to excessive impact or vibration, the inside mechanism may be damaged even though the outside is intact. The turbocharger should be kept horizontally. If there is much engine oil in the turbocharger and it is kept vertically with the turbine housing downward, the engine oil may be provided to variable mechanism assembled towards the turbine housing, which may lead to a malfunction of the variable mechanism.
  • Page 75 05-4 After installing to the engine, replenish a small amount of clean engine oil to the inlet before connecting the oil inlet pipe of the turbocharger. Do not let any metal debris enter when installing to the engine. The engine oil may be provided to the compressor housing if you rapidly operate the turbocharger with excessive revolutions immediately after installing to the engine.
  • Page 76 05-5 0000-00 1. COMPONENTS The components of the exhaust system consist of: 1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted). 2. EGR cooler: Decreasing EGR gas (NOx) efficiently by cooling the EGR gas and let it flow to the intake manifold.
  • Page 77 3) System Met with EURO IV Regulations The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December 2007 comply with the EURO IV regulations. Modified components from the old engine model are as...
  • Page 78 08-4 2. CDPF (EURO IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and Sensors Differential Pressure Sensor (ΔP sensor) Under air cleaner in right side of engine compartment As the soot is filtered in the CDPF, the pressure between the front side and the rear side of the filter is...
  • Page 79 08-5 1533-01 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
  • Page 80 08-6 1. OVERVIEW As the solution for environmental regulations and PM (Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
  • Page 81 08-7 1533-01 2.CDPF (EURO IV) SYSTEM CONTROL 1) General Description As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration. The CDPF assembly is integrated with DOC (at front side) and DPF (at rear side).
  • Page 82 08-8 2) System Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
  • Page 83 08-9 1533-01 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type.
  • Page 84 08-10 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
  • Page 85 08-11 1533-01 Front temperature sensor Rear temperature sensor (Measuring the temperature of (Measuring the temperature of exhaust exhaust gas passedthrough gas passed through DOC) exhaust manifold) Differrential pressure sensor Differrential pressure sensor (Front pressure port) (Rear pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects the intoCDPF assembly after...
  • Page 86 08-12 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 87 08-13 1533-01 ▶ Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration tem- perature due to low speed driving or other reason during the regeneration process, the soot is con-tinuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to in-form this situation to the driver.
  • Page 88 08-14 4. COMPONENTS OF CDPF SYSTEM 1) Mounting Condition and Location Differential Pressure Sensor Rear exhaust gas temperature sensor Engine compartment (RH) Rear pressure port Differential Front pressure port pressure sensor CDPF assembly Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
  • Page 89 07-3 0000-00 1. SPECIFICATIONS Ssangyong genuine engine oil (Approved by MB Engine Oil Quality class Sheet 229.1 or 229.3 or 229.31 for DSL/GSL ENG without CDPF) (Approved by MB Sheet 229.31 for DSL ENG with CDPF) Viscosity: MB sheet No. 224.1 Standard: 9.3ℓ...
  • Page 90 07-4 1. LAYOUT OF LUBRICATION SYSTEM PCV Oil Separator Cylinder head cover (oil + gas) Oil (gauge pipe) Inlet port Oil (gauge pipe) The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover. Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port.
  • Page 91 07-5 0000-00 Low Oil Pressure Warning Lamp (Instrument Cluster) Oil Filter & Oil Cooler Oil filter Oil cooler Cylinder Head Cover Oil Pressure Switch...
  • Page 92 07-6 2. SCHEMATIC DIAGRAM...
  • Page 93 08-3 0000-00 1. LAYOUT OF COOLING SYSTEM Water Pump Coolant Port Port to EGR cooler Coolant reservoir Radiator PWM Fan Assembly EGR Cooler PWM fan unit From coolant port To water pump Flap door...
  • Page 94 08-4 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT (EURO4) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
  • Page 95 08-5 0000-00 2. SCHEMATIC DIAGRAM Coolant Flow in Engine 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...
  • Page 96 09-3 0000-00 1. SPECIFICATIONS Description Unit Specification Starter Type WP220 Output power No load test (12 volts) Drive pinion speed at no load 4500 Drive pinion speed at load rpm/A 1700/430 Brush length Armature diameter Armature run-out Segment groove depth 21.7 Alternator Type...
  • Page 97 09-4 2. SPECIAL SERVICE TOOL Name Description Glow plug remover Tool for removing the glow plug from cylinder head...
  • Page 98 09-5 0000-00 1. LAYOUT OF PRE-GLOW SYSTEM The pre-glow system in D20DT engine has four glow plugs. And, the terminal T for pre-glow completion signal is not used since the remote start function has been deleted. Engine ECU Pre-glow Indicator (Instrument cluster) Glow Plug Control Relay Glow Plug...
  • Page 99 09-6 ▶ Circuit Diagram ▶ Specifications Description Specification Rated voltage DC 12V Operating voltage DC 8~15V -40 ~ 100°C Operating temperature Relay operating voltage Over 6.5V Relay OFF voltage OVER 1.5v 11.3Ω Relay coil resistance Voltage drop Below 150Mv in each glow plug (Current: 16A) Parasitic current Max.
  • Page 100 09-7 0000-00 2. OPERATION 1) Operation Glow plug is installed in the cylinder head. It enhances the cold starting performance and reduces the exhaust gas during cold starting. 1. Pre-heating If normal communication with the ECU is established 2 seconds after the power is supplied to the IGN terminal from the battery, the ECU supplies the battery voltage to glow plugs.
  • Page 101 09-8 ▶ K-Line Communication ECU starts to communicate by sending the result to pre-glow timer relay through K-Line. Pre-glow timer relay sends the message with self-diagnosis data for glow plug to ECU. The glow plug responses only for request. ECU starts self-diagnosis operation from 2 seconds after power input. Communication error occurs when: ·...
  • Page 102 12-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 103 12-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Improper use of the cruise control could be dangerous.
  • Page 104 12-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 105 12-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...
  • Page 106 12-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 107 12-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 108 12-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 109 12-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention. But if you turn off the ignition switch, the memorized set speed is cleared and you cannot recover the previous set speed.
  • Page 110 12-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 111 12-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 112 NO DATA...
  • Page 113 01-3 0000-00 1. ENGINE LAYOUT Front view Rear view Right view Left view...
  • Page 114 01-4 2. MAJOR COMPONENTS ▶ Front view Vacuum pump Camshaft position sensor Oil filter assembly Power steering pump pulley Oil pressure switch Idler pulley No. 2 Water pump pulley Alternator pulley Auto tensioner Idler pulley No. 1 A/C compressor pulley Isolation damper ▶...
  • Page 115 01-5 0000-00 ▶ Right view Front exhaust gas temperature sensor Oil dipstick tube & gauge assembly E-VGT actuator E-VGT turbocharger Coolant screw plug Oil drain plug ▶ Left view Thermostat assembly Variable swirl valve assembly E-EGR valve E-EGR solenoid valve Oil cooler assembly EGR cooler Electronic throttle body...
  • Page 116 Always turn the engine off and allow it to cool before starting the maintenance. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
  • Page 117 01-7 0000-00 1) Service Interval Daily Weekly Description Service interval inspection inspection Engine oil & oil Inspection Change every 20,000 km or 12 months filter (The service interval should be shortened under severe conditions) General Change every 15,000 km or 12 months (The service interval should be shortened under severe conditions) Coolant...
  • Page 118 01-8 2) Specification and Capacity Engine oil Specification Quality class: Ssangyong genuine engine oil (Total Quartz INEO ECS 5W 30, SK ZIC SY 5W 30) or oil Approved by MB Sheet 229.51 Capacity approx. 6.0 litter Specification Ssangyong genuine coolant Anti-Freeze SYC-1025...
  • Page 119 01-9 0000-00 4. CAUTION WHEN SERVICING THE ENGINE 1) Cleaness Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces when assemblying the components.
  • Page 120 01-10 (3) Cautions before service Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never remove the coolant reservoir cap when the engine and radiator are hot. (4) Lubrication system Prolonged exposure to the engine oil make cause a skin cancer or an irritation. Used engine cotains the hazardous material that may cause the skin cancer.
  • Page 121 01-11 0000-00 5. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 122 01-12 6. TIGHTENING TORQUE Note (total Tightening Numbers of Name Size tightening torque (Nm) fastener torque) M12×82 55±5Nm, Main bearing cap Not-reusable 180˚ M9×52 40±5Nm, Connecting rod cap 50 ~80Nm 90˚+10˚ M6×20 10±1Nm Crankshaft rear seal M8×35 25±2.5Nm Oil pump M10×22 45±5Nm, Drive plate...
  • Page 123 01-13 0000-00 Note (total Numbers of Tightening Name Size tightening fastener torque (Nm) torque) M6×12 10±1Nm Hot water inlet pipe M6×12 10±1Nm Hot water inlet pipe M10×90 (LO) 25±2.5Nm Alternator 알터네이터 M10×90 (하) 25±2.5Nm M10×116 (HI) 46±4.6Nm M10×116 (상) 46±4.6Nm M8×85 Air conditioner 25~2.5Nm...
  • Page 124 01-14 Note (total Tightening Numbers of Name Size tightening torque (Nm) fastener torque) 45±4.5Nm Idler pulley/tensioner pulley 20±2Nm Glow plug M8×25 10±1Nm Vacuum pump M6×40 10±1Nm Timing gear case cover M6×45 10±1Nm M6×50 10±1Nm M6×35 10±1Nm Cylinder head cover M6×16 10±1Nm Oil dipstick gauge cover 25±2.5Nm...
  • Page 125 01-15 0000-00 7. CODING AND INITIALIZATION 1) Engine Variant Coding Unit Selection Description Remarks PTC auxilary heater For PTC auxilary heater equipped vehicle, select "YES". Glow plug Relay (K-line) Select "AQGS". AQGS (CAN) AQGS (CAN) Transmission 6-speed M/T Select the appropriate system. Select 5-speed A/T (DC 5 AT) Select...
  • Page 126 02-3 0000-00 1. SPECIFICATION Unit Description Specification Remark Cylinder head Height 131.9 to 132.1 mm Flatness below 0.1 mm Valve protrusion Intake valve 0.6 to 1.0 mm Exhaust valve 0.6 to 1.0 mm Flatness on manifold Intake manifold 0.08 mm side Exhaust manifold 0.08 mm...
  • Page 127 02-4 2. TIGHTENING TORQUE Bolt Remark Specified torque Component Size Quantity (Total torque) (Nm) M12×82 55±5Nm, Main bearing cap Not re-usable 180˚ M9×52 40±5Nm, Connecting rod cap 50 to 80 Nm 90˚+10˚ M6×20 10 ± 1 Nm Rear cover M8×35SOC 25 ±...
  • Page 128 02-5 0000-00 Specified torque Bolt Remark Component Size (Nm) Quantity (Total torque) M6×16 10±1Nm Hot water inlet pipe M10×90 25±2.5Nm Alternator M10×116 46±4.6Nm M8×25 A/C bracket 7.8~11.8Nm M6×25 10±1Nm A/C sub bracket M8×35 25±2.5Nm Intake manifold M8×110 25±2.5Nm M8×40 25±2.5Nm Oil filter module M8×20 25±2.5Nm...
  • Page 129 02-6 Bolt Remark Specified torque Component Size Quantity (Total torque) (Nm) 20±2Nm Glow plug M8×25 10±1Nm Vacuum pump M12×55 85±8.5Nm Timing gear case cover M6×25 10±1Nm M6×45 10±1Nm M6×50 10±1Nm M6×35 10±1Nm Cylinder head cover M6×16 10±1Nm Oil gauge tube 25±2.5Nm Oil filter cap M8×35SOC...
  • Page 130 02-7 0000-00 3. CHECK AND INSPECTION 1) Cylinder (1) Compression pressure test ▶ Specified value 16.5 : 1 Compression ratio at normal operating temperature (80˚C) Test condition 32 bar Standard Compression pressure 18 bar Minimum Maximum 3 bar Differential limit between cylinders The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket).
  • Page 131 02-8 Crank the engine for approx. 10 seconds by using the start motor. Record the test result and measure the compression pressure of other cylinders with same manner. If the measured value is out of specified value, perform the cylinder pressure leakage test.
  • Page 132 02-9 0000-00 (3) Piston protrusion check Position the piston at TDC and measure the piston protrusion from crank case mating surface. Specified value 0.475 to 0.745 mm Measure it at both ends of crankshaft.
  • Page 133 02-10 2) Cylinder Head (1) Cylinder head mating surface check ▶ Specified value 131.9 to 132.1 mm Total height "A" 131.9 mm Minimum height after machining 0.1 / 150 Longitudinal direction Flatness 0.15 Transverse direction Parallel deviation of cylinder head below 0.1 mm Peak-to valley of surface Rmax 7 Rz 6.3...
  • Page 134 02-11 0000-00 4. GUIDELINES ON ENGINE SERVICE To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 135 02-12 ▶ Fuel and lubrication system Do not allow the fluid and engine oil to make contact with the body paintwork and hoses. If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking should be prohibited.
  • Page 136 02-13 0000-00 5. MAJOR CHANGES Front mounting insulator(LH, RH) The optimized engine mountings have been introduced after performing the system analysis and on-vehicle test. Rear mounting insulator The optimized engine mountings have been introduced after performing the system analysis and on-vehicle test.
  • Page 137 02-14 1. BELT LAYOUT It is single drive type and uses FEAD (Front End Accessories Drive) design to make a compact layout. ▶ Components D20DTR Engine HPS (Hydraulic Power Steering) Crankshaft pulley (DDU) Auto tensioner Tensioner pulley Vacuum pump A/C compressor pulley Alternator pulley Water pump pulley Idle pulley #1...
  • Page 138 02-15 0000-00 1) Crankshaft Pulley (Isolation Damper) (1) Overview The strut type tensioner automatically adjusts the belt tension to provide the reliability and durability for the system. And, the belt tension is decreased to minimize the friction loss and improve the belt operating noise.
  • Page 139 02-16 (3) Features Rubber damper: Decrease crankshaft torsion Improve belt NHV: Reduce unbalance speed to crankshaft due to irregular combustion Minimize noise: Anti-vibration from crankshaft and belt Post bonded type rubber damper: Improve durability of rubber damper...
  • Page 140 02-17 0000-00 2) Belt Tensioner (1) Overview The torque deviation from crankshaft affects the components in belt drive system and the belt movement. The auto tensioner system is to adjust this deviation automatically. In D20DTR engine, one of the mechanical tensioner, pivot damped tensioner is used to keep the damping force, system reliability and durability.
  • Page 141 02-18 2. VACUUM PUMP Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole in hollow shaft. ▶...
  • Page 142 02-19 0000-00 1) Location 2) Operation The vacuum pump is engaged to the exhaust camshaft. Connection between vacuum pump and exhaust camshaft Oil supply and driving Vacuum pump Exhaust camshaft...
  • Page 143 02-20 3. ENGINE MOUNTING D20DTR engine uses 3-point mounting type that supports the engine and transmission simultaneously. ▶ Components Front mounting insulator (Right side) Front mounting insulator (Left side) Location Insulator Location Insulator Rear mounting insulator...
  • Page 144 02-21 0000-00 1) Functions Appearance Type and function Front mounting insulator (Right side) Type: Rubber mounting Function: Supports the torque reaction Front mounting insulator (Left side) Type: Rubber mounting Function: Supports the torque reaction Rear mounting insulato Type: Rubber mounting Function: Supports the powertrain rod...
  • Page 145 02-22 4. INTAKE/EXHAUST MANIFOLD 1) Intake Manifold Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas. ▶...
  • Page 146 02-23 0000-00 5. CYLINDER HEAD COVER AND OIL SEPARATOR 1) Cylinder Head Cover The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type oil separator improves the oil consumption. ▶ Components Front view Cylinder head cover Rear view...
  • Page 147 02-24 2) Oil Separator (1) Overview Oil separator separates the particle in blow-by gas to minimize the engine oil consumption and reduces the inflow oil from intake system into the combustion chamber. The separated oil returns to oil pan through cylinder head. (2) Layout Oil separator Blow-by outlet hose...
  • Page 148 02-25 0000-00 6. CYLINDER HEAD Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install in vertical direction. This enables the compact layout in cylinder head assembly. ▶...
  • Page 149 02-26 1) Cylinder Head (1) Overview The cylinder is made by gravity casting and the water jacket is integrated type. The cylinder oil passage is drilled and sealed by cap. The Camshaft bearing cap is also made by casting and installed on the cylinder head. (2) Features Location of Expansion Plugs Front...
  • Page 150 02-27 0000-00 ▶ Closed flow type water jacket (improving cooling performance) 2) Camshaft (1) Overview Hollow type camshaft contains cam, octagon cam, HP pump gear and intake/exhaust gears. Camshaft operates the intake/exhaust valves, vacuum pump and HP pump, and transfers the engine oil to vacuum pump through the internal oil passage.
  • Page 151 02-28 3) Valve Assembly (Installed in Cylinder Head) (1) Features Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash Optimized adjustment of valve clearance reduces the valve noise. Roller type finger follower reduces the friction loss. Vertical installation. Simple and compact design reduces the moving operation (improving valve following and fuel consumption at high speed) (2) Arrangement...
  • Page 152 02-29 0000-00 4) Cylinder Head Gasket (1) Features Sealing the cylinder gas pressure - Peak pressure: 190 bar Minimizing the distortion of engine structure (cylinder head, block): profile stopper, backland stopper Material: MLS (Multi Layer Steel), Gasket (3 layers) Thickness of gasket: 3 types (1.2 /1.3 /1.4 mm) Thickness marking Ex: 1.3t (2) Thickness of cylinder head gasket...
  • Page 153 02-30 7. CHAIN AND GEAR DRIVE SYSTEM D20DTR engine uses single stage chain drive system. Timing chain drives the exhaust side and gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil pump to lubricate the engine.
  • Page 154 02-31 0000-00 2) Timing Chain and Gear (1) Timing chain Simple layout: optimized timing, enhanced Single stage layout: minimized chain load Chain upper bush - Single bush type (112 EA) Chain lower bush - Single bush type (60 EA) (2) Tensioner Tensioner adjusts the chain tension to keep it tight during engine running.
  • Page 155 02-32 (3) Mechanical Tensioner Assembly Operating principle - Use only spring tension Tensioner type - Compensation and impact absorbing Static and dynamic force - Spring (4) Guide rail The guide rail is used for optimizing the movement of chain drive system. And it also prevents the chain from contacting each other when the chain is loose, and reduces the chain wear.
  • Page 156 02-33 0000-00 (5) Timing gear case cover Timing gear case cover (TGCC) Timing gear case cover Oil seal Screw plug...
  • Page 157 02-34 ▶ Features Major function: Protecting the chain drive system, minor function: Shielding the chain noise. Install crankshaft front seal and screw plug on the timing gear case cover. Location of chain tensioner screw plug A671 997 01 46 Crankshaft front seal Do not touch the inner lip of crankshaft front seal.
  • Page 158 02-35 0000-00 8. OIL PAN The oil pan in D20DTR engine improves the NVH. Especially, the oil draining is much easier than before. ▶ Components Oil pan sassembly...
  • Page 159 02-36 9. DUAL MASS FLYWHEEL (DMF) & DRIVE PLATE 1) Overview Flywheel is installed on crankshaft. When starting the engine, this functions as follows: Reducing the irregular speed of crankshaft due to unbalanced combustion -> Improving the power train NVH, Improving the driving performance Reducing the clutch noise by using ball bearing...
  • Page 160 02-37 0000-00 3) Operation Compensating the irregular operation of engine: The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more (less pulsation absorbing effect). Transaxle protection function: Reduces the torsional vibration to powertrain (transaxle) by reducing the irregularity of engine.
  • Page 161 02-38 4) Features Reduced vibration noise from the powertrain by blocking the torsional vibrations Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation Reduced shifting shocks Smooth acceleration and deceleration 5) Advantages Improved torque response by using 3-stage type spring: Strengthens the torque response in all ranges (low, medium, and high speed) by applying respective spring constant at each range.
  • Page 162 02-39 0000-00 10. PISTON/CRANKSHAFT/CYLINDER BLOCK The crankshaft and the cylinder block convert the compression pressure to the rotating energy. ▶ Components Cylinder block Piston Connecting rod Crankshaft...
  • Page 163 02-40 1) Piston (1) Overview Piston assembly contains piston, #1 ring, #2 ring, oil ring, piston pin and snap ring. The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy. (2) Layout Material: B2+ #2 ring...
  • Page 164 02-41 0000-00 (3) Functions Piston transfers the combustion energy from engine to connecting rod. Especially in the direct injection engine such as D20DTF, it provides the combustion space and largely effects to the engine performance and exhaust gas. ▶ Piston ring #1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank chamber, and prevents the engine oil getting into combustion chamber.
  • Page 165 02-42 Selecting piston oversize Top of piston Top of cylinder block Piston Cylinder bore Engine Part NO Marking NO. 671 030 06 17 671 037 07 01 671 037 08 01 D20DTF 671 037 09 01 671 037 10 01 671 037 11 01...
  • Page 166 02-43 0000-00 2) Connecting Rod (1) Overview Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft. The big end is connected to connecting rod bearing and the crank pin journal, and the small end is connected to the piston pin.
  • Page 167 02-44 (3) Selection of crankshaft pin journal bearing The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections. Three sets in the table below have nearly same oil clearance (0.015~0.063 mm) of bearing. Identification: Coloe mark on bearing side surface Upper bearing Lower bearing Journal...
  • Page 168 02-45 0000-00 3) Crankshaft (1) Overview Crankshaft is installed on the cylinder block. (2) Arrangement Upper thrust bearing Crankshaft main bearing upper Crankshaft main bearing upper Crank pin journal Main journal Lower thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower...
  • Page 169 02-46 (3) Selection of crankshaft main bearing Mating surface of crankshaft sprocket Bottom of cylinder block Selection of lower main bearing Selection of upper main bearing Selection of bearing according to pin punch & Mark Color Thickness of main color bearing (mm) Mark Color...
  • Page 170 02-47 0000-00 4) Cylinder Block (1) Overview The major dimensions in D20DTR are similar to D20DT engine. It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation. (2) Layout Right side Right side Expansion plug Screw plug...
  • Page 171 02-48 Left side Expansion plug (3) Features For simple manufacturing, the crankcase blow- by gas passage and the oil return hole are made by casting on the cylinder block.
  • Page 172 02-49 0000-00 The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase. The main flow of coolant starts from outlet port of water pump and goes along the longitudinal direction of engine. The coolant passage from cylinder head to inlet port of water pump is integrated in cylinder head. Water jacket core The engine oil from oil pump is supplied to the main oil gallery through oil channel, oil filter module and cross bore in cylinder block without using external pipes.
  • Page 173 03-3 2210-01 1. SPECIFICATION Description Specification Fuel Diesel Type Fuel heater + priming pump + water separator integrated type Filter type Changeable filter element type Change interval every 40,000 km Fuel filter every 45,000 km Water separation every 20,000 km interval every 15,000 km Water accumulating capacity...
  • Page 174 03-4 2. MAINTENANCE AND INSPECTION 1) Maintenance Procedures for DI Engine Fuel System Always keep the workshop and lift clean (especially, from dust). Always keep the tools clean (from oil or foreign materials). Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. Wash your hands and do not wear working gloves.
  • Page 175 03-5 2210-01 Follow the job procedures. If you find a defective component, replace it with new one. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques during installation.
  • Page 176 03-6 2) Diagnostic Test for Engine Fuel System (1) Overview If a DTC is displayed on the diagnostic device, check the low pressure- and high pressure fuel systems before removing the components. To run the system properly, the electric system must be intact but for the DI engine, the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device.
  • Page 177 03-7 2210-01 (3) Excessive backleak of injector ▶ Excessive injector backleak Occurs when the injector control valve is not sealed due to the entry of the foreign materials. ▶ Example: Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector...
  • Page 178 03-8 (4) Loss of pump pressure/flow ▶ Loss of HP pump pressure/flow Faulty fuel supply line, or damaged or worn pump causes the lack of flow pressure and flow volume ▶ Example: Air in fuel supply line Excessive load on fuel supply line (←400 mBar) Burned out and mechanical worn pump High temperature of fuel supply (>...
  • Page 179 03-9 2210-01 3) DI Engine Fuel System Pressure Test (1) Test device (Tool kit) Device for high pressure Device for low pressure (2) Pre-check Check-tighten fuel supply line Check fuel level in fuel tank Check air in fuel supply line (bubble in fuel supply line or fuel) Check fuel supply line for leaks (low pressure and high pressure) Check that specified fuel is used Check fuel filter for contamination...
  • Page 180 03-10 (3) DI Engine Fuel System Check Procedure If several DTCs are output simultaneously, check the electric wiring for open or short circuit. Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry out the high pressure fuel system check.
  • Page 181 03-11 2210-01 (4) Fuel System Check Procedure...
  • Page 182 03-12 (5) High Pressure System Pressure Test ▶ Fuel rail pressure test Disconnect the fuel rail pressure sensor connector and then IMV connector. Connect the pressure tester to the fuel rail pressure sensor connector. Crank the engine 2 times for 5 seconds. Read the highest pressure value displayed on the tester display.
  • Page 183 03-13 2210-01 ▶ How To Use Pressure Tester Press the "TEST" button on the tester to check if the message "TEST?" is displayed. If the button is pressed again at 4 seconds after starting engine cranking, the highest pressure is displayed on the tester. The fuel rail pressure value can be checked using a diagnostic device.
  • Page 184 03-14 (6) Low Pressure System Pressure Test ▶ Inspection procedure All wirings/connectors and fuel lines should be connected and the engine should work properly. Prepare a special tool for low pressure test and clean it thoroughly to prevent foreign materials from entering. Disconnect the key connector for fuel filter connection, and connect both connectors to the fuel filter and hose.
  • Page 185 03-15 2210-01 ▶ Static test for backleak of injector Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool). Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 186 03-16 ▶ Dynamic test for backleak of injector Warm up the engine so that the engine coolant temperature be over 80℃ and star the engine again. Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool).. Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 187 03-17 2210-01 ▶ HP pump pressure test Prepare a special tool for high pressure test and clean it thoroughly to prevent foreign materials from entering. Disconnect the high pressure fuel supply pipe on the HP pump and install the close rail in the tool kit.
  • Page 188 03-18 3. CAUTIONS FOR DI ENGINE 1) Cautions for DI Engine This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine, warning lights, symptoms when engine malfunctioning, causes and actions. DI Engine Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high power and reduces less emission..
  • Page 189 03-19 2210-01 2) Cleanness (1) Cleanness of DI engine fuel system ▶ Cleanness of DI engine fuel system and service procedures The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1,800 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.
  • Page 190 03-20 (2) Di engine and its expected problems and remedies can be caused by water in fuel ▶ System supplement against paraffin separation In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally.
  • Page 191 03-21 2210-01 1. OVERVIEW The components in fuel system supply the fuel and generate the high pressure to inject the fuel to each injector. They are controlled by the engine ECU. The common rail fuel injection system consists of fuel tank, fuel line, low pressure line which supplies low pressure fuel to the low pressure pump (including high pressure pump), common rail which distributes and accumulates the high pressurized fuel from the fuel pump, high pressure line which connected to the injector, and the engine control unit (ECU) which calculates the accelerator pedal position and...
  • Page 192 03-22 2. SYSTEM LAYOUT AND OPERATION 1) Layout For sensor and actuator control logic, refer to Chapter "Engine Control". Engine ECU (D20DTR) Injector (C3I) Pre-injection, main injection, after-injection by signals from Engine control by various signals HFM sensor Measuring intake air mass and temperature Crankshaft position sensor Fuel tank...
  • Page 193 03-23 2210-01 High pressure pump Accelerator pedal position sensor Plunger type HP pump (1,800 bar) Vane type LP pump (6 bar) Generating high pressurized fuel and supplying it according to engine rpm, Detecting driver's intention required volume, required pressure for speed up/down Fuel filter assembly Supplying clean fuel/fuel heating/water separation by...
  • Page 194 03-24 2) Fuel System Flow Diagram The fuel from the fuel tank is supplied to the fuel heater of fuel filter/priming pump and then low pressure generated by the low pressure pump (built into HP pump) is transmitted to the HP pump. The fuel pressure at the HP pump is controlled by the IMV valve, and the maximum allowed pressure is 1,800 bar.
  • Page 195 03-25 2210-01 3) Input/Output devices Refer to Chapter "Engine Control".
  • Page 196 03-26 The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and controls the overall operation of the vehicle. The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio control based on these signals.
  • Page 197 04-3 1719-00 1. SPECIFICATION Unit Description Specification Filter type Dry, filter element Initial resistance Max. 300 mmAq Air cleaner element Service interval EU: Change every 20,000 km GEN: Change every 15,000 km Weight 103.9 kg Air cleaner assembly -30 ~ 100˚C Operating temperature Core material Aluminum...
  • Page 198 04-4 2. INSPECTION 1) Troubleshooting ▶ When Abnormal Noises are Heard from the Engine Room For the vehicle equipped with DI engine, if a learning noise occurs in each range or other noises occur, the major cause of it is a faulty turbocharger assembly. But an interference issue, poor tightness or loose in the intake and exhaust system also can cause those noises.
  • Page 199 04-5 1719-00 3) Troubleshooting Sequence The basic checks for intake system are as follows: ▶ Basic Checks for Intake System Make sure to replace or clean the air cleaner element periodically. Otherwise, engine will be derated or work abnormally because of low intake air volume.
  • Page 200 04-6 1. OVERVIEW The intake system for D20DTR engine is equipped with a throttle body which includes a flap. This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off.
  • Page 201 04-7 1719-00 1719-02 Swirl control valve Operating variably in accordance with the engine load and rpm.* For more information, refer to Chapter "Engine Control". 1719-01 Intake manifold Passage for variable swirl valve and for intake air 1719-16 Electric throttle body * For more information, refer to Chapter "Engine Control".
  • Page 202 04-8 3. INPUT/OUTPUT OF INTAKE SYSTEM For more information, refer to Chapter " Engine Control".
  • Page 203 04-9 1719-00 4. OPERATING PROCESS ▶ Work Flow...
  • Page 204 04-10 1) Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Squish: Squish is the air flows due to the piston head.
  • Page 205 04-11 1719-00 Engine speed Swirl valve Amount of Load Remarks swirl Low speed, Increased EGR ratio, better air-fuel below 3,000 rpm Closed Heavy Low load mixture (reduce exhaust gas) High speed, Increase charge efficiency, higher over 3,000 rpm Open Light High load engine power The variable swirl valve actuator operates when...
  • Page 206 05-3 1729-01 1. TROUBLESHOOTING 1) Work Flow...
  • Page 207 05-4 2. CAUTIONS Do not park the vehicle on flammable materials, such as grass, leaves and carpet. Do not touch the catalyst or the exhaust gas ignition system when the engine is running. If a misfire occurs in the combustion chamber or the emission of pollutant exceeds the specified level, the catalyst can be damaged.
  • Page 208 05-5 1729-01 1. OVERVIEW This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion. 2. LAYOUT Exhaust manifold assembly Exhaust front pipe assembly CDPF assembly For more information, refer to Chapter "Engine Control".
  • Page 209 05-6 3. OPERATING PROCESS 1) Exhaust Gas Flow 2) Input & Output Devices...
  • Page 210 06-3 1914-01 1. SPECIFICATION Unit Description Specification Max. expansion coefficient Max. turbine speed 226,000rpm Turbocharger Max. temperature of turbine housing 790 ℃ Weight 6.5kg E-VGT actuator Operation duty cycle 250Hz...
  • Page 211 06-4 2. INSPECTION 1) Cautions During Driving The following lists cautions to take during test drive and on the turbocharger vehicle, which must be considered during the operation. It's important not to drastically increase the engine rpm starting the engine. It could make rotation at excessive speed even before the journal bearing is lubricated and when the turbocharger rotates in poor oil supply condition, it could cause damage of bearing seizure within few seconds.
  • Page 212 06-5 1914-01 2) Inspection of Turbocharger When problem occurs with the turbocharger, it could cause engine power decline, excessive discharge of exhaust gas, outbreak of abnormal noise and excessive consumption of oil. On-board Inspection Check the bolts and nuts foe looseness or missing Check the intake and exhaust manifold for looseness or damage Check the oil supply pipe and drain pipe for damages Check the housing for crack and deterioration...
  • Page 213 06-6 3) Inspection of Turbine Thoroughly check the followings. Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it could damage the turbocharger or be hazardous during inspection. Interference: In case where is trace of interference or smallest damage on the compressor wheel means, most of times, that abrasion has occurred on the journal bearing.
  • Page 214 06-7 1914-01 4) Possible Causes of Defect The following tries to understand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where adhesive of gaskets has been contaminated into the oil line.
  • Page 215 06-8 Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil line.
  • Page 216 06-9 1914-01 Turbine Side: Inflow of foreign materials from engine Compressor Side: such as air filter, muffler and nut...
  • Page 217 06-10 Defects caused by reasons other than that of the turbocharger.
  • Page 218 06-11 1914-01 3. TROUBLESHOOTING The followings are cautions to take in handling defects of turbocharger, which must be fully aware of. 1) Cautions After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting condition of vacuum port and modulator, which is connected to the actuator.
  • Page 219 06-12 2) Work Flow for Troubleshooting...
  • Page 220 06-13 1914-01...
  • Page 221 06-14...
  • Page 222 06-15 1914-01...
  • Page 223 06-16...
  • Page 224 06-17 1914-01 1. SYSTEM DESCRIPTION OF E-VGT (Electric-Variable Geometry Turbine) 1) Overview The E-VGT turbocharger has one shaft where at each ends are installed with two turbines having different angles to connect one end of housing to the intake manifold and the other end to the exhaust manifold.
  • Page 225 06-18 2) Features (1) Performance (for EURO V) Enhanced emmission control: By temperature control with CDPF system Target temperature and airflow control (2) E-VGT Actuator (Electric-Actuator) Optimizes the exhaust gas flow rate by controlling the vanes inside the turbine housing with the E- Actuator.
  • Page 226 06-19 1914-01 2. COMPONENTS * 세부제어로직은 엔진제어편 참조 E-VGT turbocharger Engine ECU (D20DTR) Accelerator pedal position sensor Atmospheric pressure, RPM signal Improves engine power E-VGT duty control Transfers driver's will to accelerate to ECU T-MAP sensor HFM sensor Coolant temperature sensor Booster pressure and Improves the engine power Operates the VGT according to...
  • Page 227 06-20 3. INPUT/OUTPUT DEVICES...
  • Page 228 06-21 1914-01 4. OPERATING PRINCIPLES The E-VGT is designed to get more improved engine power in all ranges by controlling the turbine as follows: 1) How it Works at Low Speed Normal turbocharger cannot get the turbo effect because the amount of exhaust gas is not enough and the flow speed is slow in a low speed zone, but VGT allows the flow passage of exhaust to narrow, resulting in increasing the flow speed of exhaust gas and running the turbine quickly and powerfully.
  • Page 229 06-22 2) How it Works at High Speed In a high speed zone, the amount of exhaust gas increases and it is accompanied with a great force. Therefore, if the inner diameter of venturi is more widened, the turbine in the turbocharger by the releasing force of abundant exhaust gas can deliver a more increased energy to the compressor.
  • Page 230 07-3 1543-00 1. SPECIFICATION Unit Specification Oil pump Lubrication system Gear pump, forced circulation Unit Specification Type Inscribed gear Oil pump Lubrication system Gear pump, forced circulation Capacity 63 L at 4,000 rpm Type Inscribed gear 5.8 bar ± 0.3 bar Relief pressure Capacity 63 L at 4,000 rpm...
  • Page 231 Recheck the oil level after 5 minutes. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
  • Page 232 07-5 1543-00 1. SYSTEM DESCRIPTION 1) Overview The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove heat from the friction part. As the engine runs, frictional heat is generated on each lubrication section. If this condition persists, the bearing can be burned and stuck.
  • Page 233 07-6 2. FUNCTIONS OF LUBRICATION 1) Lubrication It creates a viscous barrier between moving parts that reduces friction, which means less heat and longer life for those parts. As a lubricant, oil must maintain a protective film to prevent metal-to-metal contact.
  • Page 234 08-3 1520-00 1. SPECIFICATION Unit Description Specification Cooling system Type Water cooling, forced circulation Coolant Capacity approx. 8.5 L Radiator Core size 662.1W x 510H x 27T (over 337,600mm²) Flow type Cross flow Min. cooling capacity over 72,000 kcal/h Antifreeze Type Long life coolant Mixing ratio...
  • Page 235 08-4 2. INSPECTION Problem Possible Cause Action Coolant level is - Leak from the radiator - Change the radiator too low - Leak from the coolant auxiliary tank - Change the coolant auxiliary tank - Leak from the heater core - Change the heater - Leak from the coolant hose - Reconnect the hose or replace...
  • Page 236 08-5 1520-00 1) Coolant Level Check Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is cooled down. The coolant level should be between the MAX and MIN mark on the coolant reservoir. Check the coolant level.
  • Page 237 08-6 2) Leak Test Release the pressure in the system by loosening the pressure cap of the coolant reservoir slightly. Then, remove the pressure cap completely. Never open the cap until the coolant temperature becomes under 90℃ to prevent any burn. Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank.
  • Page 238 08-7 1520-00 3. CAUTIONS If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity can be decreased resulting in poor circulation in the cooling system which leads to overheated engine. Use of non-recommended coolant could cause damage to the cooling system and overheating of the engine.
  • Page 239 08-8 1. SYSTEM DESCRIPTION 1) Overview Coolant reservoir Long life coolant is used. Water pump Sealing Oil filter module Water pump Impeller vane The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine. Thermostat When the engine coolant reaches 90℃, the thermostat...
  • Page 240 08-9 1520-00 Coolant temperature sensor Measures the coolant temperature and sends the result to the engine ECU. Electric fan Circulates the fresh air forcibly to exchange heat with the radiator core fin. Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core.
  • Page 241 09-3 1451-01 1. SPECIFICATION Unit Description Specification Crankshaft pulley : Alternator pulley 1 : 2.94 Normal output (idling/2200 rpm) 70/120 A Alternator Regulator voltage 14.6 V Length 12.5 mm Brush Wear limit 7 mm Type Battery Capacity 90 AH...
  • Page 242 09-4 2. INSPECTION 1) Alternator Output Test Item How to check DTC set value / Action Disconnect the cable connected to the B Pass: If the measured current is 45 terminal on the alternator. Connect one end A or higher. of the ammeter to the B terminal and the Fail: If the measured current is less other end to the cable connected to the B...
  • Page 243 09-5 1451-01 2) Troubleshooting for Alternator Item Cause Action Defective alternator voltage regulator Replace the alternator Overcharged battery Defective voltage detection wiring Repair or replace Loose alternator drive belt Adjust the belt tension or replace Poor connection of related circuit or open Retighten the loose connection or circuit repair open circuit...
  • Page 244 09-6 3) Checking Battery...
  • Page 245 09-7 1451-01 (1) Checking ▶ Using battery tester PASS (11.0 V or more): Explain to the customer that the battery is reusable. Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the customer.
  • Page 246 09-8 (3) Starting with jumper cable If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to start the engine. ▶ Connecting order The positive (+) terminal of the discharged battery The positive (+) terminal of the booster battery The negative (-) terminal of the booster battery Connect one end of the other jumper cable to the body of the discharged vehicle, such as the engine block or a front towing hook.
  • Page 247 09-9 1451-01 (4) Maintenance If the charge warning lamp ( ) on the instrument cluster comes on while driving, there is a malfunction in the charge system including the battery. Therefore, carrying out the system check is needed. Make sure that the battery cables are firmly connected. If the terminals are corroded, clean them with a wire brush or sandpapers.
  • Page 248 09-10 1. SYSTEM DESCRIPTION 1) Overview The charge system is designed to supply electrical energy to the vehicle while driving, and supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy. The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change.
  • Page 249 09-11 1451-01 2. OPERATING PROCESS 1) Charging Flow...
  • Page 250 09-12 2) Charging The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge, slip ring and brush. ▶ Charging time according to vehicle conditions and environment Specification: Charging a fully depleted high- capacity battery takes twice or more as long as charging a fully depleted battery for small vehicles.
  • Page 251 09-13 1451-01 3. CIRCUIT DIAGRAM...
  • Page 252 10-3 1413-00 1. SPECIFICATION Description Specification Glow plug Rated voltage 12 V Operating voltage 6 ~ 16 V 1000 ~ 1115°C Maximum temperature 18 seconds after ignition ON: 980~1100°C Operating temperature 60 seconds after ignition ON: 980~1100°C Glow plug control unit EMS operating voltage 6 ~ 16 V -40°C ~ 110°C...
  • Page 253 10-4 1. OVERVIEW The pre-heating system for D20DTR engine has the glow plug to the cylinder head (combustion chamber), and improves the cold start performance and reduces the emission level. The pre-heating resistor (air heater) is used to heat the intake air. This enables the diesel fuel to be ignited in low temperature condition.
  • Page 254 10-5 1413-00 2. SYSTEM OPERATION 1) Input/Output Diagram of Glow Plug Control Unit 2) System Diagram...
  • Page 255 10-6 3) Circuit Diagram...
  • Page 256 10-7 1413-00 4) Operation Glow plug is installed in the cylinder head. It enhances the cold starting performance and reduces the exhaust gas during cold starting. ECU receives the data (engine rpm, coolant temperature, vehicle speed) through CAN lines. Based on the data, GCU controls the pre-glow, cranking and post-glow.
  • Page 257 10-8 (3) Operation ▶ Pre-Glow: Step 1 If normal communication with the ECU is established 2 seconds after the power is supplied to the IGN terminal from the battery, the GCU supplies the battery power to raise the temperature of the glow plug to 1000℃...
  • Page 258 10-9 1413-00 ▶ During cranking: Step 2 and step 3 Step 2: If the ECU receives the cranking signal after pre-heating (step 1), the GCU supplies the voltage of 6.8 V for 1 sec to raise the temperature to 1,100℃. Step 3: The GCU supplies the voltage of 5.1 V to keep the temperature at 1,000°C.
  • Page 259 10-10 ▶ Normal operation mode This shows the pre-glow and post-glow step as a chart.
  • Page 260 10-11 1413-00 ▶ Operation when there is no engine start signal (cranking) after ignition ON...
  • Page 261 11-3 1461-01 1. SPECIFICATION Description Specification Capacity 12 V, 2.3 kW Engagement Meshed type Rotating direction Clockwise Pinion gear manufacturing Cooled forging Solenoid operating voltage Max. 8 V Weight 2.5 kg Bracket manufacturing Aluminum die casting...
  • Page 262 11-4 2. TROUBLESHOOTING Possible Cause　 Problem Action Low battery voltage Charge or replace Loose, corroded or damaged battery cable Repair or replace Engine will not crank Faulty starter or open circuit Faulty ignition switch or blown fuse Repair or replace Poor engine ground Repair Low battery voltage...
  • Page 263 11-5 1461-01 1. SYSTEM DESCRIPTION The starter (start motor) starts the engine with rotational power by converting the electric energy to the mechanical energy. When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the pinion gear clutch overruns to protect the pinion gear.
  • Page 264 11-6 2) Circuit Diagram...
  • Page 265 12-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 266 12-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Improper use of the cruise control could be dangerous.
  • Page 267 12-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 268 12-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...
  • Page 269 12-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 270 12-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 271 12-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 272 12-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention. But if you turn off the ignition switch, the memorized set speed is cleared and you cannot recover the previous set speed.
  • Page 273 12-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 274 12-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 275 13-3 1793-00 1. SPECIFICATION Item Specification EGR response time 50 ms Motor Driven by DC motor Valve EGR gas flow rate 120 kg/h Sensing type Hole sensor E-EGR valve 5V ± 10% Supplied voltage Position sensor Maximum signal 5% ~ 95% range Maximum power ＜15mA...
  • Page 276 13-4 1. SYSTEM DESCRIPTION 1) Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. To meet Euro-V regulation, the capacity and response rate of E-EGR valve in D20DTR engine have been greatly improved.
  • Page 277 13-5 1793-00 2) Location and Components HFM sensor E-EGR cooler and bypass valve EGR cooler EGR bypass Used as a main map value to control the EGR. See the section "Engine control" for E-EGR The coolant temperature, engine rpm, engine valve control logic.
  • Page 278 13-6 2. OPERATING PROCESS 1) Schematic Diagram...
  • Page 279 13-7 1793-00 2) Input/Output Devices...
  • Page 280 13-8 3) Control Logic The EGR system controls the EGR amount based on the map values shown below: ※ Main map value: Intake air volume ※ Auxiliary map value: Compensation by the coolant temperature Compensation by the atmospheric pressure: Altitude compensation Compensation by the boost pressure deviation (the difference between the requested value and the measured value of boost pressure) Compensation by the engine load: During sudden acceleration...
  • Page 281 14-3 2412-02 1. SPECIFICATION Emission Regulation Euro-V 154.06㎠ Front Area 158 X 124 X 78L Size 158 X 124 X 195L Shell SUS430J1L X 1.5t CDPF Canister End Cone SUS430J1L X 2.0t (Single) Catalyst Capacity 4.2L CDPF Material of Filter AT (Aluminum-Titanium Alloy)
  • Page 282 14-4 2. CAUTIONS ▶ Standard pattern of soot accumulation (1) Abnormal Soot Accumulation (2) Normal Soot Combustion ▶ Cautions to protect the catalyst filter Use the designated fuel only. Observe the recommended service intervals of engine oil. Check the engine oil level frequently and add if necessary. Do not idle the vehicle unnecessarily.
  • Page 283 14-5 2412-02 (3) Warning Lamp Related to CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 284 14-6 Excessive overload of CDPF (warning lamp illuminated) Illuminating If the vehicle is driven at a speed of 5 to 10 km/h for an extended period of time, the soot accumulated in the CDPF cannot be burned as the CDPF cannot reach the regeneration temperature.
  • Page 285 14-7 2412-02 1. OVERVIEW The DOC (Diesel Oxidation Catalyst) generates CO2 and H2O which are harmless through the oxidation process of CO and HC. And the DPF (Diesel Particulate Filter) collects PM (Particle Matter) and is regenerated to reduce the quantity of particulates, HC and CO. But there is a limitation in reducing the emission of exhaust gas for each system, so the CDPF which combines these two system is applied.
  • Page 286 14-8 2. COMPONENT Front temperature CDPF Rear temperature sensor sensor DOC+DPF Measures the temperature Protects the turbocharger. of fuel combustion. Differential pressure Engine ECU Throttle sensor DCM 3.7 valve Calculates the amount of PM collected by reading the pressure difference between before and after the CDPF.
  • Page 287 14-9 2412-02 3. INPUT/OUTPUT DEVICES Front temperature sensor: This sensor is installed at the inlet of DOC and detects whether the DOC can burn (oxidize) the post-injected fuel or not. Rear temperature sensor: This sensor is installed at the inlet of DPF and monitors that the temperature of the exhaust gas is kept at 600℃.
  • Page 288 14-10 4. POST-INJECTION AND AIR MASS CONTROL A DPS (Differential Pressure Sensor) measures the pressure difference between before and after the CDPF and detects whether the soot is collected in the CDPF or not. If PM is collected in the CDPF (In this case the pressure difference between before and after the CDPF exceeds the specified value.
  • Page 289 14-11 2412-02 Front temperature sensor Rear temperature sensor HFM sensor Intake air mass Engine ECU (D20DTR) Measures the temperature of exhaust gas. Measure the outlet temperature of DOC. This sensor is located at the rear side of exhaust manifold and This sensor is located at the monitors the temperature of rear side of DOC and...
  • Page 290 14-12 5. OPERATING PROCESS [Configuration and principle of operation] Collecting PM Oxidation (DOC) → Regeneration The exhaust gas passed through the When the exhaust gas enters The engine ECU detects the exhaust manifold into the CDPF assembly, its amount of PM collected by the enters into the CDPF CO, HC and PM are reduced information from the...
  • Page 291 14-13 2412-02 1) Oxidation of DOC The DOC oxidizes HC and CO of the exhaust gas in the two-way catalytic converter at 180℃ or more, and performs best at the temperature between 400 and 500℃. The front EGT sensor detects whether the DOC can burn (oxidize) the post-injected fuel or not, and sends the signal to the ECU to maintain the DOC operating temperature between 300 and 500℃.
  • Page 292 14-14 2) Collecting PM of DPF There is a filter installed in the DPF and the PM filtered by this filter is burned (regeneration) when the temperature of exhaust gas is increased due to post-injection. The filter has a honeycomb-like structure to capture the particulate matter and the inlet and outlet of each channel are closed alternatively.
  • Page 293 14-15 2412-02 3) PM Regeneration of DPF The differential pressure sensor installed in the DPF measures the pressure values of inlet and outlet of CDPF. And the amount of the PM collected in the filter is calculated based on the exhaust temperature, intake air mass flow, booster pressure, etc.
  • Page 294 14-16 4) Fuel Injection During CDPF Regeneration The injection method in D20DTR engine has three steps; Pilot injection, Main injection, Post injection ▶ Post injection The post injection is the injection process after main injection and consists of ‘After injection”, “Post 1 injection”...
  • Page 295 14-17 2412-02 6. ELECTRIC CIRCUIT DIAGRAM...
  • Page 296 14-18 7. CAUTIONS 1) Designated Engine Oil for CDPF (Low Ash Oil) Need to use the designated engine oil for CDPF The smoke from the vehicle may generate the particle material in the ambient air. CDPF is the device to reduce the smoke by collecting and recycling it. To ensure the performance of CDPF, the designated engine oil should be used.
  • Page 297 15-3 0000-00 1. ENGINE DATA LIST Data Unit Value ℃ 0.436 V (130℃) to 4.896 V (-40℃) Coolant temperature ℃ -40 to 130℃ (varies by ambient air Intake air temperature temperature or engine mode) 700 ± 50 (P/N), 600 ± (D) Idle speed Engine load 18~25%...
  • Page 298 15-4 1. MAJOR COMPONENTS Rear EGT sensor Oxygen sensor Glow plug Front EGT sensor Differential pressure sensor Injector (C3I) HFM (air mass/ Camshaft position Variable swirl valve temperature) sensor actuator...
  • Page 299 15-5 0000-00 Fuel temperature Coolant temperature EGR valve Fuel rail pressure sensor sensor sensor E-EGR bypass valve E-VGT actuator GCU (Preglow control Water sensor unit) T-MAP sensor Knock sensor Electric throttle body D20DTR ECU (2 ea)
  • Page 300 15-6 2. SYSTEM OPERATION 1) Input/Output of ECU (1) ECU Block diagram...
  • Page 301 15-7 0000-00 (2) Components for ECU Input -Auto cruise switch - Rear right wheel speed (without ABS) - Refrigerant pressure sensor - Clutch pedal signal - Blower switch signal - Brake pedal signal Crankshaft Accelerator pedal Throttle position Knock sensor position sensor sensor sensor...
  • Page 302 15-8 (3) Components for ECU Output E-EGR valve A/C compressor Injector Throttle position sensor E-EGR cooler Variable swirl E-VGT actuator IMV valve bypass valve valve PTC heater Cooling fan - Glow plug unit - Instrument cluster - ABS & ESP unit - TCU - GCU - Self diagnosis...
  • Page 303 15-9 0000-00 2) ECU Control (1) Function a. ECU Function ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and analyzes to control respective actuators. ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft angle based on input data and stored specific map to control the engine power and emission gas.
  • Page 304 15-10 (2) Fuel injection control a. Multi injection Fuel injection process consists of 3 steps: Main Injection, Pilot Injection, Post Injection Function Produces engine power Injection Main Reduces PM by injecting before PM control Pilot 1 After main injection. Pilot 2 Reduces NOx and noise by Post 1 Reduces PM by enabling fuel...
  • Page 305 15-11 0000-00 This is the injection before main injection. This consists of 1st and 2nd pilot injection, and Pre-injection. The steps are normally used to control the NOx, noise, idle stability and engine vibration. Inject a small amount of fuel before main injection prevents the instant high combustion temperature. It reduces the NOx and decreases the engine noise and vibration.
  • Page 306 15-12 b. Pilot Injection Injection before main injection. Consists of 1st and 2nd pilot injection, and Pre-injection Inject a small amount of fuel before main injection to make the combustion smooth. Also, called as preliminary injection or ignition injection. This helps to reduce Nox, engine noise and vibration, and to stabilize the idling.
  • Page 307 15-13 0000-00 c. Main Injection The power of the vehicle is determined by the main fuel injection volume. Main injection calculates the fuel volume based on pilot injection. The calculation uses the value for accelerator pedal position, engine rpm, coolant temperature, intake air temperature, boost pressure, boost temperature and atmospheric pressure etc.
  • Page 308 15-14 (3) Fuel Pressure Control ▶ Fuel Pressure Fuel pressure is controlled by IMV opening according to the calculated value by ECU. ▶ Pressure in the fuel rail is determined according to engine speed and load on the engine. When engine speed and load are high The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize combustion.
  • Page 309 15-15 0000-00 (4) Injection Timing Control ▶ Injection timing is determined by the conditions below. Coolant temperature Hot engine - Retarded to reduce Nox Cold engine - Advanced to optimize the combustion Atmospheric pressure Advanced according to the altitude Warming up Advanced during warming up in cold engine Rail pressure Retarded to prevent knocking when the rail pressure is high...
  • Page 310 15-16 A fourth correction is made according to the pressure error. This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the pressure demand. A fifth correction is made according to the rate of EGR. This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation.
  • Page 311 15-17 0000-00 B. Driver Demand The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes of the pedal position.
  • Page 312 15-18 C. Idle Speed Controller The idle speed controller consists of 2 principal modules: The first module determines the required idle speed according to: * The operating conditions of the engine (coolant temperature, gear engaged) * Any activation of the electrical consumers (power steering, air conditioning, others) * The battery voltage * The presence of any faults liable to interface with the rail pressure control or the injection control.
  • Page 313 15-19 0000-00 F. Pilot Flow Control The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined according to the engine speed and the total flow. A first correction is made according to the air and water temperature. This correction allows the pilot flow to be adapted to the operating temperature of the engine.
  • Page 314 15-20 (6) MDP Learning Control MDP (Minimum Drive Pulse ) refers to the minimum power supply pulse for injection which the injector can perform. It is possible to control the fuel volume for each injector accurately through correct learning for the MDP value. The basic process of MDP learning is that the pulse slightly higher than MDP is supplied and then (b) the vibration generated from the cylinder is...
  • Page 315 15-21 0000-00 C. Learning Conditions Idle MDP learning Drive MDP learning over 60℃ over 60℃ Coolant temperature Idling over 50km/h (over 5 seconds) Vehicle speed 2,000 to 2,500 rpm Engine rpm 0 < Fuel temperature < 80℃ Fuel temperature 2 times for each cylinder (every 5 2 times for each cylinder Learning seconds)
  • Page 316 15-22 (7) Knocking Control A. Resetting the pilot injection The knocking control is used to reset the pilot injection flow in closed loop for each injector. This method allows the correction of any injector deviations over a period of time. The principle of use of the knocking control is based on the detection of the combustion noises.
  • Page 317 15-23 0000-00 This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse value replaces the value obtained during the previous resetting. The first MDP value is provided by the C3I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
  • Page 318 15-24 (8) Swirl control A. Overview ▶ Variable swirl valve The strong swirl caused by intake air is important element for anti-locking function in diesel engine. The swirl control valve partially closes the intake port to generate the swirl according to the engine conditions. When the engine load is in low or medium range, the swirl could not be generated because the air flow is slow.
  • Page 319 15-25 0000-00 B. Input/Output for variable swirl valve...
  • Page 320 15-26 C. Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port...
  • Page 321 15-27 0000-00 Engine speed Swirl valve Amount of Load Remarks swirl Low speed, below 3,000 rpm Increased EGR ratio, better air-fuel Closed Heavy Low load mixture (reduce exhaust gas) High speed, over 3,000 rpm Increase charge efficiency, higher Open Light High load engine power The variable swirl valve actuator operates when...
  • Page 322 15-28 (9) EGR control A. Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. To meet Euro-V regulation, the capacity and response rate of E-EGR valve in D20DTR engine have been greatly improved.
  • Page 323 15-29 0000-00 C. Input/Output of E-EGR system...
  • Page 324 15-30 D. Bypass control for EGR cooler ▶ Cooler temperature When the coolant temperature is below 70℃, the exhaust gas is bypassed the EGR cooler. ▶ Exhaust gas temperature When the exhaust gas temperature is below 300℃, the exhaust gas is bypassed the EGR cooler. Otherwise, PM could be increased due to too low exhaust gas temperature.
  • Page 325 15-31 0000-00 F. Features As EGR ratio goes up, smoke volume will be As EGR temperature goes up, the higher. But, this lowers the combustion concentration of NOx will be higher. Thus, it is chamber temperature and accordingly the necessary to cool down the exhaust gas. concentration of NOx is decreased.
  • Page 326 15-32 (10) E-VGT control A. Overview E-VGT (Electric-Variable Geometry Turbine) turbocharger system in D20DTF engine uses the venturi effect that controls the flow rate of exhaust gas by adjusting the passage in turbine housing. The newly adopted DC motor actuator (E-actuator) controls the E-VGT system more precisely and faster. To get the high operating power from turbine, the ECU reduces the exhaust gas passage In low speed range and increases it in high speed range.
  • Page 327 15-33 0000-00 C. Input/Output for E-VGT system...
  • Page 328 15-34 D. E-VGT system control Turbocharger system operates the E-VGT actuator according to the signals for engine epm, accelerator pedal position, atmospheric pressure, T-MAP, coolant temperature and intake air temperature. Turbocharger actuator is performed PWM control by ECU. In general, the boost pressure feedbacks the turbocharger operation and the boost temperature is used for calculating the precise density.
  • Page 329 15-35 0000-00 (11) Wide band oxygen sensor control A. Overview For diesel engine, combustion is not performed at the optimum (theoretically correct) air-fuel ratio and the oxygen concentration is thin in most cases. So the wide-band oxygen sensor is used for this kind of engine, and this sensor is a little different from the one that used for gasoline engine.
  • Page 330 15-36 C. Input/Output for oxygen sensor...
  • Page 331 15-37 0000-00 D. Oxygen sensor control The wide band oxygen sensor uses ZnO2. It produces the voltage by movement of oxygen ions when there is oxygen concentration difference between exhaust gas and atmosphere. If a certain voltage is applied to the sensor, the movement of oxygen ions occurs regardless of the oxygen density.
  • Page 332 15-38 (12) Cooling fan control A. Overview of cooling fan and A/C compressor The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. The water pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head.
  • Page 333 15-39 0000-00 C. Input/Output for cooling fan and A/C compressor...
  • Page 334 15-40 D. Cooling fan and A/C compressor control ▶ Conditions for cooling fan The cooling fan module controls the cooling fan relay, high speed relay and low speed relay. The cooling fan is controlled by the series and parallel circuits. Coolant temperature Refrigerant pressure A/C switch...
  • Page 335 15-41 0000-00 (13) PTC heater control A. Overview The supplementary electrical heater is installed in DI engine equipped vehicle as a basic equipment. The PTC system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor. This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment.
  • Page 336 15-42 C. Operation process The ceramic PTC has a feature that the resistance goes up very high at a certain temperature. There are three circuits in PTC heater. Only one circuit is connected when PTC1 relay is ON, and two circuits are connected when PTC2 relay is ON.
  • Page 337 15-43 0000-00 D. PTC operation process The PTC operating condition (ON) is controlled in two steps. Basically, the engine ECU controls the relay to supply the power to PTC according to the coolant temperature sensor and ambient temperature sensor. ▶ 1st step (initial operation of PTC) Coolant temperature <...
  • Page 338 15-44 (14) Immobilizer control A. Overview The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized persons. The transponder integrated in the key and the engine control unit have the same code. When the ignition key with the integrated transponder is turned to the ON position, the ECU (Engine Control Unit) checks the crypto code of the key and, if correct, allows the vehicle to start the engine.
  • Page 339 15-45 0000-00 ▶ Key approval process When turning the ignition switch to ON position, the power is supplied to BCM and ECU. ECU communicate with the immobilizer key to check if it is valid crypto code. If it is valid, ECU start to control the engine when turning the ignition switch to START position.
  • Page 340 15-46 (15) CDPF control A. Overview As the solution for environmental regulations and PM Particle Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxidation Catalyst) is reduced.
  • Page 341 15-47 0000-00 C. Input/Output for CDPF control...
  • Page 342 15-48 D. Operation process When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF, the sensor sends signal indicating the soot is accumulated and the post injection is performed to raise the temperature of exhaust gas. The amount of fuel injected is determined according to the temperature of exhaust gas detected by the rear temperature sensor.
  • Page 343 15-49 0000-00 E. Cautions Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. ▶ Use only specified engine oil (Low Ash Oil) The vehicle equipped with CDPF should use specific engine oil to improve the engine performance and fuel economy, and ensure the service life of CDPF.
  • Page 344 15-50 3) Input/Output for CAN communication...
  • Page 345 01-3 0000-00 1. STRUCTURE AND COMPARISON ▶ D27DT (EU IV) Engine - Front View ▶ D27DT (EU IV) Engine - Top View...
  • Page 346 01-4 ▶ D27DT (EU IV) Engine - Side View ▶ D27DT (EU IV) Engine - Left Side View...
  • Page 347 01-5 0000-00 ▶ D27DT Engine (General) - Front View ▶ D27DT Engine (General) - Top View...
  • Page 348 01-6 ▶ D27DT Engine (General) - Side View ▶ D27DT Engine (General) - Left Side View...
  • Page 349 01-7 0000-00 2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications...
  • Page 350 01-8 2) D27DT Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure...
  • Page 351 01-9 0000-00 3. TIGHTENING TORQUE This table shows the tightening torques for removal/mounting and disassembly/reassemly of the engine.
  • Page 352 01-10...
  • Page 353 01-11 0000-00...
  • Page 354 01-12 MAJOR CHANGES IN D27DTP (POWER UP) ENGINE (COMPARED TO D27DT) The shape and size of D27DTP (POWER UP) are slightly different from those of D27DT engine but the basic configuration of two systems is almost same. 1) Engine Assembly...
  • Page 355 01-13 0000-00 2) Major Changes and Summary...
  • Page 356 01-14...
  • Page 357 01-15 0000-00...
  • Page 358 01-16...
  • Page 359 01-17 0000-00...
  • Page 360 01-18...
  • Page 361 01-19 0000-00...
  • Page 362 01-20...
  • Page 363 01-21 0000-00 5. GUIDELINES FOR SERVICE WORKS 1) For Safety To perform the service works easily and safely, the service technicians must keep the proper working procedures and rules. This manual provides the useful instructions to the service technicians so that they can perform the service works with standard working process, skills, tips in time.
  • Page 364 To improve the efficiency of service work, use only recommended and specified tools. Use only Ssangyong genuine spare parts. Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new ones. If reused, normal functions cannot be maintained.
  • Page 365 01-23 0000-00 3) Guidelines on Engine Service To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 366 01-24 ▶Fuel and lubrication system Do not allow the fluid and engine oil to make contact with the body paintwork and hoses. If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking should be prohibited.
  • Page 367 01-25 0000-00 6. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 368 01-26 1. ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows:...
  • Page 369 01-27 0000-00...
  • Page 370 01-28 ▶ Engine Compartment Layout Engine assembly FFH Assembly (Only for vehicle with FFH) Engine oil dipstick Power steering oil tank Vacuum pump Engine oil filler cap Oil filter and cooler Fan shroud Fuel filter and priming pump E-EGR Valve Brake booster High-capacity PCV oil separator Brake oil tank...
  • Page 371 01-29 0000-00 ▶ Major Sensors and Components...
  • Page 372 01-30 2. SYSTEMS IN ENGINE COMPARTMENT 1) Engine Accessories Related to ECU...
  • Page 373 01-31 0000-00...
  • Page 374 01-32 2) Preheat System...
  • Page 375 01-33 0000-00 3) Fuel System...
  • Page 376 01-34 ▶ Fuel Supply System...
  • Page 377 01-35 0000-00 4) Lubrication System...
  • Page 378 01-36 5) Cooling System...
  • Page 379 01-37 0000-00 6) Intake System...
  • Page 380 01-38 7) Exhaust System...
  • Page 381 02-3 1212-01 1. D27DT ENGINE STRUCTURE 1) Major Components in Engine and Engine Compartment The advanced electronically controlled D27DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
  • Page 382 02-4 2) Engine Structure Front View Rear View 1. TVD (Torsional Vibration Damper) 7. Viscos fan clutch 13. Oil filter 2. Air conditioner compressor 8. Auto tensioner pulley 14. Vacuum pump 3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor 4.
  • Page 383 02-5 1212-01 Top View 19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor 20. Intake manifold 25. Injector 30. PCV valve and oil separator 21. Water outlet port 26. Fuel return line 31. Oil dipstick 22. Common rail 27.
  • Page 384 02-6 Left Side View Right Side View 33. Cylinder head 38. EGR-RH (#3) pipe 42. Turbo charger booster vacuum 34. Cylinder block 39. PCV valve and oil separator modulator 35. Oil pan 40. Oil dipstick 43. EGR valve vacuum modulator 36.
  • Page 385 02-7 1212-01 2. SPECIFICATIONS...
  • Page 386 02-8 3. ENGINE PERFORMANCE CURVE ▶Output and Torque...
  • Page 387 02-9 1212-01 ▶Oil Temperature/Pressure and Boost Pressure...
  • Page 388 02-10 4. TIGHTENING TORQUE...
  • Page 389 02-11 1212-01...
  • Page 390 02-12...
  • Page 391 03-3 1881-09 MAJOR CHANGES IN FUEL SYSTEM OF D27DTP (POWER UP) ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D27DTP (POWER UP) engine. The major changes are as follows. Refer to the next pages for further details.
  • Page 392 03-4 2) Common Rail · The orifice is added to the connection to D27DTP & D27DT (EU IV) the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume.
  • Page 393 03-5 1881-09 3) Fuel Rail - Chrome Color · The I.D and O.D of the fuel rail between D27DTP & D27DT (EU IV) HP pump and common rail are increased * Fuel pipe (Common rail → Injector) according to the increased amount of fuel injection.
  • Page 394 03-6 2. COMPONENTS OF FUEL SYSTEM...
  • Page 395 03-7 1881-09 ▶Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System...
  • Page 396 04-3 2321-01 1. INTAKE SYSTEM LAYOUT The intake system for the D27DTP (POWER UP) engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off. Therefore, the structure of the intake manifold has been changed.
  • Page 397 05-3 1792-01 1. COMPONENTS The components of the exhaust system for the D27DTP (POWER UP) engine have been changed as follows: 1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) 2.
  • Page 398 06-3 1725-12 1. OVERVIEW FOR CDPF (EURO IV) 1) General Description The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine previously. However, it is now installed to the all 2009 DI engine models, except the Actyon Sports.
  • Page 399 06-4 2. CDPF(EURO IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and sensors Differential pressure sensor (△P sensor) Under air cleaner in righ side of engine compartment...
  • Page 400 06-5 1725-12 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
  • Page 401 06-6 1. OVERVIEW As the solution for environmental regulations and PM (Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
  • Page 402 06-7 1725-12 2. CDPF (EURO IV) SYSTEM CONTROL 1) Combustion Temperature and Procedures As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
  • Page 403 06-8 2) Sytem Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
  • Page 404 06-9 1725-12 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type.
  • Page 405 06-10 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
  • Page 406 06-11 1725-12 Front temperature sensor (Measuring the temperature of Rear temperature sensor exhaust gas passed through (Measuring the temperature of exhaust gas passed through DOC) exhaust manifold) Differrential pressure sensor (Front Differrential pressure sensor (Rear pressure port) pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects into CDPF assembly after...
  • Page 407 06-12 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF ▶CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 408 06-13 1725-12 ▶Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process, the soot is continuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to inform this situation to the driver.
  • Page 409 06-14 4. COMPONENTS OF CDPF SYSTEM ▶Mounting condition and location Differential Pressure Sensor Engine compartment (RH) Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
  • Page 410 NO DATA...
  • Page 411 08-3 1520-01 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D27DTP (POWER UP) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
  • Page 412 08-4 ▶ Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine...
  • Page 413 NO DATA...
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  • Page 415 11-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 416 11-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc.
  • Page 417 11-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 418 11-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...
  • Page 419 11-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 420 11-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 421 11-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 422 11-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention.
  • Page 423 11-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 424 11-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 425 01-3 0000-00 1. STRUCTURE AND COMPARISON ▶ D27DTP (POWER UP) + CDPF Engine - Front View ▶ D27DTP (POWER UP) + CDPF Engine - Top View...
  • Page 426 01-4 ▶ D27DTP (POWER UP) + CDPF Engine - Side View ▶ D27DTP (POWER UP) + CDPF Engine - Left Side View...
  • Page 427 01-5 0000-00 ▶ D27DT (EU IV) Engine - Front View ▶ D27DT (EU IV) Engine - Top View...
  • Page 428 01-6 ▶ D27DT (EU IV) Engine - Side View ▶ D27DT (EU IV) Engine - Left Side View...
  • Page 429 01-7 0000-00 ▶ D27DT Engine (General) - Front View ▶ D27DT Engine (General) - Top View...
  • Page 430 01-8 ▶ D27DT Engine (General) - Side View ▶ D27DT Engine (General) - Left Side View...
  • Page 431 01-9 0000-00 2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications...
  • Page 432 01-10 2) D27DTP (Power Up) Engine Performance Curve (1) Output and Torque: vehicle with automatic transmission Oil Temperature/Pressure and Boost Pressure: vehicle with automatic transmission...
  • Page 433 01-11 0000-00 3) D27DT Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure...
  • Page 434 01-12 3. TIGHTENING TORQUE This table shows the tightening torques for removal/mounting and disassembly/reassemly of the engine.
  • Page 435 01-13 0000-00...
  • Page 436 01-14...
  • Page 437 01-15 0000-00 MAJOR CHANGES IN D27DTP (POWER UP) ENGINE (COMPARED TO D27DT) The shape and size of D27DTP (POWER UP) are slightly different from those of D27DT engine but the basic configuration of two systems is almost same. 1) Engine Assembly...
  • Page 438 01-16 2) Major Changes and Summary...
  • Page 439 01-17 0000-00...
  • Page 440 01-18...
  • Page 441 01-19 0000-00...
  • Page 442 01-20...
  • Page 443 01-21 0000-00...
  • Page 444 01-22...
  • Page 445 01-23 0000-00...
  • Page 446 01-24 5. GUIDELINES FOR SERVICE WORKS 1) For Safety To perform the service works easily and safely, the service technicians must keep the proper working procedures and rules. This manual provides the useful instructions to the service technicians so that they can perform the service works with standard working process, skills, tips in time.
  • Page 447 To improve the efficiency of service work, use only recommended and specified tools. Use only Ssangyong genuine spare parts. Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new ones. If reused, normal functions cannot be maintained.
  • Page 448 01-26 3) Guidelines on Engine Service To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 449 01-27 0000-00 ▶Fuel and lubrication system Do not allow the fluid and engine oil to make contact with the body paintwork and hoses. If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking should be prohibited.
  • Page 450 01-28 6. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.
  • Page 452 01-30 1. ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows:...
  • Page 453 01-31 0000-00...
  • Page 454 01-32 ▶ Engine Compartment Layout Engine assembly FFH Assembly (Only for vehicle with FFH) Engine oil dipstick Power steering oil tank Vacuum pump Engine oil filler cap Oil filter and cooler Fan shroud Fuel filter and priming pump E-EGR Valve Brake booster High-capacity PCV oil separator Brake oil tank...
  • Page 455 01-33 0000-00 ▶ Major Sensors and Components...
  • Page 456 01-34 2. SYSTEMS IN ENGINE COMPARTMENT 1) Engine Accessories Related to ECU...
  • Page 457 01-35 0000-00...
  • Page 458 01-36 2) Preheat System...
  • Page 459 01-37 0000-00 3) Fuel System...
  • Page 460 01-38 ▶ Fuel Supply System...
  • Page 461 01-39 0000-00 4) Lubrication System...
  • Page 462 01-40 5) Cooling System...
  • Page 463 01-41 0000-00 6) Intake System...
  • Page 464 01-42 7) Exhaust System...
  • Page 465 02-3 1212-01 1. D27DT ENGINE STRUCTURE 1) Major Components in Engine and Engine Compartment The advanced electronically controlled D27DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
  • Page 466 02-4 2) Engine Structure Front View Rear View 1. TVD (Torsional Vibration Damper) 7. Viscos fan clutch 13. Oil filter 2. Air conditioner compressor 8. Auto tensioner pulley 14. Vacuum pump 3. Power steering pump pulley 9. Auto tensioner 15. Crank position sensor 4.
  • Page 467 02-5 1212-01 Top View 19. Cylinder head cover 24. Fuel pipe 29. Booster pressure sensor 20. Intake manifold 25. Injector 30. PCV valve and oil separator 21. Water outlet port 26. Fuel return line 31. Oil dipstick 22. Common rail 27.
  • Page 468 02-6 Left Side View Right Side View 33. Cylinder head 38. EGR-RH (#3) pipe 42. Turbo charger booster vacuum 34. Cylinder block 39. PCV valve and oil separator modulator 35. Oil pan 40. Oil dipstick 43. EGR valve vacuum modulator 36.
  • Page 469 02-7 1212-01 2. SPECIFICATIONS...
  • Page 470 02-8 3. ENGINE PERFORMANCE CURVE ▶Output and Torque...
  • Page 471 02-9 1212-01 ▶Oil Temperature/Pressure and Boost Pressure...
  • Page 472 02-10 4. TIGHTENING TORQUE...
  • Page 473 02-11 1212-01...
  • Page 474 02-12...
  • Page 475 03-3 1881-09 MAJOR CHANGES IN FUEL SYSTEM OF D27DTP (POWER UP) ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D27DTP (POWER UP) engine. The major changes are as follows. Refer to the next pages for further details.
  • Page 476 03-4 2) Common Rail · The orifice is added to the connection to D27DTP & D27DT (EU IV) the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume.
  • Page 477 03-5 1881-09 3) Fuel Rail - Chrome Color · The I.D and O.D of the fuel rail between D27DTP & D27DT (EU IV) HP pump and common rail are increased * Fuel pipe (Common rail → Injector) according to the increased amount of fuel injection.
  • Page 478 03-6 2. COMPONENTS OF FUEL SYSTEM...
  • Page 479 03-7 1881-09 ▶ Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System...
  • Page 480 04-3 2321-01 1. INTAKE SYSTEM LAYOUT The intake system for the D27DTP (POWER UP) engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off. Therefore, the structure of the intake manifold has been changed.
  • Page 481 05-3 1792-01 1. COMPONENTS The components of the exhaust system for the D27DTP (POWER UP) engine have been changed as follows: 1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) 2.
  • Page 482 06-3 2412-02 1. OVERVIEW FOR CDPF (EURO IV) 1) General Description The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine previously. However, it is now installed to the all 2009 DI engine models, except the Actyon Sports.
  • Page 483 06-4 2. CDPF(EURO IV) SYSTEM The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and sensors Differential pressure sensor (△P sensor) Under air cleaner in righ side of engine compartment...
  • Page 484 06-5 2412-02 Throttle Body CDPF system controls the amount of intake air by controlling the electronic throttle body. The electronic throttle body has the following main functions. CDPF control - added a function that increases the exhaust gas temperature by closing the throttle valve flap to minimize the intake air amount by the fuel injection amount during the CDPF regeneration range with the low engine load range.
  • Page 485 06-6 1. OVERVIEW As the solution for environmental regulations and PM (Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
  • Page 486 06-7 2412-02 2. CDPF (EURO IV) SYSTEM CONTROL 1) Combustion Temperature and Procedures As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
  • Page 487 06-8 2) Sytem composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and intake air.
  • Page 488 06-9 2412-02 Throttle bodies by engine type The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has following functions by the engine type.
  • Page 489 06-10 3. SOOT FILTERING AND BURNING PROCEDURES 1) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
  • Page 490 06-11 2412-02 Front temperature sensor (Measuring the temperature of Rear temperature sensor exhaust gas passed through (Measuring the temperature of exhaust gas passed through DOC) exhaust manifold) Differrential pressure sensor (Front Differrential pressure sensor (Rear pressure port) pressure port) The exhaust gas enters When the exhaust gas The engine ECU detects into CDPF assembly after...
  • Page 491 06-12 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF ▶CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 492 06-13 2412-02 ▶Overload of CDPF (warning lamp blinking) If the CDPF cannot reach the regeneration temperature due to low speed driving or other reason during the regeneration process, the soot is continuously accumulated in the CDPF. When this condition continues and the CDPF is overloaded with soot, the engine warning lamp blinks to inform this situation to the driver.
  • Page 493 06-14 4. COMPONENTS OF CDPF SYSTEM ▶Mounting condition and location Differential Pressure Sensor Engine compartment (RH) Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
  • Page 494 NO DATA...
  • Page 495 08-3 1520-01 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D27DTP (POWER UP) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
  • Page 496 08-4 ▶ Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine...
  • Page 497 NO DATA...
  • Page 498 NO DATA...
  • Page 499 11-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 500 11-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc.
  • Page 501 11-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 502 11-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...
  • Page 503 11-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 504 11-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 505 11-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 506 11-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention.
  • Page 507 11-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 508 11-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 509 01-4 1. COMPONENT LOCATOR 1) Front View...
  • Page 510 01-5 0000-00 ▶ Front View FUNCTION FUNCTION HFM sensor Intake manifold Intake air duct 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...
  • Page 511 01-6 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...
  • Page 512 01-7 0000-00 2. DESCRIPTION AND OPERATION 1) Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important.
  • Page 513 02-3 1113-01 1. SPECIFICATIONS 1) Engine Specifications...
  • Page 514 02-4 2) Performance Curve...
  • Page 515 02-5 1113-01 2. SPECIAL TOOLS AND EQUIPMENT...
  • Page 516 02-6...
  • Page 517 02-7 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin...
  • Page 518 02-8 3. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 519 02-9 1113-01 1) Fastener Tightening Specifications (Cont'd)
  • Page 520 03-3 2211-22 1. FUEL SYSTEM SPECIFICATION ▶ Use Only Unleaded Fuel Rated at 89 Octane or Higher Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of theengine. Fuel with too low an octane number can cause engine knock. ▶...
  • Page 521 03-4 ▶ Temperature vs resistance...
  • Page 522 NO DATA...
  • Page 523 05-3 2420-01 1. OVERVIEW OF EXHAUST SYSTEM When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials. Check the complete exhaust system and the nearby body areas and trunk lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections, or other deterioration which could permit exhaust fumes to seep into the trunk may be an indication of a problem in one of these...
  • Page 524 05-4 4. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 525 06-3 9210-01 1. OIL CIRCULATION...
  • Page 526 06-4 ▶ OIL CIRCULATION FUNCTION FUNCTION Oil pump Oil supply (to exhaust camshaft) Oil gallery (to oil filter) Oil supply (to intake camshaft) Oil supply Oil filter (to exhaust camshaft bearing) Oil supply Oil pressure switch (to intake camshaft bearing) Oil gallery Main oil gallery (oil supply to exhaust valve tappet)
  • Page 527 07-3 2110-01 1. GENERAL SPECIFICATIONS...
  • Page 528 07-4 2. SPECIAL TOOLS AND EQUIPMENT...
  • Page 529 07-5 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 530 07-6 1. GENERAL DESCRIPTION The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly. The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat and housing, a water pump, and a water pump drive belt.
  • Page 531 07-7 2110-01 2. COMPONENT LOCATOR...
  • Page 532 07-8 Radiator Inlet hose Electric fan Outlet hose Shroud 3 way hose Deaeration tube Deaeration hose (reserver tank) Clamp Clamp Deaeration hose (radiator) Clamp Electric fan mounting bracket Make up hose holder Bolt (M6, 8 pieces) Reserver tank Bolt (M6, 4 pieces) Bolt (M6, 2 piece) Bolt (M6, 4 pieces) Cooling fan...
  • Page 533 08-3 1452-01 1. GENERAL SPECIFICATIONS...
  • Page 534 08-4 2. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 535 08-5 1452-01 1. CHARGING SYSTEM OPERATION Alternators use a new type of regulator that incorpo-rates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier alternators. A conventional pulley and fan are used. There is no test hole. 1) Charging Time Required The time required to charge a battery will vary depending upon the following factors: ▶...
  • Page 536 08-6 3. IGNITION SYSTEM OPERATION This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition system ignition coil.
  • Page 537 08-7 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT...
  • Page 538 09-3 1522-16 1. ENGINE DATA DISPLAY TABLE...
  • Page 539 09-4 1) Temperature vs Resistance 2. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 540 10-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 541 10-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Improper use of the cruise control could be dangerous.
  • Page 542 10-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 543 10-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...
  • Page 544 10-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 545 10-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 546 10-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 547 10-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention. But if you turn off the ignition switch, the memorized set speed is cleared and you cannot recover the previous set speed.
  • Page 548 10-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 549 10-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 550 01-3 8410-00 1. CAUTIONS WHEN WORKING ON ELECTRICAL UNITS Disconnect the negative cable from the battery in advance when working on electrical units. Make sure to turn "OFF" the ignition switch and other lamp switches before disconnecting or connecting the negative battery cable.
  • Page 551 01-4 Make sure a connector is connected securely. Loose connection results in malfunction. When disconnecting a connector equipped with a lock, press it down to the direction in the below figure. When checking voltage or continuity of the connector terminal with a circuit tester, connect the tester probe to the terminal at the harness side.
  • Page 552 01-5 8410-00 2. CHECKING CABLES AND WIRES Check for loose connection or rust. Check terminals and wires for corrosion due to electrolyte leakage. Check terminals and wires for open circuit. Check the wire insulation and coat for damage, cracks or deterioration. Check if the conductive parts of the terminals do not contact with vehicle body or other metal parts.
  • Page 553 02-3 8710-08 1. SPECIFICATIONS 1) Electrical Performance Item Requirement Remark Rated voltage DC 12.0V Operatiing voltage DC 9.0V ~ 16.0V Should operate normally within this range. DC 7.0V ~ 18.0V (CAN) -30°C ~ +80°C Operating temperature Should operate normally within this range. -40°C ~ +85°C Reserved temperature Max.
  • Page 554 02-4 3) Rated Load Description Rated Load Chime bell/ Buzzer DC 12V 350mA/DC 12V 40mA (Inductive load) Front room lamp DC 12V 16W (Lamp load) Ignition key hole illumination DC 12V 1.2W (Lamp load) Seat belt warning lamp DC 12V 1.2W (Lamp load) Seat belt warning lamp DC 12V 1.2W (Lamp load) Parking brake warning lamp...
  • Page 555 02-5 8710-08 4) Input Signals Input Signal Name Logic Status IGN1 ON=BAT (IGN "ON" or "START") IGN2 ON=BAT (IGN "ON") ALT_D ON=BAT (Engine running) Key reminder switch IN=BAT (Key in) Driver’s door switch OPEN=GND, CLOSE=OPEN Passenger’s door switch OPEN=GND, CLOSE=OPEN - OPEN (one of rear seat)=GND Rear door switch - CLOSE (all rear seats)=OPEN...
  • Page 556 02-6 Input Signal Name Logic Status Front defogger switch ON=GND, OFF=OPEN ON=GND, OFF=OPEN Central door lock switch SPWM easy access switch ON=GND, OFF=OPEN Multifunction auto light switch ON=GND, OFF=OPEN ON=BAT/GND, OFF=OPEN (5.1V~9.2V) Turn signal light switch SPWM (Seat Position with Memory) ON=GND (PWM), OFF=OPEN Rain sensor ON=GND (DATA), OFF=BAT...
  • Page 557 02-7 8710-08 2. MAJOR CHANGES REKES Key Front Front Back Back Changed the appearance of mechanical key and the company symbol...
  • Page 558 02-8 1. OVERVIEW STICS (Super Time & Integrated Control System)) communicates with the transmitter (remote controller) and other electronic units to transmit and receive the signals and data. The STICS includes the following functions: Wiper control Ignition key reminder Door locking/unlocking Lamp control Defogger control Time lagging control for power window...
  • Page 559 02-9 8710-08 2. LOCATION ICM Relay Box STICS Chime...
  • Page 560 02-10 3. OPERATION 1) Function Description (1) Wiper control ▶ Wiper and Washer Operations Front wiper operation Front Automatic Wiping Speed Control Switch The interval of wiping speed can be adjusted by turning MIST the control knob upward or downward when the windshield wiper switch is in AUTO position.
  • Page 561 02-11 8710-08 Front auto washer switch When pressing this switch with the front wiper switch in “OFF” position, washer fluid will be sprayed Rear washer and wiper and the wiper will automatically operate 4 times. When the switch is fully turned, washer Then, the fluid will be sprayed again and the wiper fluid will be sprayed onto the rear will automatically operate 3 times.
  • Page 562 02-12 ▶Wiper MIST and Front Washer Coupled Wiper The wiper relay is turned on at 0.3 seconds after from the time when the washer switch is turned on for 0.1 to 0. 59 seconds (T2) with the ignition switch "ON". If the wiper parking terminal gets off, the wiper relay is turned off.
  • Page 563 02-13 8710-08 When the washer switch is turned on for more than 0.6 seconds during the wiper operation by AUTO switch, the wiper operates three times. When it is turned on for a certain period of time (0.1 to 0.59 seconds), the wiper operates once.
  • Page 564 02-14 System Diagram Operating MIST switch for 0.1 to 0.59 second Operating MIST switch for more than 0.59 second...
  • Page 565 02-15 8710-08 ▶Auto Washer and Wiper Switch When the auto washer switch is turned on with the ignition switch "ON" and the AUTO switch "OFF", the washer motor output gets ON for 2 second. If the system recognizes the output signal, the wiper low relay output gets ON during 4 cycles and the washer motor output gets ON for 2 second.
  • Page 566 02-16 The auto washer switch output is overridden during the washer coupled wiper operation. The auto washer switch input is overridden during the auto washer coupled wiper operation. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive AUTO wiper operation.
  • Page 567 02-17 8710-08 System Diagram...
  • Page 568 02-18 ▶Wiper Operation with Rain Sensor & Auto Light Sensor (except for EU market) RKSTICS with rain sensing function has the system layout as shown in the figure below. System layout...
  • Page 569 02-19 8710-08 ▶ Auto Switch Position Reminder (Power-Up Reminder Wiper) When turning off and on the IGN2 switch with the auto switch on, the system drives the wiper motor through LOW relay one cycle regardless of communication with rain sensor. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the auto switch from "OFF"...
  • Page 570 02-20 System Diagram AUTO Mode Switch ON Ignition Switch ON...
  • Page 571 02-21 8710-08 ▶ Washer Coupled Wiper in Rain Sensing Mode The washer coupled wiper is operated when receiving the washer switch input with the ignition switch "ON" and the AUTO switch "ON" in the rain sensing mode. At this moment, the communication with the rain sensor is overridden.
  • Page 572 02-22 System Diagram IGN ON & AUTO Mode Switch ON...
  • Page 573 02-23 8710-08 ▶ Rain Sensing Sensitivity Control The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (while the ignition key is in the "ON" position, the AUTO switch is in the "ON" position, and the wiper motor is in "Parked"...
  • Page 574 02-24 IGN ON & AUTO Mode Switch ON IGN ON, AUTO Mode Switch ON, Wiper Motor Parked...
  • Page 575 02-25 8710-08 ▶ When the Wiper Parking Signal is Abnormal The wiper system continuously outputs the wiper parking signal when the wiper parking terminal is grounded (while the ignition key is in "ON" position and the AUTO switch is in "ON" position). * The wiper motor runs only when the rain sensor requires the wiper operation.
  • Page 576 02-26 When the parking terminal is fixed to HIGH with the ignition key and the AUTO switch in "ON" position, the wiper system outputs the wiper operating signal for 2 seconds, then continuously outputs the wiper parking signal. The wiper motor runs only when the rain sensor requires the wiper operation.
  • Page 577 02-27 8710-08 ▶Defective Rain Sensor The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON"...
  • Page 578 02-28 The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the AUTO switch is in "ON" position). System Diagram IGN ON, AUTO Mode Switch ON, Rain Sensor Defective Signal Received...
  • Page 579 02-29 8710-08 ▶Troubleshooting Symptom 1: There is no signal wiping in AUTO mode. The windshield wiper should operate one wiping cycle when the engine is started with the wiper switch in AUTO. The windshield wiper should operate one wiping cycle when the wiper switch is turned to AUTO from OFF.
  • Page 580 02-30 ▶Auto Light Control (except for EU market) The tail lamps and headlamps can be controlled by the communication with the rain sensor only when the auto light switch is in "AUTO" position with the ignition switch "ON". Rain detected headlamp: If it rains heavy which requires the highest AUTO speed, the headlamps are turned on automatically (while the light switch is in "AUTO"...
  • Page 581 02-31 8710-08 Emitter lense The emitter lens located at bottom of rain sensing unit guides the infrared rays from the LED to the target point. Auto light sensor (Vertical) Auto light sensor (Horizon) Auto light sensor...
  • Page 582 02-32 ▶ Speed Sensitive AUTO Wiper For RKSTICS without the rain sensor, perform the following operation: Controls the wiper intermittent operation by the values from the vehicle speed and the volume. Calculates and converts the Intermittent interval automatically by using the AUTO VOLUME when the ignition switch is in the "ON"...
  • Page 583 02-33 8710-08 [Pause time of vehicle speed sensitive INT wiper AUTO] Pause time Speed Sensitive INT Wiper - The wiper relay stays ON for remaining period specified INT switch when turning off the INT switch during INT operation. - The wiper operates in previously set speed when turning ON the INT switch from OFF position with the IGN ON.
  • Page 584 02-34 (2) Ignition Key Reminder When opening the driver’s door while the ignition key is inserted into the key cylinder, the chime sounds (0.02 s ON and 1.38 s OFF). When removing the ignition key or closing the driver’s door during the chime operation, the buzzer stops its operation.
  • Page 585 02-35 8710-08 (*1): Driver’s or passenger’s door lock switch (*2): Driver’s or passenger’s door switch ▶All Door Lock Prevention Function when a Door is Open All doors, except the tailgate and hood, output "UNLOCK" signal for 5 seconds when the "LOCK" signal is inputted (while the ignition key is removed and one of any doors is open).
  • Page 586 02-36 (3) Warning Buzzer Related Functions ▶ Tail Lamp Left On Warning The buzzer sounds with the interval of 0.3 second when opening the driver's door while the tail lamp is turned on and the ignition key is removed. The buzzer output stops when turning off the tail lamp and closing the driver's door. The system outputs "UNLOCK"...
  • Page 587 02-37 8710-08 System Diagram Tail Lamp Relay ON Tail Lamp Relay ON & Driver’s Door Open...
  • Page 588 02-38 ▶Door Ajar Warning The warning light in instrument panel comes on when opening any of doors including tailgate while the vehicle speed is below 10 km/h. The warning light goes off when closing the door under step 1. The warning light blinks when the vehicle speed is over 10 km/h while the warning light is turned on. The warning light blinks when a door is open while the vehicle speed is over 10 km/h.
  • Page 589 02-39 8710-08 System Diagram...
  • Page 590 02-40 ▶ Seat Belt Warning The seat belt warning light comes on and the chime bell sounds for 6 seconds when turning the ignition key to "ON" from "OFF". If the seat belt is fastened before turning the ignition key to the the "ON"...
  • Page 591 02-41 8710-08 System Diagram Before Fastening Seat Belt Turning the Ignition Switch to ON after Fastening Seat Belt Seat Belt Warning Light Chime The seat belt warning light comes on and the chime buzzer sounds for 6 seconds when turning the ignition key to "ON"...
  • Page 592 02-42 ▶ Parking Brake Warning The parking brake warning light comes on for approx. 4 seconds when turning the ignition key from the "OFF" to the "ON" position regardless of the vehicle speed and the parking brake switch position. After this 4 seconds, the warning lamp comes on, goes off or blinks according to the vehicle speed and the parking brake switch position.
  • Page 593 02-43 8710-08 System Diagram...
  • Page 594 02-44 (4) Lamp Control Function ▶ Front Room Lamp The front room lap comes on when opening a front door with the “Door” switch ON. The front room lamp comes on when opening a front door. The front room lamp goes out immediately after closing the door with the ignition ON. The front room lamp stays on for 2 seconds after closing the door, and then dims out in 3 seconds.
  • Page 595 02-45 8710-08 System Diagram Front Room Lamp The driver’s spot lamp and passenger’s spot lamp comes on when pressing appropriate lamp switch (1, 2) in. The front room lamp comes on when pressing the “Door” switch (3) Center Room Lamp “Door”...
  • Page 596 02-46 ▶ Ignition Key Hole Illumination The ignition key hole illumination comes on when opening the driver's door or passenger's door when the ignition key is removed. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1. The output stops when the ignition key is turned to "ON"...
  • Page 597 02-47 8710-08 ▶ Circuit Diagram of Tail Lamp Auto-Cut (Battery Saver) ▶ Tail Lamp Auto Cut (Battery Saver) The tail lamp is turned on or off according to the operations of the tail lamp switch. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door after removing the ignition key without turning off the tail lamp.
  • Page 598 02-48 System Diagram Power OFF, IGN ON and Tail Lamp Switch ON with Driver’s Door Open...
  • Page 599 02-49 8710-08 (5) Defogging Function ▶ Circuit Diagram of Front/Rear Defogger The defogger system defrosts or demists the window glass with the heated wire integrated in glass. When operating the defogger switch, STICS controls the operating time only in IGN2 position. Rear defogger switch (Tailgate window and outside rearview mirror heated glass switch) The tailgate window and...
  • Page 600 02-50 ▶ Windshield heated glass (deicer) switch The front defogger output is "ON" when turning "ON" the front defogger (heated glass) switch while the ignition switch is "ON" (with engine running). The output stops when turning on the front defogger (heated glass) switch again during its operation. The output is "ON"...
  • Page 601 02-51 8710-08 ▶ Rear Defogger Timer The rear defogger output is "ON" when turning "ON" the rear defogger switch while the IGN 2 switch is "ON" (with engine running). The output is "OFF" when turning "ON" the rear defogger switch again during output. The output is "ON"...
  • Page 602 02-52 (6) Central Door Lock/Unlock The door lock system outputs "LOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the lock position. The door lock system outputs "UNLOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the unlock position.
  • Page 603 02-53 8710-08 System Diagram Driver's door lock/unlock switch Passenger's door lock/unlock switch ▶Door Lock/Unlock by Central Door Lock Switch The door lock system outputs "LOCK/UNLOCK" signal for 0.5 seconds when operating the central door lock switch. (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) The "LOCK"...
  • Page 604 02-54 System Diagram ▶ Door LOCK/UNLOCK by Remote Control Key The door lock relay output is "ON" for 0.5 seconds when receiving the remote control lock signal. The door unlock relay output is "ON" for 0.5 seconds when receiving the remote control unlock signal.
  • Page 605 02-55 8710-08 System Diagram Door Unlock/Panic Button Door unlock & Disarming theft deterrent mode: briefly press Panic: press for more than 2 seconds (operative only when the ignition key is in Indicator key cylinder) Briefly press: Blinks once Press and hold: Blinks twice Door LOCK Function Briefly press: Locking the doors and Arming the theft deterrent mode...
  • Page 606 02-56 ▶ Auto Door Lock The door lock system outputs "LOCK" when the vehicle speed maintains over 50 km/h. However, it doesn't output "LOCK" when all doors are locked or failed. If any of doors is unlocked after outputting "LOCK" in step 1, outputs "LOCK" up to 5 times (except step 1) at the interval of one second.
  • Page 607 02-57 8710-08 System Diagram Power OFF, ACC ON, IGN ON...
  • Page 608 02-58 ▶ Auto Door Unlock (Crash Unlock) The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to "ON" position. After this period, the door lock system outputs "UNLOCK" for all doors for 5 seconds from 40ms after receiving the air bag collision signal.
  • Page 609 02-59 8710-08 System Diagram IGN ON The "Unlock" control by air bag signal prevails over any "LOCK" or "UNLOCK" control by other functions. The "LOCK/UNLOCK" request by other functions will be ignored after/during the output of "UNLOCK" by the air bag. However, the door lock is controlled by other functions when the ignition switch is "OFF".
  • Page 610 02-60 (7) Time Lag Power Window Control The power window relay output is "ON" when turning on the ignition switch. The power window relay output is "ON" for 30 seconds when turning off the ignition switch. The power window relay output is "OFF" when opening the driver's door or the passenger's door. The power window relay is turned "OFF"...
  • Page 611 02-61 8710-08 ▶ Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN: Any of all door switches (including hood and tailgate) is in "OPEN" position. DOOR CLOSE: All door switches (including hood and tailgate) are in "CLOSE" position. The door lock/unlock operation does not affect the engine hood. DOOR LOCK: Indicates that all door lock switches (including tailgate) are in LOCK positions.
  • Page 612 02-62 ▶ Power Sleep Mode Entering Condition When all the doors including the hood are closed. When the ignition key is in "OFF" position. When there is no key in the driver's/passenger's door key cylinder. The system enters into the sleep mode for saving power if there is any change for 6 seconds while the driver's/passenger's/rear doors and tailgate are locked with the above three conditions met.
  • Page 613 02-63 8710-08 (8) Theft Deterrent ▶ Arming Conditions of Theft Deterrent Mode When receiving the door lock signal with the key removed, all doors are locked and the theft deterrent mode is activated. At this moment, the turn signal lamps blink twice. When pressing the lock switch on remote control key again in the theft deterrent mode, the turn signal lamps blink twice and the horn sounds once.
  • Page 614 02-64 System Diagram Ignition Key Removed, Door Closed...
  • Page 615 02-65 8710-08 ▶ Disarming Conditions The theft deterrent mode is disarmed when unlocking the doors with unlock button on REKES key or when moving the driver’s door lock switch to unlock position from lock position. When the deterrent mode is disarmed, the hazard warning flashers blink once. The doors can be unlocked by using a mechanical key in theft deterrent mode.
  • Page 616 02-66 ▶ After Alarm Period The siren and hazard warning flashers will be turned off. System Diagram Alarm Stop Conditions are Met...
  • Page 617 02-67 8710-08 ▶ Operations when removing and installing the battery Installed Normal Armed Warning Remark Removed Normal Armed Ready Armed Warning Warning Completion 배터리 장착시 경보상태이면 사이렌 및 비상 경고등 점멸 출력은 동작시킨다. RELOCK Ready (경계상태에서 경보조건 발생시와 동일한 동작을 행한다.) RELOCK Operation: It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key, the system outputs "LOCK"...
  • Page 618 02-68 ▶PANIC Alarm When receiving the panic signal with Power OFF, ACC and IGN ON, the siren and turn signal lamps operate for 27 seconds (ignition key should be in ignition key cylinder). When pressing any button on REKES key during the panic operation, the panic alarm stops. (Other commands are overridden) System Diagram In Theft Deterrent Mode...
  • Page 619 02-69 8710-08 (9) Specifications of Remote Control Key When any of switches on remote control key is pressed, the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle. ▶Door Lock ▶Door Unlock/ Panic Button Lock (briefly press) Unlock (briefly press)
  • Page 620 02-70 ▶ Remote Door Lock All doors are locked when briefly pressing the door LOCK switch on remote control key (less than 0.5 seconds). The theft deterrent mode is activated when locking the doors with Lock button on REKES key. (Hazard warning flashers blink twice)
  • Page 621 02-71 8710-08 System Diagram...
  • Page 622 02-72 ▶ Door Unlock The door unlock operates when pressing the door unlock switch on the remote control key for less than 0.5 seconds. The door unlock relay is "ON" for 0.5 seconds when receiving the door unlock message from the remote control key.
  • Page 623 02-73 8710-08 ▶ Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock, the doors are automatically locked and the armed mode of anti-theft system is activated again. System Diagram In Theft Deterrent Mode Any Door is Not Open in 30 Seconds after Unlocking Doors...
  • Page 624 02-74 4. CIRCUIT DIAGRAM ▶ Power/Ground, Diagnostic, Chime, Buzzer, Warning lamps (Brake, Seat belt, Door ajar)
  • Page 625 02-75 8710-08 ▶ Central Door Locking...
  • Page 626 02-76 ▶ Tail Lamp, Hazard Warning Flasher, Power Window...
  • Page 627 02-77 8710-08 ▶ Defogger...
  • Page 628 02-78 ▶ Panic, Auto Light/Rain Sensing, Room Lamp...
  • Page 629 02-79 8710-08 ▶ FRT Wiper/Washer...
  • Page 630 02-80 5. REKES CODING 1) Operating Condition The ignition key should be removed from the ignition key cylinder. 2) Code Registration The code can be registered only by the scan tool. 3) Transmitter Coding Up to five transmitter can be registered. The received code cannot be output during registration.
  • Page 631 02-81 8710-08 4) Diagnostic Connector The diagnostic connector is located at bottom of instrument panel. It consists of 16 pins. The REKES key should be coded by the scan tool. Diagnostic connector ▶ Connector Pin Pin No. Function CAN HI S203 "18" CAN LO S203 "8"...
  • Page 632 02-82 5) Coding Procedure The REKES key should be coded (up to 5 keys) by the scan tool when replacing it with new one. Connect the scan tool to the diagnostic connector. Select “RK-STICS” on the screen, and “Remote Control Coding” in Diagnosis screen. Remove the ignition key from the key cylinder and press “NEXT’.
  • Page 633 02-83 8710-08 The first key coding screen below is displayed with a beep. Press “NEXT” to perform the second key coding. The screen below will be displayed after completion of second key coding. Press “PREVIOUS” to complete the key coding. Exit from the diagnosis program and disconnect the scan tool from the diagnostic connector.
  • Page 634 04-3 7010-09 1. SPECIFICATIONS (D20DTR) Unit Description Specification 420uH ± 20 Coil inductance Coil turns Coil wire Rich wire (TBD) Immobilizer control unit Modulation 134.2kHz ± 4KHz/PWM Input/Output frequency Antenna cable Twisted rich wire (TBD) 134.2kHz ± 4KHz Frequency Transponder -40℃...
  • Page 635 04-4 2. MAJOR CHANGES Blanking Key - Changed the material of key fob. - Changed the key plate design.
  • Page 636 04-5 7010-09 1. OVERVIEW The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized persons. The transponder integrated in the key and the engine control unit has the same code. When the ignition key with the integrated transponder is turned to the ON position, the ECU (Engine Control Unit) checks the crypto code of the key and, if correct, allows your vehicle to start the engine.
  • Page 637 04-6 ▶ What is the immobilizer system?(D20DT, D27DT, D27DTP, G32D) The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
  • Page 638 04-7 7010-09 2. SYSTEM DIAGRAM ▶ D20DTR The certification for the immobilizer is performed when turning the ignition switch to the "ON" position after the CAN communication between the ECU and immobilizer is established. ▶ D20DT, D27DT, D27DTP, G32D...
  • Page 639 04-8 3. OPERATING PROCESS (D20DTR) 1) Operation and Warning Lamp (1) Operating process The ECU sends the challenge message to immobilizer control unit when turning on the ignition. (It requests the validation of key. If failed, sends validation signal 3 times in 2 seconds again. If the validation is failed again, stop the validation and wait for 10 seconds, and then start new validation process.) The immobilizer control unit sends the crypto code to the transponder.
  • Page 640 04-9 7010-09 (2) Immobilizer and Warning Lamp This indicator comes on when the ignition key is Instrument cluster communicating with the engine control unit (during engine starting) and goes out after starting the engine. Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: immobilizer unit is not coded...
  • Page 641 04-10 ▶ Immobilizer Function (D20DT, D27DT, D27DTP, G32D) The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
  • Page 642 04-11 7010-09 ▶ Immobilizer and Warning Lamp This indicator comes on when the ignition key is communicating with the engine control unit (during engine starting) and goes out after starting the engine. Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: immobilizer unit is not coded...
  • Page 643 04-12 4. CIRCUIT DIAGRAM ▶ D20DTR...
  • Page 644 04-13 7010-09 ▶ D27DT/D27DTP...
  • Page 645 04-14 5. FUNCTION 1) Overview The information below is the function that applies to the REKES key and immobilizer key. Indicator Door Unlock/Panic Briefly press: blinking once Press and hold: Blinking twice Unlock (briefly press) If you press this button briefly, all doors and the tailgate are unlocked and the theft deterrent mode is deactivated.
  • Page 646 05-3 7410-32 1. SPECIFICATIONS 1) Driver's Power Seat Inputs Specification Type Reed switch type 50 ± 20 % ON:OFF ratio Contact current Max. 0.5 A Chattering Max. 0.2 msec 228 mm ± 3 mm Stroke Sliding 23˚ (front) ↔ 0˚ ↔ 48˚ (rear) Reclining 30 ±...
  • Page 647 05-4 2) Actuator Actuator Specifications Rated voltage DC 12V Operation current Sliding Max 2A (No-load) Reclining (REC) Max 3.6A (AT 1.5 Nm) For sliding/ Max 8.0A (AT 12 Nm) reclining/raising front and rear (DC motor) Lift (FRT/RR) Max 3A Limited current Sliding Max 16A Reclining...
  • Page 648 05-5 7410-32 ▶ Position Sensor and Folding Switch Inputs Specification Type Variabel resistance Rated voltage DC 5V Position sensor ± 0.1 V (± 2% from max. output) Output tolerance Supply current Max 20 mA, 0.25W Vertically and horizontally: ± 8˚ Operation range Type Self-return type (active high)
  • Page 649 05-6 4) Buzzer ▶Electric Specifications Output Specification Rated voltage DC 12V Rated current Max 30 mA Buzzer Acoustic pressure MIN 92 dB 2200 ± 150 Hz Base frequency ▶Outputs Output time: 2Hz, DUTY 20% (ON: 0.1 sec., SPWM unit OFF: 0.4 sec.) Buzzer output conditions When the memory operation is permitted Buzzer...
  • Page 650 05-7 7410-32 2. MAJOR CHANGES Changed the memory recall logic Changed logic Changed the number of buzzer operation (2→3) after recall of memory setting for driver’s seat & outside rearview mirror.
  • Page 651 05-8 1. OPERATION 1) Switch Operation Seat position control: Sliding, Seatback reclining, Seat height adjustment, Seat cushion angle adjustment. Seat height & Seat cushion angle adjustment Sliding Seatback reclining Outside rearview mirror position switch Outside rearview Outside rearview mirror position operation: Up/Down/Left/Right (venter mirror folding control...
  • Page 652 05-9 7410-32 2) Driver's Seat and Outside Rearview Mirror Memory Setting and Recalling ▶ Setting Conditions Parking brake : Applied Vehicle speed : lower than 1 km/h Shift lever : In "P" position Ignition: ON (Don't start the engine for safety) * Data source - Parking brake &...
  • Page 653 05-10 ▶ Cancellation of Memory Setting When no position button is pressed within 5 seconds after pressing the memory set button When operating the driver's seat and the outside rearview mirror manually When turning the ignition OFF while setting the memory When the parking brake is relased or the shift lever is moved from the "P"...
  • Page 654 05-11 7410-32 ▶ Conditions that cannot recall the memory settings Ignition OFF Vehicle with A/T: The shift lever is any position other than "P" with the parking brake released. Vehicle with M/T: The parking lever is released The seat memory stop button ( : stop switch) is pressed during the recall process If the seat position is manually adjusted during recall process, the seat recall operation stops but the outside rearview mirror continues to move to the set position.
  • Page 655 05-12 3) Outside Rearview Mirror Folding/Unfolding Function (1) Folding/Unfolding When pressing the folding switch for approx. 1 second, the outside rearview mirrors are folded/unfolded. This folding/unfolding function can be used for 24 to 30 seconds even after turning off the ignition switch (However, this delayed operating time stops when opening the driver's door).
  • Page 656 05-13 7410-32 4) Easy Access Function ▶ Seat Return Operation When Turning the Ignition Switch to ON Position When turning the ignition switch to ON from OFF position with the easy access switch pressed, after 30 ms, STICS starts to send the return signal to SPWM unit. If SPWM receives the data properly, it operates the return operation.
  • Page 657 05-14 ▶ Easy Access Operation When Getting Off When removing the ignition key (key reminder switch OFF) from the ignition switch with the easy access switch pressed, STICS sends the easy access data to SPWM unit. The SPWM unit immediately moves the seat backwards for approx. 50 mm and lowers it as far as it goes.
  • Page 658 05-15 7410-32 ▶ Conditions for Stop and Prohibition of Easy Access Operation The easy access switch is in "OFF" position. The STICS sends "Stop" signal to SPWM unit when turning off the easy access switch during the easy access operation. If STICS receives the easy access switch signal in sequence of ON, OFF, then OFF within one second during the easy access operation, STICS overrides the third signal and doesn't send any date to SPWM unit.
  • Page 659 07-3 8611-31 1. OVERVIEW The front seat warmer system consists of the variable control type front seat warmer unit and its operation switch. The rear seat warmer unit is not variable control type but ON/OFF control type. The rear seat warmer switches LH/RH control the rear seat warmer relays LH/RH in the ICM.
  • Page 660 07-4 3. CIRCUIT DIAGRAM ▶ Front variable seat warmer (Seat/outside mirror memory)
  • Page 661 07-5 8611-31 ▶ Front variable seat warmer (Seat/outside mirror non-memory)
  • Page 662 07-6 ▶ Rear seat warmer...
  • Page 663 08-3 8010-01 1. SPECIFICATIONS 1) Power, Voltage, Current Description Specification Rated voltage DC 12V Operating voltage DC 9V ~ 16V Inspection voltage DC 13.5V -30°C ~ +75°C (during driving) Operating temperature Storage temperature -40˚C ~ +85˚C Performance reserve DC 10V ~ 15V temperature Dark current below 3 mA at stable status (stand-by mode) after 180 seconds from...
  • Page 664 08-4 3) Color and Specification for Indicators and Warning Lamps Name Color Specification Name Color Specification Turn signal Green 3.3V 4WD HIGH indicator Green 3.3V indicator (L, R) 20 mA (P/TIME) 20 mA Seat belt reminder 2.0V 4WD LOW indicator Yellow 2.0V 20 mA...
  • Page 665 08-5 8010-01 1. OVERVIEW Two types (Black-Face type and Clear type) of meter cluster are used in this model. The meter clusters uses CAN communication lines with the electric units and the LCD display window is located on the lower side of the meter cluster. 2.
  • Page 666 08-6 3. WARNING LAMPS AND INDICATORS 1) Black-Face Type...
  • Page 667 08-7 8010-01 Trip switch...
  • Page 668 08-8 2) Clear Type...
  • Page 669 08-9 8010-01...
  • Page 670 08-10 2) Description for Warning Lamps and Indicators ▶ High beam indicator Blue This indicator comes on when the high beam headlamp is switched on. ▶ Front fog light indicator Green This indicator comes on when the front fog light is switched on. ▶...
  • Page 671 08-11 8010-01 ▶ Low fuel level warning lamp Yellow This warning lamp indicates that the fuel level in the tank is getting exhausted (GSL: below 12 liters, DSL: below 9.5 liters). The illuminating point of this warning lamp varies according to the driving conditions such as driving angle and road conditions.
  • Page 672 08-12 ▶ ESP indicator/warning lamp Yellow ON: This warning lamp comes on when ESP system is defective. Blinking: This indicator blinks when the ESP system is operating. This warning lamp comes on when the ignition switch is turned to “ON” and should go off in a few seconds.
  • Page 673 08-13 8010-01 ▶ Brake warning lamp This warning lamp comes on when the ignition switch is turned to “ON” and should go off in a few seconds. This warning lamp comes on when the parking brake is applied and/or the brake fluid level is lower than a specified level.
  • Page 674 08-14 ▶ Hazard indicator This indicator blinks when the hazard warning flashers are switched on. ▶ Auto cruise indicator Green This indicator comes on when the cruise control system is switched on. ▶ Left Turn signal indicator Green This indicator blinks when the left turn signal switch is turned on. Both indicators blink when the hazard warning switch is turned on.
  • Page 675 08-15 8010-01 ▶ HDC indicator Red/Green This indicator comes on or blinks according to HDC operations. ▶ TPMS warning lamp Yellow This warning lamp comes on when the ignition switch is turned to “ON” and should go off in a few seconds. This indicator comes on when the TPMS is defective.
  • Page 676 08-16 ▶ 4WD LOW indicator (TOD, P/TIME) Yellow When shifting the driving mode to “4L”, this indicator blinks until the shifting operation is completed. After completion of the mode change to 4L, the indicator comes on. ▶ 4WD HIGH indicator (P/TIME) Green When shifting the driving mode from “4L”...
  • Page 677 08-17 8010-01 3) Display Sequence...
  • Page 678 08-18 4) Illumination Level Adjustment The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps in day mode and night mode. Day Mode (Tail Lamp OFF) Night Mode (Tail Lamp ON) The illumination level for instrument cluster can be adjusted by TRIP switch in 6 steps.
  • Page 679 08-19 8010-01 5) System Analysis...
  • Page 680 08-20...
  • Page 681 08-21 8010-01 6) Odometer (ODO) and Trip Meter (TRIP) The total driving distance (0 to 999,999 km or 0 to 999,999 miles) and the trip distance (0.0 to 999.9 km or 0.0 to 9,999.9 miles) are calculated by using the value of pulse per 1 km which is programmed in the EEPROM.
  • Page 682 08-22 7) Buzzer ▶ Specifications Function Signal -20 ~ +70 ℃ Operating temperature -30 ~ +80 ℃ Storage temperature Sound pressure level 70dB/min (2kHz, square wave, 10cm) ▶ Output Buzzer Priority Description Remark ON_TIME OFF_TIME 160ms Available only in “R” (M/T) and Buzzer output (R 부저...
  • Page 683 08-23 8010-01 8) Functions of HDC Indicator HDC Indicator HDC Switch The brake system operates properly even if the HDC system is defective. HDC indicator ON when; Turning the ignition ON There is an error in HDC system The brake system overheats...
  • Page 684 08-24 HDC Warning HDC Indicator Lamp Green HDC Operation Turning the ignition ON (From hence, this signifies the operation mode with engine running. If the ignition is turned OFF, HDC stops the operation even HDC switch is still ON.) Not available HDC switch OFF HDC system is defective Stand-by...
  • Page 685 08-25 8010-01 9) ESP Warning Lamp ▶ ESP Warning Lamp Blinking in Control ESP 작동등 ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to warn the driver. The ESP warning lamp goes off when ESP function is deactivated.Even when the ESP is operated for a very short period of time, the ESP warning lamp blinks at least four times every 175 milliseconds.
  • Page 686 08-26 ▶ ESP System Cancellation Using the ESP OFF Switch When the ESP switch is pressed (for over approximately 150ms), the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP warning lamp on the instrument panel comes on.
  • Page 687 08-27 8010-01 10) TPMS Indicator and Warning Lamps ▶ Tire Pressure Indication TPMS related Indicators The tire pressure cannot be displayed on the meter cluster immediately after starting the engine. TPMS start to recognize the tire pressures in 10 minutes of continuous driving (over 20 km/h) after starting the engine.If the system is not ready yet, LCD display shows “--”.
  • Page 688 08-28 4. WARNING ▶ TPMS Warning Lamp and Tire Pressure Warning (Global Warning) Warning ON Conditions Failure Warning Lamp Yellow Yellow Comes on immediately Blinks (0.4s ON/OFF) for 70 seconds and the stays Error in TPMS system Yellow Yellow Comes on immediately Affected tire symbol Defective wheel module Yellow...
  • Page 689 08-29 8010-01 ▶ Tire Pressure Indicator Tire Pressure Indicator (Changed from ODO mode to Tire pressure display mode) In ODO mode, the symbol for abnormal tire comes In tire pressure display mode, the symbol for on in yellow. abnormal tire comes on in yellow and the other symbols come on in green.
  • Page 690 08-30 5. SELF DIAGNOSIS 1. Turn the ignition ON with the TRIP switch pressed. Activation: 2. Press and hold the TRIP switch 5 to 10 seconds after engine start, and then press it 5 times briefly. 3. The system starts the self-diagnosis. IGN OFF or engine start Deactivation: 1.
  • Page 691 07-3 8511-29 1. SPECIFICATIONS 1) Multi-Function Switch Description Specifications Multifunction Rated voltage DC 12V switch -30℃ ~ +80℃ Operating temperature range Rated load Light switch Turning on: 1 A (Relay load) Dimmer and passing switch High beam: 9.2 A (Realy load) Low beam: 1 A (Realy load) Passing: 10 A (Relay load) 6.6 ±...
  • Page 692 07-4 2. MAJOR CHANGES Center Switch Cluster Changed to independent switch type from integrated switch type Hazard Switch Changed the design of hazard switch...
  • Page 694 07-6 1. OVERVIEW Multifunction Switch Auto Washer Switch Rear wiper and washer When the front wiper coupled operation switch is off and this switch Rear wiper operation is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times.
  • Page 695 07-7 8511-29 Center Switch Cluster Hazard Switch PAS off Switch Heated Windshield Glass Switch(Deicer) Heated Tailgate Glass & ESP OFF switch Outside Rearview Mirror Galss Switch HDC switch Cruise Control Switch ACCEL ON/OFF DECEL 4WD Switch Front Seat Heating Switch LH Seat warmer RH Seat warmer Part-time...
  • Page 696 10-3 8310-00 1. SPECIFICATIONS OF LAMPS ▶ Exterior Lamps Description Numbers Headlamp High beam 55W/15W Low beam Tail/Position lamp Front combination Front fog lamp lamp Turn signal lamp Outside turn signal lamp (supplemental turn signal lamp) Rear combination Stop lamp (Upper) lamp Stop lamp (Lower) Tail lamp...
  • Page 697 10-4 2. SPECIFICATIONS OF AUTO LIGHT Description Specification Operating voltage 9V ~ 16V Load Maximum 200 mA (relay load) -30℃ ~ 85℃ Operating temperature -40℃ ~ ±120℃ Operating temperature Location Top center of inner side of windshield glass In vehicle for EU market, the auto light function is not available. ▶...
  • Page 698 10-5 8310-00 3. MAJOR CHANGES ▶ Front Side Head Lamp High beam Low beam High beam Low beam Turn signal/Tail lamp Tail lamp - Changed the head lamp design and functions. - Deleted the turn signal lamp and changed the tail lamp to LED type from bulb type. Front Combination Lamp Fog lamp Fog lamp...
  • Page 699 10-6 ▶ Rear Side Changed the design of reflex reflector Rear Combination Lamp Tail lamp Tail/Stop lamp Stop lamp Tail lamp Turn signal lamp Back-up lamp Back-up lamp Rear fog Stop lamp Turn signal lamp lamp (EU) - Changed the design and functions of rear combination lamp. - Changed the stop lamp and tail lamp to LED type from bulb type.
  • Page 700 10-7 8310-00 ▶ Others Outside Turn Signal Lamp Outside turn signal lamp - Introduced new outside turn signal lamp (LED type). Side Repeater Lamp - Deleted the side repeater lamp.
  • Page 701 10-8 1. EXTERIOR LAMPS 1) Overview The exterior lamps consist of front lamps, rear lamps and side lamps. Front lamps: Head lamp, Front combination lamp Rear lamps: Rear combination lamp, License plate lamp, High mounted stop lamp, Reflex reflector Side lamps: Outside turn signal lamp 2) Layout ▶...
  • Page 702 10-9 8310-00 ▶ Rear Side High Mounted Stop Lamp Rear Combination Lamp Tail lamp Stop lamp Turn signal lamp Back-up lamp Rear fog lamp (EU) License Plate Lamp Reflex Reflector...
  • Page 703 10-10 3) Operating Process (1) Head lamp aiming (Up/Down) Ordinary operations of head lamp are controlled by the light switch on multifunction switch. The operations by REKES are controlled by STICS. STICS controls the head lamp and tail lamp with LIN data from the auto light sensor when the light switch is in “AUTO”...
  • Page 704 10-11 8310-00 (2) Tail Lamp STICS turns on the tail (position) lamp relay when receiving the lamp on signal from the light switch. Front Side Position lamp Rear side Tail lamp In vehicle for EU market, the tail (position) lamp comes on when turning the ignition switch to ON position regardless of light switch operation.
  • Page 705 10-12 ▶ Control by STICS Tail Lamp Left ON Warning The buzzer sounds with the interval of 0.3 second when opening the driver's door while the tail lamp is turned on and the ignition key is removed. The buzzer output stops when turning off the tail lamp and closing the driver's door. The system outputs "UNLOCK"...
  • Page 706 10-13 8310-00 (3) Auto Light The auto light sensor unit is installed to the back side of the ECM mirror located upper center of the windshield, and detects the illuminance change. The STICS communicates with the auto light sensor when the ignition is turned on, and turns on or off the tail lamp and headlamp automatically according to the signals from the sensor when the light switch is set to AUTO position.
  • Page 707 10-14 (4) License Plate Lamp The license plate lamp comes on when the light switch is turned on (Tail, AUTO, Low, High).
  • Page 708 10-15 8310-00 ▶ Circuit Diagram of Head Lamp...
  • Page 709 10-16 ▶ Circuit Diagram of Tail Lamp...
  • Page 710 10-17 8310-00 (5) Front Fog Lamp The front fog lamp comes on when the front fog lamp is turned on only with the light switch ON. The front fog lamp goes out when turning off the ignition or light switch. Front fog lamp ▶...
  • Page 711 10-18 (6) Turn Signal Lamp The left or right turn signal lamp blinks when moving the light switch to appropriate direction. When pressing the hazard switch, both turn signal lamps come on simultaneously. Front Side Outside turn signal lamp Turn signal lamp Rear Side Turn signal lamp ▶...
  • Page 712 10-19 8310-00 ▶ Circuit Diagram of Turn Signal Lamp...
  • Page 713 10-20 (7) Stop Lamp The stop lamp switch turns on the stop lamp when depressing the brake pedal. When releasing the brake pedal, the stop lamp goes out. High mounted stop lamp Stop lamp Rear fog lamp (for EU) (8) Back-up Lamp The back-up lamp comes on when moving the gear shift lever to “R”...
  • Page 714 10-21 8310-00 ▶ Circuit Diagram of Stop Lamp and Back-up Lamp...
  • Page 715 10-22 2. INTERIOR LAMPS 1) Overview The interior lamps consist of front room lamps (2), center room lamp, rear room lamp, glove box lamp, sun visor lamps (2), courtesy lamps (4), and scuff lamps (4). 2) Layout Front Room Lamp Center and Rear Room Lamp Sun Visor Lamp...
  • Page 716 10-23 8310-00 Door Courtesy Lamp One lamp in each door...
  • Page 717 10-24 3) Operating Process (1) Front Room Lamp Door switch: The front room lamps come on when opening a front door with the switch pressed in. Driver’s spot lamp switch: The front room lamp (driver’s) comes on when pressing this switch. Passenger’s spot lamp switch: The front room lamp (passenger’s) comes on when pressing this switch.
  • Page 718 10-25 8310-00 (2) Center and Rear Room Lamp OFF position: The lamp does not come on. ON position: The lamp stays on. DOOR position (●): The lamp comes on when the door is opened. The lamp goes out DOOR (●) when closing the opened door.
  • Page 719 10-26 (4) Glove Box Lamp The glove box lamp comes on when opening the glove box with the tail lamp on. (5) Door Courtesy Lamp and Scuff Lamp The door courtesy lamp comes on when opening the door. (6) Sun Visor The sun visor lamp comes on when opening the vanity mirror.
  • Page 720 10-27 8310-00 (7) Circuit Diagram of Room Lamp...
  • Page 721 08-3 7810-00 1. WIPER CONTROL ▶ Wiper mist & washer coupled wiper ▶ Auto washer coupled wiper ▶ Rain sensor coupled wiper operation (LIN) ▶ Speed sensitive intermittent wiper ▶ Wiper low/high control 2. CAUTIONS ON RAIN SENSOR When the wiper switch is in the AUTO position, the wiper will operate for 1 cycle if the initial engine start is made.
  • Page 722 08-4 3. MAJOR CHANGES Windshield wiper blade Wiper blade design and wiper arm pressure Previous Current Wiper arm pressure: Driver: 850±50gn Passenger: 750±50g Steel blade → Rubber blade - Wiper blade design changed (blade size is same) Driver side: 20inch Passenger side: 20inch...
  • Page 723 08-5 7810-00 1. WIPER AND WASHER SYSTEM 1) AUTO Washer Coupled Wiper Function Operating part for rear wiper/washer AUTO washer switch (press) If you press the AUTO washer switch briefly with the ignition key ON and INT-AUTO switch "OFF", the washer motor is operated for about 1 seconds to spray washer fluid once after the switch is turned ON and the wiper relay is turned ON for 4 cycles.
  • Page 724 08-6 2. RAIN SENSING SYSTEM In the rain sensing wiper operation system, the rain sensing unit only sends the information about the amount of rain drops to the STICS, and it does not operate the wiper directly. The wiper and washer are controlled by the STICS according to the driver's choice.
  • Page 725 08-7 7810-00 ▶ STICS The rain sensor detects the amount of rain drops and sends the operating request signal to the STICS, which drives the wiper directly. At this moment, the STICS also sends the information on whether the wiper is in operation mode or whether the multifunction wiper switch is in AUTO position to the rain sensor.
  • Page 726 08-8 3. SYSTEM LAYOUT (INCLUDING RAIN SENSOR) Wiper and washer switch Rain sensor unit Wiper Front wiper Rear wiper Wahser nozzle Front Rear...
  • Page 727 08-9 7810-00 STICS Windshield washer reservoir tank assembly Rear wiper (DPS) Wahser motor Front Rear...
  • Page 728 08-10 4. WIPER AND WASHER OPERATION 1) Windshield Wiper Control Function MIST The wiper operates for 1 cycle when pushing up the lever. The lever will return to the "OFF" position when released. Stop the operation. AUTO Wiper speed controls automatically according to the vehicle speed or amount of rain (rain sensing wiper).
  • Page 729 08-11 7810-00 (1) Wiper mist When the multifunction switch is pushed to the MIST position for 0.1 sec. or more with the IGN1 ON, the wiper relay is turned on after 0.1 sec. has passed. When the wiper returns to the park position, the wiper relay is turned off.
  • Page 730 08-12 (2) Wiper LO/HI control The wiper LOW relay is turned on when the multifunction wiper switch is at the LO position. The wiper HIGH relay is turned on when the wiper switch is at the HI position. When the wiper switch is at the HI position, both the LOW relay (constant operation) and HIGH relay are operated.
  • Page 731 08-13 7810-00 2) Windshield Washer Control Function (1) Windshield washer coupled wiper Wiper and Washer Coupled Operation Pull the switch briefly (for less than 0.6 sec.) : One wiping cycle Pull and hold the switch for more than 0.6 sec. : Three wiping cycles with washer fluid spray The wiper relay turns ON when turning on the front washer switch with IGN ON.
  • Page 732 08-14 The wiper relay is turned on 0.3 seconds after pulling up the washer switch to ON position with IGN ON. If the washer switch is turned on for more than 0.6 seconds, the wiper relay is activated three times after releasing the washer switch and then the wiper motor is set to parking position.
  • Page 733 08-15 7810-00 If the wiper switch is in Auto position (sensing the vehicle speed and rain drops), the wiper operates three times when the washer switch is turned on for more than 0.6 seconds, and it operates once when the washer switch is turned on for less than 0.6 seconds.
  • Page 734 08-16 (2) AUTO washer coupled wiper Auto washer switch If pressing the switch when the wiper switch turns to the "OFF" position, washer fluid is sprayed once and wiper operates 4 times. After a while, washer fluid is sprayed once more and the wiper operates 3 times.
  • Page 735 08-17 7810-00...
  • Page 736 08-18 3) Rear Wiper Control Function Rear wiper switch When the switch is fully turned, washer fluid will be sprayed onto the rear window glass and the wiper will also operate. When the switch is released, it will stop in the Rear Wiper Operation mode and only the wiper will keep operating.
  • Page 737 08-19 7810-00 4) Rear Washer Control Function When the switch is fully turned, washer fluid will be sprayed onto the rear window glass and the wiper will also operate. When the switch is released, it will return to the “OFF" position and turn off the wiper and washer.
  • Page 738 08-20 5) Rain Sensor Coupled Wiper Control Function AUTO operation and sensitivity control AUTO: Wiper operates automatically by rain sensor FAST <----> Auto delay/auto speed control A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly.
  • Page 739 08-21 7810-00 (1) Rain sensor coupled wiper operation (LIN) ▶ System layout...
  • Page 740 08-22 (2) Power-up reminder wiper When turning off and on the INT auto switch, the system drives the wiper motor for one cycle through LOW relay regardless of communication with rain sensor. When the INT/AUTO wiper switch is turned on from off with the ignition switch ON, the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals.
  • Page 741 08-23 7810-00 (3) Washer coupled wiper operation during rain sensor coupled operation When the washer switch is turned on during rain sensor coupled operation with IGN ON and INT/AUTO switch ON, the communication with rain sensor is overridden and the wiper system operates in washer coupled wiper operation mode.
  • Page 742 08-24 (4) Sensitivity control (instant wiping) When the wiping speed control switch is turned to "FAST (ex: 0→1)" with IGN ON, INT/AUTO switch ON and wiper motor STOP (parking position), the wiper motor operates one cycle at low speed. (Only when the rain sensor detects rain drops) If the wiping speed control switch is changed more than 1 stages within 2 seconds, the wiper motor operates only one cycle.
  • Page 743 08-25 7810-00 (5) For abnormal wiper parking signal The wiper system sends continuously the signal for current status when the wiper parking terminal is shorted to ground with IGN2 ON and intermittent wiper switch in "ON" position. * The wiper motor is operated only when there is a request from the rain sensor. When the parking terminal is shorted to power with IGN2 ON and intermittent wiper switch in "ON"...
  • Page 744 08-26 (6) For faulty rain sensor When the wiper speed control switch is turned to step 2 from step 3, the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal (S_RSFAULT) from rain sensor unit with IGN ON and INT/AUTO switch ON.
  • Page 745 08-27 7810-00 (7) Speed sensitive intermittent wiper For the vehicles without rain sensor, the stics operate the wiper as follows: When turning the ignition switch to ON from OFF position with the intermittent wiper switch in "ON" position, the wipers do not operate. When turning the wiper switch to ON from OFF position after turning the ignition switch to ON position, the wipers operate one cycle.
  • Page 746 08-28 ▶ Speed sensitive intermittent wiper interval Calculation of Pause Time Pause time: The period while the wiper motor is at parking position Elapsed time: Total operating time after the wiper motor has started its operation from parking position The graph for pause time in previous page is generated by vehicle speed and wiping speed control switch.
  • Page 747 11-3 8611-09 1. SYSTEM LAYOUT AND OVERVIEW The rain sensing wiper unit in this vehicle doesn't control the wiper directly. The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. Rain Sensor Unit Multifunction Wiper Switch: (Auto Light Sensor Integrated Type)
  • Page 748 11-4 ▶ STICS The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. At this moment, STICS determines the wiper operation mode (washer, MIST, AUTO), then sends the information to the rain sensor. STICS Engine Compartment Fuse Front wiper...
  • Page 749 11-5 8611-09 2. FUNCTIONS OF RAIN SENSING WIPER SYSTEM 1) Power-up Reminder Wiper When turning off and on the INT auto switch, the system drives the wiper motor for one cycle through LOW relay regardless of communication with rain sensor. When the INT/AUTO wiper switch is turned on from off with the ignition switch ON, the wiper low relay is turned on once to operate the wiper motor regardless of the rain sensor signals.
  • Page 750 11-6 2) Washer Coupled Wiper Operation During Rain Sensor Coupled Operation When the washer switch is turned on during rain sensor coupled operation with IGN ON and INT/AUTO switch ON, the communication with rain sensor is overridden and the wiper system operates in washer coupled wiper operation mode.
  • Page 751 11-7 8611-09 3) Sensitivity Control (Instant Wiping) When the wiping speed control switch is turned to "FAST (ex: 0→1)" with IGN ON, INT/AUTO switch ON and wiper motor STOP (parking position), the wiper motor operates one cycle at low speed. (Only when the rain sensor detects rain drops) If the wiping speed control switch is changed more than 1 stages within 2 seconds, the wiper motor operates only one cycle.
  • Page 752 11-8 5) For Abnormal Wiper Parking Signal The wiper system continuously sends the signal for current status when the wiper parking terminal is stuck in ground with IGN2 ON and intermittent wiper switch in "AUTO" position. The wiper motor is operated only when there is a request from the rain sensor.
  • Page 753 11-9 8611-09 6) For faulty rain sensor When the wiper speed control switch is turned to step 2 from step 3, the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal (S_RSFAULT) from rain sensor unit with IGN ON and INT/AUTO switch ON.
  • Page 754 11-10 3. OPERATION MODE OF RAIN SENSING WIPER SYSTEM Rain detected headlamp: If it rains heavy which requires the intermediate INT speed, the headlamps are turned on automatically. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level.
  • Page 755 11-3 8790-04 1. SPECIFICATION Description Specification Rated voltage DC 13.5V (IGN voltage) Operating voltage DC 9.0V ~ 16.0V -30℃ ~ +80℃ Operating temperature -40℃ ~ +85℃ Storage temperature Maximum humidity Maximum resistance voltage Insulating resistance No heat & fire due to current leak Max.
  • Page 756 11-4 3. MAJOR CHANGES PAS sensor holding type Spring type lock → Holder type lock Number of Rear PAS sensors Left Center (LH) Center (RH) Right Left Center Right 3 sensors → 4 sensors PAS Unit Operating voltage: 12V → 8V, Connector pin: 3 pins → 4 pins...
  • Page 758 11-6 1. OVERVIEW When the gear selector lever is shifted into “D” or “R” position, the parking aid system (PAS) is activated and the sensors in the front or rear bumper detect the distance to any obstacle. Driver can figure out the distance from the obstacle to the vehicle by the alarming sound. The alarm interval becomes faster as the vehicle approaches the object.
  • Page 759 11-7 8790-04 PAS buzzer Location of Rear PAS Sensor Left Center (LH) Center (RH) Right This switch turns the front PAS sensor ON and - 4 sensors OFF. When the LED on the switch is ON, PAS - Operable only when reverse driving system is not available.
  • Page 760 11-8 3. OPERATING PROCESS 1) Detection Range Front + Rear PAS Front RH Rear RH sensor sensor Rear center- RH sensor Rear center-LH sensor Front LH Rear LH sensor sensor Rear PAS Rear RH sensor Rear center-RH sensor Rear center-LH sensor Rear LH sensor...
  • Page 761 11-9 8790-04 (1) Sensing Distance: 30cm ~120cm (Straight distance from sensor) ▶ Front sensor ▶ Rear sensor ▶ Detecting range and alarm interval (alarm from external buzzer) Rear sensor (Center left, Rear Front Level Alarm interval Center right) (Left, Right) (Left, Right) 30~50cm 30~50cm...
  • Page 762 11-10 (2) Vertical Detection Range Front Rear 0~Bottom of bumper (Range From bottom of bumper Height (Range C) Detection No detectable Detection area ±5cm ±5cm Tolerance The sensors may not detect the obstacle when it is above the range “A” (80cm). (3) Horizontal Detection Range...
  • Page 763 11-11 8790-04 2) Function ▶ Operating conditions IGN ON ▶ Operations The front PAS sensors are available when the gear selector lever is in “D” position. The front and rear PAS sensors are available when the gear selector lever is in “D”, “R” position.
  • Page 764 11-12 Rear PAS system...
  • Page 765 11-13 8790-04 4. OPERATION MODE ▶ Operation of LED ▶ Operation of front PAS OFF switch Switch Sensor OFF(LED ON) Front Rear ON(LED OFF) Front Rear ▶ Operation when detecting the obstacle...
  • Page 766 11-14 ▶ Operation of self-diagnosis If the vehicle speed exceeds 15km/h, the front sensors are turned off. If it goes below 10km/h, the sensors start their operation again. (Gear selector lever in “D” position & Front PAS OFF switch in “OFF” position) When turning on the ignition, the self-diagnosis is performed, but no buzzer output.
  • Page 767 11-15 8790-04 5. CIRCUIT DIAGRAM...
  • Page 768 11-16 6. FLOW CHART ▶ Front + Rear PAS System...
  • Page 769 11-17 8790-04 ▶ Rear PAS System...
  • Page 770 14-3 8910-05 1. SPECIFICATION Unit Description Specification Voltage DC 14.4V Audio Operating voltage DC 10.8V~16.0V 45W/ch (4Ω) Output 4Ω Speaker Impedance Current consumption below 5A, max. 10A Dark current below 3mA Frequency FM : 87.5 ~ 108MHz MW: 522 ~ 1620 KHz LW : 144 ~ 290 KHz Latin FM : 87.5 ~ 108 MHz...
  • Page 771 14-4 Unit Description Specification Micro pole antenna Audio Operating current max. 150mA Operating voltage DC 10.5V ~ 16V -30℃ ~ +60℃ Operating temperature -40℃ ~ +80℃ Storage temperature 75Ω(FM) Input/Output impedance...
  • Page 772 14-5 8910-05 2. MAJOR CHANGES Audio Assembly Changed the audio assembly (added Bluetooth hands-free function) Audio Antenna Audio type AVN type Changed the antenna from integrated type to micro pole type.
  • Page 773 14-6 1. LAYOUT Audio Radio USB/AUX Bluetooth hands-free Audio Remote Control Switches Front Door Front Door Speaker Audio Assembly Tweeter Speaker...
  • Page 774 14-7 8910-05 Micro Pole Antenna USB/AUX Hands-free Rear Door Speaker Microphone...
  • Page 775 14-8 1) Switches Name Power/Mute/Pause/Enter/Volume button Station memory button (1~6) and Audio function button Bluetooth hands-free CALL button Bluetooth hands-free END button Previous (≪) and Next (≫) button SCAN/INFO button BAND/AS button SETTING button Display window (LCD) RDS setup Disc Play button Disc Eject button Disc slot...
  • Page 776 15-3 8510-00 1. SPECIFICATIONS Unit Description Specification Rated voltage Current consumption MAX 3.5A 415 ± 20HZ Horn Frequency 350 ± 20HZ HIGH 110 ± 5dB Sound level Operating voltage 12V~15V Rated voltage Maximum operating current Cigarette lighter 5MΩ Isolated resistance 13±5 sec after pushing it Return time Rated voltage...
  • Page 777 15-4 2. MAJOR CHANGES 1) Power Outlet & Digital Clock Power Outlet - Deleted the speaker and installed new power outlet on top of center instrument panel. Digital Clock - Deleted the multi-station and installed new digital clock.
  • Page 778 15-5 8510-00 1. OVERVIEW The electric accessories are: Horn, Cigarette lighter, Power outlet, Digital clock and Siren (Theft deterrent alarm) 1) Interior Electric Accessories Digital Clock Tray in luggage compartment Cigarette Lighter Power Outlet...
  • Page 779 15-6 2) Exterior Electric Accessories Siren (Theft Deterrent Alarm) RH Horn (Low) LH Horn (High)
  • Page 780 15-7 8510-00 2. OPERATING PROCESS 1) Horn (1) Operating Condition B+ (always ON) (2) Operation The horn sounds when pressing the horn switch on the steering wheel. Horn switch (air bag module integrated) (3) Operating Process...
  • Page 781 15-8 2) Cigarette Lighter & Power Outlet (1) Operating Conditions Cigarette lighter & Power outlet: ACC, IGN ON Indicator in cigarette lighter: Tail lamp ON (2) Operation of Cigarette Lighter Press in the cigarette lighter and wait until it pops out. Heating coil The barrel of the cigarette lighter becomes very hot when it is fully charged.
  • Page 782 15-9 8510-00 3) Digital Clock (1) Adjustment Hour button SET button Minute button ▶ How to change the time on digital clock “S” button: Reset the “Minute”. To change the time indication type between 24-hour and 12-hour, press this button for more than 3 seconds. “H”...
  • Page 783 01-2 1. GENERAL INFORMATION ▶ ▶ Automatic transaxle (DSI M78) Tip switch on steering wheel Manual gear shift on “M” position Shift down Shift up The six speed automatic (M78) transmission is available in two variants: four wheel drive and two wheel drive.
  • Page 784 01-3 3650-01 ▶ Gear position display on instrument cluster Gear position indicator (for A/T) The gear position indicator shows the currently selected gear position. Positions of gear select lever P : Parking R : Reverse N : Neutral D : Drive Tip Switch in “M”...
  • Page 785 01-4 2. FEATURES AND SPECIFICATIONS 1) Specifications Description DSI M78 (6-speed) Remarks 3.536:1 2.143:1 1.478:1 1.156:1 Gear ratio 0.866:1 0.677:1 Reverse 3.094:1 Fluid Fluid Fuchs ATF 3292 ATF Fuchs ATF 3292 ATF 용량 약 9.5L Capacity Approx. 9.5 L Transmission fluid Change interval Check the fluid at every 교환주기...
  • Page 786 01-5 3650-01 2) Appearance ▶ 4WD Automatic Transmission Oil cooler return Torque converter Oil cooler outlet Servo Adapter housing Inhibiter switch ▶ 2WD Automatic Transmission...
  • Page 787 01-6 3) Sectional Diagram...
  • Page 788 01-7 3650-01 4) Shift Pattern Diagram Vehicle speed(Km/h) Output shaft speed(rpm)
  • Page 789 01-8 3. TIGHTENING TORQUE Description Size Tightening torque(Nm) Transfer case housing M12 x 32 54 ~ 68 Extension housing M12 x 32 54 ~ 68 Oil pan M6 x 16 4 ~ 6 Valve body to transmission housing M6 x 26 8 ~ 13 Valve body to transmission housing M6 x 45...
  • Page 790 01-9 3650-01 1. OVERVIEW The six speed automatic (M78) transmission is available in two variants: four wheel drive and two wheel drive. The transmission has the following features: Six Forward Speeds One reverse gear A torque converter with an integral converter lock-up clutch Electronic shift and pressure controls A single planetary gear-set A double planetary gear-set...
  • Page 791 01-10 2. FEATURES 1) Features ▶ Early Downshifts with Hard Braking and Skip Shifts When heavy braking is detected, the transmission downshifts early and skips gears to provide increased engine braking to provide gear selection for tip-in. ▶ Gear Hold on Uphill/Downhill If the accelerator pedal is released when travelling uphill, upshifts are prevented to reduce busyness on grades.
  • Page 792 01-11 3650-01 2) Cooling System The transmission cooling system ensures rapid warm-up and constant operating temperature resulting in reduced fuel consumption and refined shift quality. It also includes a cooler by-pass within the hydraulic system to allow sufficient cooling and lubrication to the transmission drivetrain in the event of a blockage in the transmission cooler.
  • Page 793 01-12 3. MODE DESCRIPTIONS 1) Functions Shift Lock Release Button Hole when Locked in the "P" Position (1) If you cannot move the gear select lever from the "P" position, try to move the lever while pushing down here with a sharp object such as a ballpoint pen. For your safety, turn off the engine and depress the brake pedal before the attempt.
  • Page 794 01-13 3650-01 2) Mode “M” (Manual Shift Mode) This allows the driver to define the highest possible gear by selecting "+" or "-" on the gear selector when the lever is in the "M" position. When the lever is first moved to the manual "M" position the transmission will select the lowest possible gear.
  • Page 795 01-14 4. LIMP HOME MODE ▶ In case of transmission malfunction If a serious fault occurs in the automatic transmission, the TCU enters the limp home mode to secure safe driving and protect the automatic transmission. As power is no longer supplied to the solenoid, the current basic function (P, R, N, D) is maintained and the 4th gear can be maintained only by the operation of the hydraulic system without electrical operation.
  • Page 796 01-15 3650-01 5. ELECTRONIC CONTROL SYSTEM 1) Overview The transmission control unit (TCU) and its input/output networks control the operations of transmission: Shift timing Line pressure Clutch pressure (shift feel) Torque converter clutch In addition, the TCU receives input signals from certain transmission-related sensors and switches.
  • Page 797 01-16 3) Transmission Control Monitoring System TCU monitors all input and output signals to identify possible failures. If a fault is detected, TCU activates the safety mode to keep the driver’s safety and the life span of transmission. ▶ Monitoring the Supply Voltage If the battery voltage is too high or too low, the TCU sets the DTC.
  • Page 798 01-17 3650-01 ▶ Pressure Modulation To provide a higher level of shift comfort and durability, the hydraulic pressure in the shift related friction elements of the transmission must be matched accurately to the input torque to transmission. This hydraulic pressure is composed of a hydraulically pre-set basic pressure and a control pressure which is set by one of the variable bleed solenoids.
  • Page 799 01-18 ▶ Winter Mode (W) When the Winter mode is selected, the second gear is engaged to start off the vehicle easily to prevent wheel spin on slippery surfaces and WINTER mode indicator comes ON. The first gear is not available in this mode. ▶...
  • Page 800 01-19 3650-01 6. CAN NETWORK 1) Network Communication The TCU sends signals to be used by other vehicle systems via the CAN bus, such as: Selector lever position Selected gear state Manual mode activation Output torque Transmission fluid temperature Engine torque reduction requests 2) Embeded Memory Module (EMM) The embedded memory module (EMM) is matched to the transmission's valve bodies...
  • Page 801 01-20 7. POWER FLOW Power flows in gears: Power flow - 1st gear (M) Power flow - 1st gear (D) Power flow - 2nd gear (D) Power flow - 2nd gear (D) - lockup (D) Power flow - 3rd gear (D) Power flow - 4th gear (D) - 4th gear (D) in Limp home mode Power flow - 5th gear (D) Power flow - 6th gear (D)
  • Page 802 01-21 3650-01 ▶ Hydraulic Circuit Diagram...
  • Page 803 01-22 1) Power Flow - Manual (M Position) ▶ Power Flow Diagram ▶ Functioning elements C2 applied, FSG (Forward Sun Gear) driven Manual 1st gear is not engaged even B2 applied to hold Rear Planet Carrier when moving the manual valve to a stationary certain position.
  • Page 804 01-23 3650-01 ▶ 1st Gear (M) (3.53:1)
  • Page 805 01-24 2) Power Flow - 1st Gear (D) ▶ Power Flow Diagram ▶ Functioning elements C2 applied, FSG (Forward Sun Gear) driven 1-2 OWC (One-Way Clutch) operated to hold Rear Planet Carrier stationary ▶ Control S1 ON, S2 OFF S1 ON, C1 shift valve moved to the left end, C1 clutch not engaged C2 shift valve open (S2 OFF), C2 clutch engaged by drive oil Drive oil (for C2 clutch engagement) is regulated by VBS S6 ▶...
  • Page 806 01-25 3650-01 ▶ 1st Gear (D) (3.53:1)
  • Page 807 01-26 3) Power Flow - 2nd Gear (D) ▶ Power Flow Diagram ▶ Functioning elements C2 applied, FSG (Forward Sun Gear) driven B1 applied to hold Rear Planet Carrier stationary ▶ Control S1 ON, S4 ON, S2 OFF S1 ON, C1 shift valve moved to the left end, C1 clutch not engaged C2 shift valve open (S2 OFF), C2 clutch engaged by drive oil Drive oil (for C2 clutch engagement) is regulated by VBS S6 S4 ON, B1 shift valve moved to the left end, B1 band operated...
  • Page 808 01-27 3650-01 ▶ 2nd Gear (D) (2.14:1)
  • Page 809 01-28 4) Power Flow - 2nd Gear (D) Lock-Up ▶ Power Flow Diagram ▶ Connecting Components Gear Engaged element ratio Lock-up clutch 2.14 Gear ON / OFF solenoids Variable pressure sol. valve-VBS ratio S5(A) S6(A) S7(A) S8(A) S9(A) S10(A) 2.14...
  • Page 810 01-29 3650-01 ▶ 2nd Gear (D) Lock-Up...
  • Page 811 01-30 5) Power Flow - 3rd Gear (D) ▶ Power Flow Diagram ▶ Functioning elements C3 clutch cannot be engaged if S7 is C2 applied, FSG (Forward Sun Gear) driven OFF and the oil pressure is not supplied C3 applied, Rear Planet Carrier driven to C3 regulator valve.
  • Page 812 01-31 3650-01 ▶ 3rd Gear (D) (1.48:1)
  • Page 813 01-32 6) Power Flow - 4th Gear (D) & 4th Gear (D) in Limp Home Mode ▶ Power Flow Diagram ▶ Functioning elements 4th gear is used as Limp Home Mode. C2 applied, FSG (Forward Sun Gear) driven C1 applied, Rear Planet Carrier driven ▶...
  • Page 814 01-33 3650-01 ▶ 4th gear (D) & 4th gear (D) in Limp home mode (1.16:1)
  • Page 815 01-34 7) Power Flow - 5th Gear (D) ▶ Power Flow Diagram ▶ Functioning elements C1 applied, Rear Planet Carrier driven C3 applied, RSG (Rear Sun Gera) driven ▶ Control S1 OFF, S2 and S3 ON S2 ON, C2 shift valve moved to the left end, C2 clutch not engaged C1 shift valve open (S1 OFF), C1 clutch engaged by drive oil S3 and S7 ON, C3 shift valve moved to the left end, C3 clutch engaged ▶...
  • Page 816 01-35 3650-01 ▶ 5th gear (D) (0.87:1)
  • Page 817 01-36 8) Power flow - 6th gear (D) ▶ Power Flow Diagram ▶ Functioning elements C1 applied, Rear Planet Carrier driven B1 applied, RSG (Rear Sun Gera) locked ▶ Control S1 OFF, S2 and S4 ON S3 ON, C2 shift valve moved to the left end, C2 clutch not engaged C1 shift valve open (S1 OFF), C1 clutch engaged by drive oil S4 ON, B1 shift valve moved to the left end, B1 Band engaged ▶...
  • Page 818 01-37 3650-01 ▶ 6th gear (D) (0.68:1)
  • Page 819 01-38 9) Power flow - Reverse (R) ▶ Power Flow Diagram ▶ Functioning elements C3 applied, RSG (Rear Sun Gera) locked B2 applied, Rear Planet Carrier locked ▶ Control S1, S2 and S3 ON Line pressure applied to B2 Band directly through manual valve S3 ON, Pressure to C3 increased or regulated S1 and S2 ON, C1 not engaged in any case ▶...
  • Page 820 01-39 3650-01 ▶ Reverse gear (R) (3.09:1)
  • Page 821 01-40 10) Power Flow - Reverse (R) Limp Home Mode ▶ Power Flow Diagram ▶ Connecting Components Gear Engaged element ratio Lock-up clutch 3.09 Gear ON / OFF solenoids Variable pressure sol. valve-VBS ratio S5(A) S6(A) S7(A) S8(A) S9(A) S10(A) 3.09...
  • Page 822 01-41 3650-01 ▶ Reverse (R) Limp Home Mode...
  • Page 823 01-42 11) Power flow - Park (P) ▶ Power Flow Diagram ▶ Connecting Components Gear Engaged element ratio Lock-up clutch Gear ON / OFF solenoids Variable pressure sol. valve-VBS ratio S5(A) S6(A) S7(A) S8(A) S9(A) S10(A)
  • Page 824 01-43 3650-01 ▶ Park...
  • Page 825 01-44 12) Neutral (N) ▶ Power Flow Diagram ▶ Connecting Components Gear Engaged element ratio Lock-up clutch Gear ON / OFF solenoids Variable pressure sol. valve-VBS ratio S5(A) S6(A) S7(A) S8(A) S9(A) S10(A)
  • Page 826 01-45 3650-01 ▶ Neutral...
  • Page 827 01-3 3650-01 1. SPECIFICATIONS Item W5A330(300) W5A580(2WD)/W5A400(4WD) W5A580(400) Input torque 330Nm 450Nm Diameter( Torque converter) 270mm 270mm Lockup function Gear ratios 3.951 3.595 2.423 2.186 1.486 1.405 1.000 1.000 0.833 0.831 Reverse: 3.167/1.926 3.147/1.93 S mode / W mode Driving type 2WD(4WD) Fluid specification Shell ATF 134...
  • Page 828 01-4 Item W5A580(2WD)/W5A400(4WD) 5.0 ± 0.2Ω M/P, S/P solenoid Resistance valve(23℃) Operating distance 0.6mm Operating current 0 ~ 1A 2.5 ± 0.2Ω Lockup solenoid Resistance valve(25℃) Operating distance 0.2mm Operating current 1.5 ~ 2.0A Operating range 3rd to 5th gears RPM sensor Resistance HALL type...
  • Page 829 01-5 3650-01 2. TIGHTENING TORQUE Description Tightening Torque (Nm) Remark Oil drain plug (oil pan) Hexagon, 5 mm Oil filler pipe (upper) 8 ~ 10 Oil filler pipe (lower) 8 ~ 10 Oil cooler pipe 30 ~ 38 Oil pan T 30 Torque converter housing/oil pump Transmission rear mounting bracket...
  • Page 830 01-6 3. MAJOR CHANGES Introduced Torsion Damper in Torque Converter The torsion damped has been newly installed in the torque converter. The torsion damper absorbs the shock, vibration and noise when delivering the engine driving force. This improves NVH performance in this vehicle.
  • Page 831 01-7 3650-01 1. OVERVIEW DC A/T Assembly Number DC A/T Assembly Number (With T/Converter) (With T/Converter) A/T Serial Number Base model AT type DC A/T Variant Number A/T Serial Number ▶DC 5-Speed Automatic Transmission DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the torque converter.
  • Page 832 01-8 ▶Characteristics...
  • Page 833 01-9 3650-01 2. POWER FLOW 1) Power Flow ▶Sectional View B1 C1 C2 B3 C3 B2 ▶Shifting elements 1) Selector program switch: "S" mode 2) Selector program switch: "W" mode 3) Overrun...
  • Page 834 01-10 ▶1st Gear (3.932) Torque converter lockup clutch 3rd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set 2nd gear ratio Input shaft: Clockwise rotation Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed Rear ring gear: Counterclockwise rotation...
  • Page 835 01-11 3650-01 ▶2nd Gear (2.408) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set Input shaft: Clockwise rotation Sun gear and planetary gear carrier: Clockwise rotation by C1 activation Rear ring gear: Clockwise rotation Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed...
  • Page 836 01-12 ▶3rd Gear (1.486) Torque converter lockup clutch Mounting elements Impeller Engine speed Rear planetary gear set Turbine wheel Transmission, input shaft Stator Front planetary gear set 1st gear ratio Center planetary gear set 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...
  • Page 837 01-13 3650-01 ▶4th Gear (1.000) Torque converter lockup Stator Turbine wheel clutch Center planetary gear Front planetary gear Engine speed Planetary gear set Impeller Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Center ring gear and rear planetary gear carrier: Clockwise rotation Front sun gear and planetary gear carrier: Clockwise rotation (direct connection) Rear ring gear: Clockwise rotation Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
  • Page 838 01-14 ▶5th Gear (0.830) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed 3rd gear ratio Impeller Transmission, input shaft Mounting elements Turbine wheel 1st gear ratio Rear planetary gear set Front planetary gear set Stator Input shaft: Clockwise rotation Front sun gear: Locked, Planetary gear carrier: Rotation with reduced speed Rear planetary gear carrier: Clockwise rotation with reduced speed...
  • Page 839 01-15 3650-01 ▶Reverse 1st Gear (3.167, "S" Mode) Torque converter lockup clutch Mounting elements Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set 2nd gear ratio Input shaft: Clockwise rotation Front ring gear: Clockwise rotation...
  • Page 840 01-16 ▶Reverse 2nd Gear (1.926, "W" Mode) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
  • Page 841 01-17 3650-01 3. CIRCUIT DIAGRAM ▶Start Motor, Selector Lever, CAN Communication...
  • Page 842 01-18 ▶Solenoid, Oil temperature sensor, Speed sensor (N2, N3)
  • Page 843 02-3 3170-01 1. SPECIFICATION Description Specification Gear ratio 4.489 : 1 2.337 : 1 1.350 : 1 1.000 : 1 0.784 : 1 0.679 : 1 Reverse 4.253 : 1 Synchronizer T: Triple-cone ring type T: Triple-cone T: Triple-cone S: Single-cone D: Double-cone S: Single-cone Reverse...
  • Page 844 02-4 2. SPECIAL SERVICE TOOLS Part No. & Name Appearance Description Install the main shaft 1st gear sleeve Part No.: SSM00203- Install the drive pinion assembly front ball bearing Name: Install the main shaft double angular ball Main shaft 1st sleeve bearing installer Install the main shaft reverse sleeve and...
  • Page 845 02-5 3170-01 Part No. & Name Appearance Description Install the counter shaft front roller bearing Part No.: SSM00203- Name: Counter shaft bearing installer Support the counter shaft when removing the Part No.: T88310011A-9 roller bearing with a puller Name: Bearing support...
  • Page 846 02-6 3. TIGHTENING TORQUE Tightening torque Part name Numbers Adhesive (Nm) 1. Seal bolt (rolling plunger and guide spring) 53.9~67.6 Loctite 2. Guide bolt 14.7~21.5 Loctite 3. Pocket ball bearing bolt 29.4~41.1 Loctite 4. Reverse shift fork retainer bolt 53.9~67.6 Loctite 5.
  • Page 847 02-7 3170-01 ▶ 3163161-00 Housing Case - Transmission Breather - Air Retainer - Bearing Pulg - Seal (53.9 ~ 67.6 Nm) Bolt - Seal (19.6 ~ 24.5 Nm) Cylinder assembly - Concentric slave Seal - Oil Plunger - Rolling Bushing Boot Spacer Guide - Oil...
  • Page 848 02-8 ▶ 3162-00 Main shaft...
  • Page 849 02-9 3170-01 Ring - Snap Ring assembly - Triple cone Ring - Snap Gear assembly - 1st speed Bearing - Ball Sleeve - 1st gear Pinion assembly - Main drive Bearing - Double angular ball Bearing - Needle roller Ring - Snap Ring - Synchronizer Gear - Main shaft 5th Ring - Snap...
  • Page 850 02-10 ▶ 33163-00 Counter shaft Ring - Snap Hub - Synchronizer Bearing - Roller Sleeeve - Synchronizer Gear - Counter shaft Ring - Synchronizer Gear - Counter shaft cluster Sleeve - Speed gear Bearing - Roller Bearing - Needle roller Sleeve ?- Speed gear Gear assembly - 6th speed Bearing - Needle roller...
  • Page 851 02-11 3170-01 ▶ 3164-00 Adapter assembly Plate - Intermediate Bolt - Seal (19.6 ~ 26.4 Nm) Guide - Oil Shaft - Reverse idler gear Bolt (7.8 ~ 9.8 Nm) Bearing - Needle roller Pin - Dowel Gear - Reverse idler Retainer - Bearing Spacer - Reverse Magnet...
  • Page 852 02-12 ▶ 3165-00 Rail and shift fork Shaft assembly - Control Lug _ Reverse shaft Ring - Retainer Fork - Reverse shaft Bearing - Retainer ball Rail - Shaft 5th & 6th Pin - Spring Fork - Shaft 5th & 6th Rail sub assembly - Shaft 1st &...
  • Page 853 02-13 3170-01 ▶ 3166-00 Extension housing Lever assembly - Semi remote Bolt - Flange (42.1 ~ 53.9 Nm) Lever - Shift Seal - Oil Boot - Rubber Seal - Oil Ring - Retainer Pin - Dowel O-ring Switch - Neutral (29.4 ~ 34.3 Nm) Bearing Gasket Shim...
  • Page 854 02-14 1. OVERVIEW 6-speed M/T Front view Sectional view 1) Characteristics of Transmission Forward and Reverse gears are helical gear. The clutch is operated by concentric slave cylinder (CSC). To prevent the improper gear shift, semi-remote control system has been introduced. To prevent the gears from engaging improperly, the synchronizer mechanisms and independent interlock systems are installed on 1/2 gears, 3/4 gears, 5/6 gears and reverse gear.
  • Page 855 02-15 3170-01 2) Sectional Diagram Transmission housing Intermediate plate Extension housing Counter shaft Main shaft Main drive gear 3) Gear Ratio Teeth Gear Final gear ratio Input Output 4.489 2.337 1.350 1.000 0.784 0.679 4.253 Idle: 25...
  • Page 856 02-16 2. POWER FLOW 1st speed 2nd speed...
  • Page 857 02-17 3170-01 3rd speed 4th speed...
  • Page 858 02-18 5th speed 6th speed...
  • Page 859 02-19 3170-01 Reverse gear...
  • Page 860 02-20 3. SHIFTING MECHANISM High-Force mechanism for reverse gear shift Control shaft Neutral switch Backup lamp switch Lug arrangement Control finger 1st/2nd 3rd/4th 5th/6th...
  • Page 861 03-3 3170-01 1. SPECIFICATIONS 1) General Specifications Description DI engine Length(mm) 4WD: 628.3, 2WD: 672 Distance between shafts(mm) Input torque(kg.m) 34.7(340Nm) Transmission control type Semi-remote Weight(kg) - not including transmission 4WD: 44, 2WD: 45 fluid(kg.m) Gear ratio/Gear teeth 1st gear 4.315 (input gear: main gear) 2nd gear...
  • Page 862 03-4 1. OVERVIEW ▶ Features All gears use the helical type and high strength materials. The helical type gear prevents the axial gear missing and provides less noise. 2WD (Gasoline) The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock...
  • Page 863 03-5 3170-01 2. SYSTEM COMPONENTS 1) Gear Combinations 2) Shift Fork and Rail Combinations...
  • Page 864 03-6 3) Sectional View...
  • Page 865 03-7 3170-01 1. Transmission front housing 38. Reverse idler gear 2. Input shaft oil seal 39. Reverse idler spacer 3. Front cover 40. Reverse idler bracket 4. Hexagon flange bolt (17 ~ 26 Nm) 41. Retainer ring 5. Oil drain plug 42.
  • Page 866 03-8 ▶ IDI Engine equipped vehicle - 4WD...
  • Page 867 03-9 3170-01 1. Transmission front housing 38. Reverse idler gear 2. Input shaft oil seal 39. Reverse idler spacer 3. Front cover 40. Reverse idler bracket 4. Hexagon flange bolt (17~26 Nm) 41. Retainer ring 5. Oil drain plug 42. Reverse lock nut 6.
  • Page 868 03-10 ▶ IDI Engine equipped vehicle - 2WD...
  • Page 869 03-11 3170-01 1. Transmission front housing 39. Reverse idler spacer 2. Input shaft oil seal 40. Reverse idler bracket 3. Front cover 41. Retainer ring 4. Hexagon flange bolt (17 ~ 26 Nm) 42. Reverse lock nut 5. Oil drain plug 43.
  • Page 870 03-12 4) Front View and Rear View Front view Rear view Oil filler plug 9. Shift lever Backup lamp switch (tightening torque: 40 ~ 50 Nm) 10. Interlock plate Concentric slave Shift rug (3 & 4th) 11. Shift rail (1 & 2nd) cylinder adaptor Spring pin (6 x 25) 12.
  • Page 871 03-13 3170-01 5) Cross Sectional Diagram of Major Components Shift rail and 5/R gear Offset lever Reverse lock spring Offset lever Reverse lock plate Offset lever bushing Reverse lock bolt Rolling plunger Stopper plate Return spring Air vent Spring plug (tightening torque: 30 ~ 40 Nm) (tightening torque: 30 ~ 35 Nm) Lock washer...
  • Page 872 03-14 6) Power Flows 1st gear Counter shaft 2nd gear...
  • Page 873 03-15 3170-01 7) Power Flows (Cont'd) 3rd gear 4th gear...
  • Page 874 03-16 8) Power Flows (Cont'd) 5th gear Reverse gear...
  • Page 875 03-17 3170-01 3. SHIFTING MECHANISM 1) Interlock System Interlock system prevents the gears from meshing over two sets. 2) Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
  • Page 876 03-18 3) Offset Lever and Rolling Plunger To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected. 1. Offset lever 3. Shift shaft 2.
  • Page 877 03-19 3170-01 Shift check device It determines the shift fork position (N or each gear) and gives a detent movement to notice a shift lever seating when operating the shift lever. Also, it prevent the selected gear from getting out of its meshed position. Gear pump out locking device It prevents the shift lever is beyond the correct shift position while shifting.
  • Page 878 03-20 5) Synchronizer ▶ Composition It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each other). 3/4 and 5/R shift: Single cone type 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner cone and middle cone) Single cone type Double cone type...
  • Page 879 03-21 3170-01 ▶ Synchronizer element A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning and the clutch gear is spinning.
  • Page 880 03-22 6) Bearing The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in transmission housing. Taper roller bearing Needle bearing Taper roller bearing Needle bearing for reverse gear (input shaft, counter shaft and output shaft) (with cut out area) Needle bearings for 1/2 and 3/4 shift Needle bearing for 5th gear...
  • Page 881 03-23 3170-01 8) Thrust Ring (Washer) When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly receives the axial force and this force acts as a resistance to rotating gears. 9) Lubrication Transmission oil: SAE 75W/90 Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease...
  • Page 882 03-24 1. Oil filler plug 2. Air vent Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm...
  • Page 883 03-25 3170-01 4. CIRCUIT DIAGRAM (BACKUP LAMP)
  • Page 884 02-3 4120-01 1. SPECIFICATIONS ▶Front Axle Description Specification Drive shaft type CV joint Axle housing type Build up Differential Type Conventional type gear type Hypoid Gear Final gear reduction ratio DI engine + M/T 3.73 DI engine + A/T 3.54 Gasoline engine + A/T 4.27 Capacity...
  • Page 885 10-3 4122-01 1. SPECIAL TOOLS AND EQUIPMENT...
  • Page 886 07-3 3260-01 1. SPECIFICATIONS...
  • Page 887 07-4 1. OVERVIEW The AWD transfer case is installed to the full time 4WD vehicle. Unlike the TOD (Torque On Demand) transfer case, it delivers the driving force to the front wheels through the internal planetary gears without a control unit to operate AWD function. It also doesn't have the TC (Transfer Case) shift motor and 4WD transfer switch.
  • Page 888 07-5 3260-01 2. LOCATION ▶ Distribution of Driving Force in AWD...
  • Page 889 07-6 3. STRUCTURE 1) Sectional View...
  • Page 890 07-7 3260-01 2) Exploded View 1. Oil seal 12. Rear output shaft assembly 2. Case assembly 13. Air breather 3. Input shaft 14. Front output shaft assembly 4. Sprocket 15. Oil seal 5. Front sun gear 16. Retaining ring 6. Differential carrier assembly 17.
  • Page 891 07-8 4. POWER FLOW ▶ Distribution of Front Output Torque ▶ Distribution of Rear Output Torque...
  • Page 892 07-9 3260-01 5. OPERATION OF DIFFERENTIAL 1) Systematic Diagram 2) Revolution Control When there is a revolution difference due to the gap of turning radius while cornering, the tight corner braking symptom occurs in part time transfer case. However, for the AWD, this gap of turning radius is compensated by the differential so that the tight corner braking symptom will not occur.
  • Page 893 07-10 ▶ When Revolution Difference Does not Occur If there is no revolution difference in front and rear shafts, the step pinion (19T/13T) and the pinion (16T) are fixed (integrated to the carrier) even when the carrier rotates. It makes the front sun gear and the rear sun gear move toward the moving direction with the torque ratio of 40:60.
  • Page 894 06-3 3240-01 1. SPECIFICATIONS...
  • Page 895 06-4 1. OVERVIEW TOD system means the full time 4WD system and the registered trade mark of Borg Warner. TOD is an abbreviation of Torque On Demand. TOD (Torque On Demand) system, which is superior than existing Full Time 4WD, checks the road surface and vehicle conditions via various sensors and, subsequently, according to the situations and conditions, distributes the most optimal driving force to front wheels and rear wheels by activating the electro-magnetic clutch located inside of TOD Transfer Case.
  • Page 896 06-5 3240-01 1) Distribution of Driving Force According to Road Surface On normal road surface In vehicle with existing part time transfer case, when a driver turns the steering wheel to park in the 4WD mode, the vehicle may halt sensation of tight corner braking phenomena.
  • Page 897 06-6 2) Function ▶ 4L Mode Selection Mode When selecting 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetary gear set.
  • Page 898 06-7 3240-01 2. POWER FLOW ▶ System Layout Instrument Panel 4WD Switch Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output...
  • Page 899 06-8 3. TOD OPERATION 1) Distribution of Driving Force According to Road Surface On normal road surface In vehicle with existing part time transfer case, when a driver turns the steering wheel to park in the 4WD mode, the vehicle may halt sensation of tight corner braking phenomena. However, in vehicle with TOD system, this phenomenon does not occur and the driving force is properly and automatically distributed.
  • Page 900 06-9 0000-00 ▶ 4L Mode When selecting 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetary gear set. ▶...
  • Page 901 06-10 ▶ 4H Mode (4WD Drive - High Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel)
  • Page 902 06-11 3240-01 ▶ 4L Mode (4WD Drive - Low Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel)
  • Page 903 06-12 3. CIRCUIT DIAGRAM...
  • Page 904 03-3 3240-01 1. SPECIFICATIONS Description Specifications Total length 343mm Mating surface of front flange 40mm Weight 32.4 kg (including oil) Oil capacity 1.4L Oil type ATF DEXRON II or III Location Transfer case Major element Housing Part-time & TOD Bolt 11EA, M8 x 1.25 Input shaft A/T: outer spline...
  • Page 905 03-4 1. OVERVIEW By using the planetary gear sets, two-gears shift type part time transfer case achieves direct connection when selecting 4WD "HIGH" and 2.48 of reduction gear ratio when selecting 4WD "LOW". The silent chain in transfer case transfers the output power to front wheels. The simple operation of switches on instrument panel allows to shift between "2H"...
  • Page 906 03-5 3240-01 ▶ Operation Description Mode Conditions Driving 2 Wheel drive Rear-wheel drive mode. This is used under mode (rear wheel) normal or high-speed driving conditions on public roads or highways. 4 Wheel drive This is used under sandy, muddy or snow- (high speed) covered road conditions 4 Wheel drive...
  • Page 907 03-6 2. LAYOUT Front axle Front locking hub system (IWE) Front propeller shaft Part-time transfer case Rear propeller shaft Rear axle...
  • Page 908 03-7 3240-01 3. SYSTEM LAYOUT...
  • Page 909 03-8 4. IWE LOCKING HUB SYSTEM 1) Overview The vacuum locking hub uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator. 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 Booster Operating Process...
  • Page 910 03-9 3240-01 (2) Vacuum System Related to 4WD Check valve This valve allows the vacuum pressure to flow through it in only one direction. This During 2WD mode, the vacuum pressure prevent the vacuum from abruptly from vacuum pump is continuously releasing due to faulty vacuum pump.
  • Page 911 03-10 5. POWER FLOW Switching 2H, 4H → 4L TCCU Vacuum solenoid Locking hub operation (Released internal vacuum) Transfer case Front propeller shaft Rear propeller shaft Front axle Rear axle Front wheel Rear wheel...
  • Page 912 03-11 3240-01 1) 2H Mode (2 Wheel Drive) ▶ Power Flow Output shaft of Rear wheel transmission Input shaft of transfer case Rear propeller shaft Rear axle ↓ Output shaft of transfer case Rear wheel The driving force is directly engaged (1:1) to rear axle and is transferred only to the rear wheels.
  • Page 913 03-12 2) 4H Mode (4 Wheel Drive - High Speed) ▶ Power Flow The driving force is pass through 4WD High magnetic clutch in transfer case and is distributed on front wheels and rear wheels (50;50).
  • Page 914 03-13 3240-01 3) 4L Mode (4 Wheel Drive - Low Speed) ▶ Power Flow The gear ratio is reduced to 2.48;1 while passing through 4WD Low range and planetary gear set in transfer case and the driving force is distributed on front wheels and rear wheels (50;50).
  • Page 915 04-3 3310-01 1. SPECIFICATION Description Specification Structure Yoke and spider type universal joint Number of spiders Front Part time T/C Rear Tube run-out below 0.3 mm Unbalance Max. 18 g.cm / 4,500 rpm (30 g.cm when re-measuring) 607.1 * Φ63.5 Front propeller shaft length * outer diameter (mm) (at compressed condition)
  • Page 916 04-4 1. OVERVIEW The propeller shaft transfers the power through the transmission and transfer case to the front/rear axle differential carrier (final reduction gear). It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending.
  • Page 917 05-3 4411-01 1. SPECIFICATIONS Description Specification Suspension type Double wishbone Spring type Coil spring Front Suspension Shock absorber type Reciprocating cylindrical type (gas type) Stabilizer bar type Torsion bar type Suspension type 5-link type / multi-link type Spring type Coil spring Rear Suspension Shock absorber type Reciprocating cylindrical type...
  • Page 918 05-4 3. LAYOUT AND COMPONENTS ▶ Front View Shock absorber assembly Coil spring Upper arm assembly Axle shaft assembly Steering knuckle Lower arm assembly Shock absorber yoke assembly Shock absorber (to yoke) bolt: 122.5 ~ 142.1 Nm Upper arm (knuckle side) nut: 137.2 ~ 156.8 Nm Lower arm (knuckle side) nut: 137.2 ~ 156.8 Nm...
  • Page 919 05-5 4411-01 In lower arm design, the current mass production vehicle (A) is different from the new model (B) from July 2012. B. Multi-link type A . 5-Link type (changed lower arm ball joint)
  • Page 920 05-6 ▶ Top View Coil spring mounting nut Tightening torque: 58.8 ~ 78.4Nm Stabilizer bar link upper nut Upper arm (frame side) bolt/nut Tightening torque: 29.4 ~ 49.0Nm Tightening torque: 107.8 ~ 127.4Nm Stabilizer bar link lower nut Tightening torque: 107.8 ~ 127.4Nm Stabilizer bar clamp bolt Tightening torque: 39.2 ~ 58.8Nm Lower arm (frame side) bolt/nut...
  • Page 922 05-8 4. SYSTEM LAYOUT AND TIGHTENING TORQUE OF REAR SUSPENSION ▶ Top View Lower arm (link) Stabilizer bar link Stabilizer bar Upper arm (link) Shock absorber Lateral rod Axle housing Coil spring seat (upper side)
  • Page 923 05-9 4411-01 Lower arm bolt/nut Tightening torque: 147.0 ~ 176.4Nm Stabilizer bar mounting bracket Upper arm bolt/nut Tightening torque: 39.2 ~ 58.8Nm Tightening torque: 147.0 ~ 176.4Nm Stabilizer bar link upper Tightening torque: 29.4 ~ 44.1Nm Stabilizer bar link lower Tightening torque: 58.8 ~ 78.4Nm Lateral rod Tightening torque: 147.0 ~ 196.0Nm...
  • Page 924 05-10 5. TROUBLESHOOTING Problem Cause Action Broken stabilizer bar Replace Vehicle rolling Faulty shock absorber Replace Loosening mounting Retighten Damaged or worn wheel bearing Replace Abnormal noise. Damaged shock absorber Replace Damaged tire Replace Over inflated tire Adjust Faulty shock absorber Replace Loosened wheel nut Tighten as specified...
  • Page 925 05-11 4411-01 1. OVERVIEW Suspension is the term given to the system of springs, shock absorbers and linkages that connects a vehicle to its wheels. Suspension systems serve a dual purpose ? contributing to the vehicle's road holding/handling and braking for good active safety and driving pleasure, and keeping vehicle occupants comfortable and reasonably well isolated from road noise, bumps, and vibrations, etc.
  • Page 926 05-12 2. FRONT SUSPENSION (DOUBLE WISHBONE) Double wishbone suspension is an independent suspension design using two (occasionally parallel) wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle. The shock absorber and coil spring mount to the wishbones to control vertical movement.
  • Page 927 05-13 4411-01 3. REAR SUSPENSION (MULTI LINK TYPE) Multi-link (5-Link) type suspension is the independent suspension. It provides good ride comfort and drivability by reducing the coil spring weight. Also, it increases the space for passenger compartment by lowering the floor. This type of suspension consists of multiple links such as coil spring, shock absorber, upper and lower arms, lateral rod and stabilizer bar.
  • Page 928 05-14 4. WHEEL ALIGNMENT Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle travel is straight and true (without "pulling"...
  • Page 929 05-15 4411-01 1) Toe-in The difference of measured distances between the front ends of the tires (A) and the rear ends of the tires (B) along the same axle when viewed the wheels from the top. 2 ± 2mm Toe-in ▶...
  • Page 930 05-16 2) Camber The angle between the center line of the tire and the vertical line when viewed from the front of the vehicle 0.12 ± 0.25° Camber 0 ± 0.25° ▶ Positive camber: Top of the tire is tilted outward The axle is not bent when it is loaded.
  • Page 931 05-17 4411-01 3) Caster The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tires from the side. 4.28 ±...
  • Page 932 NO DATA...
  • Page 933 06-3 4850-01 1. SPECIFICATION Unit Description Specification Front brake Type Ventilated disc Ø294 mm Outer diameter of disc Ø45.0 x 2 mm Inner diameter of caliper cylinder Thickness of disc 28 mm (wear limit: 25.4 mm) Above 60 cm² Area of brake pad Pad wear indicator Mechanical type Rear brake...
  • Page 934 06-4 2. TROUBLESHOOTING Problem Possible Cause Action Noise or vehicle Incorrectly mounted back plate or caliper Repair vibration when applied Loosened bolt of back plate or caliper Retighten Uneven wear of brake disc Replace Brake pad contamination Clean or replace Sticking brake pad on contact surface Replace Wear or hardening of brake pad...
  • Page 935 06-5 4850-01 Problem Possible Cause Action Increased pedal stroke Air in brake line Bleed air Oil leak Repair Worn brake pad Replace Excessive clearance between push rod and Adjust master cylinder Worn or damaged piston seal Replace Brake dragging Parking brake is not fully released Release Incorrect adjustment of parking brake Adjust...
  • Page 936 06-6 Problem Cause Action Burning smell around Too frequent braking in high driving speed Reduce the use of tire foot brake/use engine brake Used only foot brake during downhill driving properly Driving with foot on brake pedal Get off the foot from pedal Foreign materials such as dirt or sand in brake Replace: caliper,...
  • Page 937 06-7 4850-01 ▶ Brake operation and noise This section describes the noise phenomena occurred possibly in the brake system operation. Distinguish between the information given below and the actual problems and then, inspect the vehicle and take appropriate measures. Noise symptoms and Causes Symptom 1.
  • Page 938 06-8 3. AIR BLEEDING Never reuse the used brake fluid. Use only specifies brake fluid (DOT 4). Add brake fluid between MAX and MIN lines on the reservoir (0.7 to 0.8 liters). Be careful not to splash the brake fluid on painted area or body. Make sure that any foreign material does not get into brake line.
  • Page 939 06-9 4850-01 ir bleed screw at rear brake Air bleed screw at front brake Repeat the air bleeding procedures until Air bleeding clear brake fluid comes out of air bleed completed Air in brake screw. fluid Check for oil leaks from the brake lines. Deteriorated fluid...
  • Page 940 06-10 4. RAKE SYSTEM CHECK ▶ Maximum Stroke of Brake Pedal Check the brake pedal with below procedures: Start the engine. Pump the brake pedal around 3 times. Depress the brake pedal with approx. 30 kg and measure the distance (A) between the upper surface of pedal pad and the lower dash panel.
  • Page 941 06-11 4850-01 ▶ Pedal Height Check the pedal height with below procedures: Push rod Start the engine and measure the length Stop lamp (A) between floor mat and pedal. switch If the measured value is out of the Operating specified value, adjust the length. rod lock nut Plunger 179 mm...
  • Page 942 06-12 ▶ Pedal Free Play Check the pedal free play with below procedures: Stop the engine. Depress the brake pedal several times to discharge the vacuum pressure of the brake booster. Depress the brake pedal until you feel the resistance, and measure the movement (A).
  • Page 943 06-13 4850-01 ▶ Brake Booster Let the engine run for 1 to 2 minutes and stop it. If the brake pedal stroke is shortened as pumping the brake pedal, the system is normal. If not, the system is defective. Depress the brake pedal several times with engine off.
  • Page 944 06-14 ▶ Brake Fluid Color - Ligh gold (New oil) → Brown → Black Service Interval/Type - Change: every 2 years, Type: DOT4 The water in the brake fluid has an adverse effect to the brake system. If the fluid contains around 3% of water, the boiling point of the brake fluid goes down by 25%.
  • Page 945 06-15 4850-01 ▶ Front Brake Pad Thickness Measure the pad thickness and replace it if it is below the wear limit. New pad Wear limit 10.5 mm 2 mm Wera limit point. If a brake pad is worn beyond the wear limit, replace both front brake pads.
  • Page 946 06-16 Clean the dissembled components and visually check the followings: Damage and tear on boot Uneven wear and oil contamination Damage, crack and wear on cylinder body (A) and guide pin (B) Wear, rust and damage on the cylinder and piston Scratch and bending on disc plate...
  • Page 947 06-17 4850-01 ▶ Rear Brake Pad Thickness Remove the front tire. 2. Measure the pad thickness and replace it if it is below the wear limit. New pad Wear limit 10 mm 2 mm Disc thickness Measure the disc thickness at over ten points.
  • Page 948 06-18 ▶ Parking Brake Check the brake force with below procedures: Count the number of the clicks (notches) when pulling up the parking brake with 19.0 ± 1.5kgf of force. Specified notches If the clicks are over or below the specified value, adjust the clicks to the specified value with the parking brake adjusting nut.
  • Page 949 06-19 4850-01 1. OVERVIEW Even though a driver cuts off the power, while driving, the vehicle continues to move due to the law of inertia. Therefore, a braking device is needed to stop the vehicle. The brake system normally uses the frictional discs that converts the kinetic energy to the thermal energy by frictional operation.
  • Page 950 06-20 ▶ Braking distance & stopping distance Stopping distance = free running distance + braking distance What is stopping distance? A certain distance (free running distance + braking distance) is needed from the moment an obstacle appears ahead until you bring your vehicle to a complete stop. This is called as stopping distance.
  • Page 952 06-22 2. SYSTEM LAYOUT HECU Assembly Brake Master Cylinder & Booster Front Brake Caliper Assembly Wheel Speed Sensor(4WD) Front Brake Pad A. Front B. Rear...
  • Page 953 06-23 4850-01 Indicator & Warning Lamp Parking Brake Lever A. ABS indicator/warning lamp B. Parking brake indicator Brake Pedal Rear Brake Caliper Assembly Parking Brake Assembly Rear Brake Pad...
  • Page 954 06-24 3. SECTIONAL DIAGRAM ▶ Front Disc Brake Brake caliper Brake pad Air bleeder screw Brake disc Wheel bolt or hub bolt Upper arm connection Air bleeder screw 2-way piston Brake caliper Brake hose Knuckle Dust shield Lower arm connection Tie rod end connection...
  • Page 955 06-25 4850-01 ▶ Rear Disc Brake Air bleeder screw Brake pad Brake caliper Brake disc Brake hub Wheel bolt or hub bolt Air bleeder screw Brake caliper Brake hose One-way piston Dust shield Parking brake connection...
  • Page 956 06-26 4. HYDRAULIC CIRCUIT with ABS Brake booster Front disc brake and caliper Brake fluid reservoir and master cylinder Rear disc brake and caliper HECU (Hydraulic & Electric Control Unit) 3-way connector...
  • Page 957 06-27 4850-01 5. CIRCUIT DIAGRAM OF STOP LAMP...
  • Page 958 07-3 4892-01 1. SPECIFICATIONS Specification Description Remark Clock frequency: 28 MHz HECU CPU: MCU60 (32bit) Memory: 128~256 kb Switch orifice Active type Output: 7~14 mA Wheel speed sensor Steering wheel angle sensor None None Sensor cluster 4WD only (integrated in ABS HECU) Longitudinal G sensor None Pressure sensor...
  • Page 959 07-4 1. SYSTEM OVERVIEW When braking suddenly or braking on slippery roads, the vehicle keeps moving forward but the wheels are locking and not rotating. If these happen, the vehicle may lose stability or rotate resulting in an accident. ABS helps to maintain directional stability and control of the vehicle. ABS is designed to secure more safety and increase the control of steering wheel during emergency braking situation.
  • Page 961 07-6 2. COMPONENTS AND LAYOUT ABS Warning Lamp EBD warning lamp (ABS warning lamp and Brake warning lamp ON together Brake Master Cylinder and Booster Front Active Wheel Speed Sensor It is installed on the front hub assembly.
  • Page 962 07-7 4892-01 HECU (Hydraulic & Electronic Control Unit) Diagnostic Connector Rear Active Wheel Speed Sensor It is installed on the rear axle.
  • Page 963 07-8 3. ABS CONTROL LOGIC The principal ABS control logic is the determination of the reference speed by choosing one wheel meeting a certain condition, while sensing the speed information from 4 wheel speed sensors when the vehicle is being driven. For example, when the comparison of the reference speed with front right wheel speed shows a slip, the control signal is determined according to whether it's deceleration or acceleration.
  • Page 964 07-9 4892-01 4. WARNING LAMPS A. ABS warning lamp B. Brake warning lamp (EBD warning lamp: ABS warning lamp + Brake warning lamp) 1) ABS Warning Lamp ABS warning lamp module indicates the self diagnosis and malfunction. ABS warning lamp ON: When turning the ignition switch to ON position, ABS warning lamp comes on for 3 seconds for self-diagnosis and goes off if the system is OK (initialization mode).
  • Page 965 07-10 5. SYSTEM OPERATION 1) Block Diagram of ABS HECU...
  • Page 966 07-11 4892-01 2) Basic Theory of ABS Function To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles. (1) Stopping distance The stopping distance depends on the vehicle weight and initial speed when braking starts. This also applies for vehicle with ABS, where ABS always tries to set an optimum brake force on each wheel.
  • Page 967 07-12 ▶ Slip The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the slip is greatest, that is 100 %. If the wheel is running freely and un-braked, the slip is the lowest, equal to 0 %. Slip can be calculated from the vehicle speed Vveh and the wheel speed Vw.
  • Page 968 07-13 4892-01 ▶ KAMM circle Before we go into the Kamm circle, you should know that a tire offers a maximum of 100 % transmissibility. It is all the same for the tire whether we require 100 % in the direction of braking or in the direction of the acting lateral force, e.g.
  • Page 969 07-14 3) Basic ABS Control ▶ Operation of ABS control unit Applications of the ABS control unit The signals produced by the wheel sensors are evaluated in the electronic control unit. From the information received, the control unit must first compute the following variables: Wheel speed Reference speed Deceleration...
  • Page 970 07-15 4892-01 4) ABS Control Pattern △V: Vehicle speed Vref: Reference speed Vw: Wheel speed The ABS control is performed by comparing the reference speed with each wheel speed. Firstly, it is determined whether the vehicle is in the deceleration or acceleration state using the wheel speed change ratio.
  • Page 971 07-16 6. HYDRAULIC CIRCUIT DIAGRAM The vehicle equipped only with the ABS controls the wheel's braking force using three 3-channel 4-sensor method. The front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves.
  • Page 972 07-17 4892-01 7. HYDRAULIC CIRCUIT DIAGRAM IN EACH OPERATION ▶Hydraulic Pressure Circuit when ABS is Not Operating The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve. At this moment, the normally-closed outlet valve is closed.
  • Page 973 07-18 ▶Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases. This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels.
  • Page 974 07-19 4892-01 8. ELECRTRIC CIRCUIT DIAGRAM...
  • Page 975 07-3 4892-01 1. SPECIFICATION Description Unit Specification Clock frequency: 28MHz Clock frequency: 33MHz CPU : MCU60(32bit) CPU : MCU6(32bit) HECU Memory: 128 ~ 256KB Memory: 256 ~ 512KB Switched Orifice Switched Orifice Output: Wheel speed sensor Active type Active type 7~14mA Max.
  • Page 976 07-4 2) Specification of Steering Wheel Angle Sensor Description Specification Remark Operating voltage 9 to 16 V Maximum output current 10mA ±100°/Sec Maximum detection angle speed -30 ~ 75℃ Operating temperature Supplying voltage 9 to 16 V (battery voltage) Output voltage (HI) approx.
  • Page 977 07-5 4892-01 2. FUNCTIONS AND COMPONENTS 1) Terms and Acronyms ABS: Anti-Lock Brake System EBD: Electronic brake-Force Distribution ESP: Electronic Stability Program ABD: Automatic Braking Differential ASR: Acceleration Slip Regulation AYC: Active Yaw Control HBA: Hydraulic Brake Assistant ARP: Active Rollover Protection HDC: Hill Descent Control 2) Functions Function...
  • Page 978 07-6 3) Components CBS 장착 차량 Component ABS/EBD (수출 Only) HECU Front wheel speed sensor Available Available Rear wheel speed sensor ABS warning lamp EBD indicator G-sensor 2WD: Not available, Not available 없음 4WD: Available Sensor cluster (Yaw-rate sensor, Lateral/Longitudinal G sensor) Not available Available ESP warning lamp &...
  • Page 979 07-7 4892-01 3. WARNING LAMPS 1. ABS warning lamp 2. Brake warning lamp 3. ESP OFF indicator 4. ESP warning lamp/indicator 5. EBD warning lamp Name Color Symbol Operating Condition ESP OFF switched ON ESP OFF indicator Amber ESP indicator (blinks) ESP operating Amber ESP warning lamp...
  • Page 980 07-8 1) ABS Warning Lamp ABS warning lamp module indicates the self diagnosis and malfunction. ABS warning lamp ON: When turning the ignition switch to ON position, ABS warning lamp comes on for 4 seconds for self-diagnosis and goes off if the system is OK (initialization mode). When the system is defective, the warning lamp comes on.
  • Page 981 07-9 4892-01 3) ESP OFF Indicator ESP OFF indicator ON: When turning the ignition switch to ON position, ESP warning lamp comes on for 4 seconds for self-diagnosis and goes off if the system is OK (initialization mode). When the ESP OFF switch is pressed to turn off ESP function, ESP OFF indicator comes on. 4) ESP OFF Switch If ESP OFF switch is pressed, ESP function is deactivated and the ESP OFF indicator in the instrument cluster comes on.
  • Page 982 07-10 4. PRECAUTIONS 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 second. The ESP system is only a supplementary device for comfortable driving.
  • Page 983 07-11 4892-01 1. ESP (Electronic Stability Program) 1) Overview As the single-track vehicle model used for the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup. The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions.
  • Page 984 07-12 2) Location of Components and Layout Meter Cluster ESP OFF indicator ESP warning lamp/indicator ABS warning lamp Parking brake warning lamp HDC indicator * EBD warning lamp: 3 + ABS/ESP HECU Sensor Cluster Brake Oil Pressure Sensor Brake Master Cylinder (ESP (ESP only) (ESP only) only)
  • Page 985 07-13 4892-01 Steering Wheel Angle Sensor (ESP only) ESP OFF/HDC Switch (ESP only) ESP OFF Switch HDC Switch Brake Booster Assembly Front Wheel Speed Sensor Rear Wheel Speed Sensor (4WD) (4WD)
  • Page 986 07-14 3) Operation of ESP System (1) Under steering ▶ What is understeering? Understeer is a term for a condition in which the steering wheel is steered to a certain angle during driving and the front tires slip toward the reverse direction of the desired direction. Generally, vehicles are designed to have understeer.
  • Page 987 07-15 4892-01 (2) Over steering ▶ What is oversteering? Oversteer is a term of a condition in which the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction. Compared to understeering vehicles, it is hard to control the vehicle during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases.
  • Page 988 07-16 (3) ESP Operation The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer, understeer or cornering.
  • Page 989 07-17 4892-01 (4) ESP controls during understeer The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeer with the yaw rate sensor and lateral sensor. Then, the ESP system applies the braking force to the rear inner wheel to compensate the yaw moment value.
  • Page 990 07-18 4) Input and Output Diagram of ESP unit...
  • Page 991 07-19 4892-01 5) Hydraulic Diagram of ESP When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4- sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4- channel method. (When controlling ABS system only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit.
  • Page 992 07-20 (1) ESP Hydraulic Unit in Idling and Bormal Braking Position In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel via the separation valve and inlet valve.
  • Page 993 07-21 4892-01 (2) When applied ESP (decreased pressure) The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
  • Page 994 07-22 (3) When applied ESP (maintained pressure) The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more.
  • Page 995 07-23 4892-01 (4) When applied ESP (increased pressure) 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.
  • Page 996 07-24 2. HBA (Hydraulic Brake Assist System) 1) Operation The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emergency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves .
  • Page 997 07-25 4892-01 2) Purpose HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster.
  • Page 998 07-26 3) Hydraulic Diagram of HBA The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels.
  • Page 999 07-27 4892-01 3. ARP (Active Roll-Over Protection) 1) Overview The ARP (Active Roll-over Protection) system is a safety assistant device that minimizes, by controlling brakes and the engine, the physical tendency of the vehicle rollover during sharp lane changes or U-turns. For the system, software is added to the existing ESP system and no additional device or switch is needed.
  • Page 1000 07-28 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. The ARP function is still available even when turning off the ESP system by ESP OFF switch.
  • Page 1001 07-29 4892-01 4. HDC (HILL DESCENT CONTROL) 1) System Overview The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about 7 km/h by 0.1G, on steep roads (slope level exceeding 10%) through a separately installed switch operation.
  • Page 1002 07-30 3) Operating Description (1) HDC (Hill Descent Control) System Operating Conditions HDC is operable only when the conditions below are met: When HDC switch is turned ON Gearshift lever position (Forward/Reverse) Automatic transmission: operates in any position except for P (parking) or N (neutral) positions. When not depressing the accelerator pedal or brake pedal.
  • Page 1003 07-31 4892-01 The percentage for gradient as below: tanθ x 100 = Gradient (%) tan θ X 100 = X 100 = 10 (%) * 1G = 9.8 m/s : acceleration In other words, the gradient of 10% means that a road has 10 m of width and 1 m of altitude from level ground.
  • Page 1004 07-32 (3) Input/Output Signals for HDC Operation Automatic transmission: Selector lever Engine torque Gas pedal module (monitoring gas pedal depression) When depressing accelerator pedal during HDC operation, it is When the HDC operates, deactivated(regardless of the HECU turns on the stop lamp slope level).
  • Page 1005 07-33 4892-01 (4) Operation of HDC Indicator Controller This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp).
  • Page 1006 07-34 (5) Warnings for HDC Operation HDC system is a supplemental system for brake system. The operating conditions should be kept. The operating noise is much different from that from ABS/ESP system. Make sure to remember the warning conditions below: The HDC system has been developed to enhance the driving safety on steep downhill.
  • Page 1007 07-35 4892-01 5. CIRCUIT DIAGRAM ▶ Wheel speed sensor, Stop lamp switch, Self-diagnosis connector, Warning lamps (ABS/ESP)
  • Page 1008 07-36 ▶ Brake pressure sensor, Steering wheel angle sensor, Sensor cluster, ESP OFF switch...
  • Page 1009 08-3 4610-00 1. SPECIFICATIONS Description Specification 항 목 사 양 Type 4-spoke type 형식 4 스포크 타입 Steering wheel 스티어링 휠 Outer diameter (mm) 외경 (mm) Type Rack and pinion type 형식 랙 및 피니언 Steering gear box 38.2° Inner Steering angle 스티어링...

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