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SSANGYONG Rexton Y290 2012 Manual

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Summary of Contents for SSANGYONG Rexton Y290 2012

Page 1 0000-00...
Page 2 2) Preheat System...
Page 3: Fuel System
0000-00 3) Fuel System...
Page 4 Fuel Supply System...
Page 5: Lubrication System
0000-00 4) Lubrication System...
Page 6 5) Cooling System...
Page 7: Intake System
0000-00 6) Intake System...
Page 8: Exhaust System
7) Exhaust System...
Page 9 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 10 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 11 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. Oil filler cap 32.
Page 12 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. Drain plug 41.
Page 13: Specifications
1212-01 2. SPECIFICATIONS...
Page 14: Engine Performance Curve
3. ENGINE PERFORMANCE CURVE...
Page 15 1212-01...
Page 16 4. TIGHTENING TORQUE...
Page 17 1212-01...
Page 19 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 20: Common Rail
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 21 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 according to the increased amount of fuel injection. Also, the engine ECU, HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely.
Page 22 2. COMPONENTS OF FUEL SYSTEM...
Page 23 1881-09 Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System...
Page 24: Intake System Layout
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 25 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 26 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 27 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 Under air cleaner in righ side of engine compartment As the soot is filtered in the CDPF, the pressure between the front side and the rear side of the...
Page 28 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 29 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 30 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 31 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 32 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 33 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 34 2412-02 Front temperature sensor (Measuring the temperature of Rear temperature sensor (Measuring the temperature of exhaust gas exhaust gas passed through exhaust manifold) passed through DOC) 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 35 2) Fuel Injection During CDPF Regeneration 3) Warning Lamp Related To CDPF 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 36 2412-02 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 37 4. COMPONENTS OF CDPF SYSTEM Differential Pressure Sensor Engine compartment (RH) Front Exhaust Gas Throttle Body Temperature Sensor Front exhaust gas temperature sensor...
Page 39 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 40 Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine...
Page 43: System Description
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 44 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 45 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 46 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 47: Operation
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 48 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. (2) When the cruise control system is not running To increase the speed with the cruise control system while the system is not running, follow the procedures below.
Page 49 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 50 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 51 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 52 (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 53: Component Locator
1. COMPONENT LOCATOR 1) Front View...
Page 54 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 Oil pan...
Page 55: Side View
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 56: Description And Operation
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 57 1113-01 1. SPECIFICATIONS 1) Engine Specifications...
Page 58: Performance Curve
2) Performance Curve...
Page 59: Special Tools And Equipment
1113-01 2. SPECIAL TOOLS AND EQUIPMENT...
Page 61 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin...
Page 62: Fastener Tightening Specifications
3. FASTENER TIGHTENING SPECIFICATIONS...
Page 63 1113-01 1) Fastener Tightening Specifications (Cont'd)
Page 64: Fuel System Specification
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. Do Not Use Methanol Fuels containing methanol (wood alcohol) should not be used in vehicle.
Page 65 Temperature vs resistance...
Page 67 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 68 4. FASTENER TIGHTENING SPECIFICATIONS...
Page 69: Oil Circulation
9210-01 1. OIL CIRCULATION...
Page 70 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) Oil gallery...
Page 71: General Specifications
2110-01 1. GENERAL SPECIFICATIONS...
Page 72: Special Tools And Equipment
2. SPECIAL TOOLS AND EQUIPMENT...
Page 73 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS...
Page 74: General Description
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 75 2110-01 2. COMPONENT LOCATOR...
Page 76 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 77 1452-01 1. GENERAL SPECIFICATIONS...
Page 78 2. FASTENER TIGHTENING SPECIFICATIONS...
Page 79: Charging System Operation
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: Size of Battery...
Page 80: Ignition System Operation
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 81 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT...
Page 82: Engine Data Display Table
1522-16 1. ENGINE DATA DISPLAY TABLE...
Page 83 1) Temperature vs Resistance 2. FASTENER TIGHTENING SPECIFICATIONS...
Page 84: System Description
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 85 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 86 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 87 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 88: Operation
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 89 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. (2) When the cruise control system is not running To increase the speed with the cruise control system while the system is not running, follow the procedures below.
Page 90 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 91 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 92 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 93 (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 94 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 95 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 96: Major Changes
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 97: Specifications
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) Operating temperature Should operate normally within this range. Reserved temperature Max.
Page 98: Rated Load
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 99: Input Signals
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) OPEN=GND, CLOSE=OPEN OPEN=GND, CLOSE=OPEN - OPEN (one of rear seat)=GND Rear door switch - CLOSE (all rear seats)=OPEN Tailgate switch OPEN=GND, CLOSE=OPEN...
Page 100 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 101 8710-08 2. MAJOR CHANGES REKES Key Front Front Back Back Changed the appearance of mechanical key and the company symbol...
Page 102 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 103 8710-08 2. LOCATION ICM Relay Box STICS Chime...
Page 104: Operation
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 105 8710-08 Front auto washer switch When pressing this switch with the front wiper switch 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 106 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 107 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 108 System Diagram Operating MIST switch for 0.1 to 0.59 second Operating MIST switch for more than 0.59 second...
Page 109 8710-08 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. Then, the wiper relay output gets OFF after 3 cycles.
Page 110 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 111 8710-08 System Diagram...
Page 112 RKSTICS with rain sensing function has the system layout as shown in the figure below. System layout...
Page 113 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 114 System Diagram AUTO Mode Switch ON Ignition Switch ON...
Page 115 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 116 System Diagram IGN ON & AUTO Mode Switch ON...
Page 117 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 118 IGN ON & AUTO Mode Switch ON IGN ON, AUTO Mode Switch ON, Wiper Motor Parked...
Page 119 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 120 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 121 8710-08 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" position and the AUTO switch is in "ON" position). System Diagram IGN ON, AUTO Mode Switch ON, Rain Sensor Defective Signal Received...
Page 122 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 123 8710-08 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 124 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 125 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 126 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 127 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 128: Ignition Key Reminder
(2) Ignition Key Reminder sounds (0.02 s ON and 1.38 s OFF). buzzer stops its operation. This function is not available when the ignition switch (IGN1) is in "ON" position. Chime Ignition Key Reminder The system outputs "UNLOCK" signal for 5 seconds after the driver's door is opened and the door lock switch is changed to "LOCK"...
Page 129 8710-08 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). When the door is closed during the UNLOCK output, the UNLOCK output stops immediately. When the ignition key is inserted during the UNLOCK output, the output continues for approx.
Page 130 (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 131 8710-08 System Diagram Tail Lamp Relay ON...
Page 132 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 133 8710-08 System Diagram...
Page 134 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 135 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 136 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 137 8710-08 System Diagram...
Page 138 (4) Lamp Control Function Front Room Lamp 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. The front room lamp goes out immediately after turning the ignition ON during the dimming period.
Page 139 8710-08 System Diagram Front Room Lamp on when pressing appropriate lamp switch (1, 2) in. The front Center Room Lamp The center room lamp comes on when opening a rear door with...
Page 140 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 141 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 142 System Diagram...
Page 143 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 outside rearview mirror heated glass is turned...
Page 144 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 145 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 146 (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 147 8710-08 System Diagram Driver's door lock/unlock switch Passenger's door lock/unlock 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 148 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 149 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 150 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 151 8710-08 System Diagram Power OFF, ACC ON, IGN ON...
Page 152 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 153 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 154: Time Lag Power Window Control
(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 155 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 156 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 157: Theft Deterrent
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 158 System Diagram Ignition Key Removed, Door Closed...
Page 159 8710-08 Disarming Conditions The theft deterrent mode is disarmed when unlocking the doors with unlock button on REKES key or deterrent mode is disarmed, the hazard warning flashers blink once. The doors can be unlocked by using a mechanical key in theft deterrent mode. However, the siren sounds and hazard warning flashers blink for 27 seconds.
Page 160 After Alarm Period The siren and hazard warning flashers will be turned off. System Diagram Alarm Stop Conditions are Met...
Page 161 8710-08 Operations when removing and installing the battery Installed Normal Armed Warning Remark Removed Normal Armed Ready Armed Warning Warning Completion RELOCK Ready 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 162 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 163 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 Lock (briefly press) Unlock (briefly press) If the Lock button is briefly pressed (0.1~0.5...
Page 164 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 165 8710-08 System Diagram...
Page 166 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. The hazard warning lamps blink once only when all the doors unlocked.
Page 167 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 168: Circuit Diagram
4. CIRCUIT DIAGRAM Power/Ground, Diagnostic, Chime, Buzzer, Warning lamps (Brake, Seat belt, Door ajar)
Page 169 8710-08 Central Door Locking...
Page 170 Tail Lamp, Hazard Warning Flasher, Power Window...
Page 171 8710-08 Defogger...
Page 172 Panic, Auto Light/Rain Sensing, Room Lamp...
Page 173 8710-08 FRT Wiper/Washer...
Page 174: Operating Condition
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 175: Diagnostic Connector
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 176 5) Coding Procedure The REKES key should be coded (up to 5 keys) by the scan tool when replacing it with new one. button on the REKES key for more than 2 seconds.
Page 177 8710-08 second key coding. The screen below will be displayed after completion of second key coding. Press Exit from the diagnosis program and disconnect the scan tool from the diagnostic connector. Make sure that the buttons on the REKES key operate properly. When coding new REKES key: When one of REKES keys is lost and a new REKES is purchased, all REKES keys should be coded.
Page 178 7010-09 1. SPECIFICATIONS (D20DTR) Unit Description Specification Coil inductance Coil turns Coil wire Rich wire (TBD) Immobilizer control unit Modulation Input/Output frequency Antenna cable Twisted rich wire (TBD) Frequency Transponder Operating temperature...
Page 179: Major Changes
2. MAJOR CHANGES Blanking Key - Changed the material of key fob. - Changed the key plate design.
Page 180 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 181 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 182: System Diagram
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 183 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 184 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 185 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. The immobilizer unit transmits the encrypted code to the transponder.
Page 186 7010-09 This indicator comes on when the ignition key is Immobilizer and Warning Lamp 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 The immobilizer indicator does not come on...
Page 187: Circuit Diagram
4. CIRCUIT DIAGRAM D20DTR...
Page 188 7010-09 D27DT/D27DTP...
Page 189 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 190: Specifications
7410-32 1. SPECIFICATIONS 1) Driver's Power Seat Inputs Specification Type Reed switch type ON:OFF ratio Contact current Max. 0.5 A Chattering Max. 0.2 msec Stroke Sliding Reclining Lift (FRT/RR) Position sensor Total number of Sliding 1,200 Pulse pulses Lift (FRT/RR) 46.93 Pulse Operation speed Sliding...
Page 191: Outside Rearview Mirror
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 192 7410-32 Position Sensor and Folding Switch Inputs Specification Type Variabel resistance Rated voltage DC 5V Position sensor Output tolerance Supply current Max 20 mA, 0.25W Operation range Type Self-return type (active high) Folding switch Contact current Min 10mA Chattering Max 10 msec Type Self-return type (Active low) Manual switch...
Page 193 4) Buzzer Output Specification Rated voltage DC 12V Rated current Max 30 mA Buzzer Acoustic pressure MIN 92 dB Base frequency 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 (memory switch ON): once After completing the memory recall (position...
Page 194: Major Changes
7410-32 2. MAJOR CHANGES Changed the memory recall logic Changed logic outside rearview mirror.
Page 195: Switch Operation
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 position: not operative)
Page 196 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 197 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" position to any other positions while setting the memory When driving the vehicle (at speed over 1 km/h) When the memory setting procedure is completed, the memory setting procedure is automatically...
Page 198 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 199 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 200: Easy Access Function
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 201 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 202 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 203 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. 2.
Page 204: Circuit Diagram
3. CIRCUIT DIAGRAM Front variable seat warmer (Seat/outside mirror memory)
Page 205 8611-31 Front variable seat warmer (Seat/outside mirror non-memory)
Page 206 Rear seat warmer...
Page 207: Specifications
8010-01 1. SPECIFICATIONS 1) Power, Voltage, Current Description Specification Rated voltage DC 12V Operating voltage DC 9V ~ 16V Inspection voltage DC 13.5V Operating temperature Storage temperature Performance reserve DC 10V ~ 15V temperature Dark current below 3 mA at stable status (stand-by mode) after 180 seconds from IGN OFF 2) Illumination Level (1) Black-Face Model...
Page 208 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 (TOD, P/TIME)
Page 209: System Layout
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 210: Warning Lamps And Indicators
3. WARNING LAMPS AND INDICATORS 1) Black-Face Type...
Page 211 8010-01 Trip switch...
Page 212 2) Clear Type...
Page 213 8010-01...
Page 214 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. Light indicator Green This indicator comes on when the tail lamp or headlamp is switched on.
Page 215 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 216 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. and should go off in a few seconds. ESP OFF indicator Yellow This warning lamp comes on when the ignition switch is turned to This indicator comes on when pressing the ESP OFF switch to deactivate the ESP function.
Page 217 8010-01 Brake warning lamp This warning lamp comes on when the ignition switch is turned to This warning lamp comes on when the parking brake is applied and/or the brake fluid level is lower than a specified level. If the ABS warning lamp and the brake warning lamp come on simultaneously, EBD system is defective.
Page 218 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 219 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 This indicator comes on when the TPMS is defective. This indicator comes on when the global warning lamps comes on (blinks for 70 seconds, 0.4s ON/OFF) Tire inflation pressure indicator Green/Yellow...
Page 220 4WD LOW indicator (TOD, P/TIME) Yellow shifting operation is completed. After completion of the mode change to 4L, the indicator comes on. 4WD HIGH indicator (P/TIME) Green until the shifting operation is completed. After completion of the mode change to 4H, the indicator comes on. 4WD CHECK warning lamp (TOD, P/TIME) warning lamp stays on, 4WD system is defective.
Page 221: Display Sequence
8010-01 3) Display Sequence...
Page 222 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 223: System Analysis
8010-01 5) System Analysis...
Page 225 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 226 7) Buzzer Specifications Function Signal Operating temperature Storage temperature Sound pressure level 70dB/min (2kHz, square wave, 10cm) Output Buzzer Priority Description Remark ON_TIME OFF_TIME 160ms Buzzer output (R position) Non-PAS (outputs 610ms after ON_TIME OFF_TIME Over-speed 500ms 200ms warning 100ms 100ms High temp.
Page 227 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 228 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 229: Esp Warning Lamp
8010-01 9) ESP Warning Lamp ESP Warning Lamp Blinking in Control 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 230 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 231 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 TPMS Warning Lamp This warning lamp comes on for 15 seconds (initially) or 10 seconds (resumed from tire pressure indication, alarm or warning condition) when the tire pressure in each wheel is in the specified value.
Page 232 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 233 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 234: Self-Diagnosis
5. SELF DIAGNOSIS Activation: 1. Turn the ignition ON with the TRIP switch pressed. 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 235: Multi-Function Switch
8511-29 1. SPECIFICATIONS 1) Multi-Function Switch Description Specifications Multifunction Rated voltage DC 12V switch 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) Turn signal light switch Wiper switch...
Page 236: Major Changes
2. MAJOR CHANGES Center Switch Cluster Changed to independent switch type from integrated switch type Hazard Switch Changed the design of hazard switch...
Page 238 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 239 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 switch...
Page 240 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 Turn signal lamp...
Page 241 2. SPECIFICATIONS OF AUTO LIGHT Description Specification Operating voltage 9V ~ 16V Load Maximum 200 mA (relay load) Operating temperature Operating temperature Location Top center of inner side of windshield glass In vehicle for EU market, the auto light function is not available. The LED stands for "Light Emitting Diode"...
Page 242 8310-00 3. MAJOR CHANGES 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 243 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 244 8310-00 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 245: Exterior Lamps
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 Outside Turn Signal Lamp Outside turn signal...
Page 246 8310-00 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 247 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 Low beam High beam Tail lamp...
Page 248 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 249 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 250: Auto Light
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 251: License Plate Lamp
(4) License Plate Lamp The license plate lamp comes on when the light switch is turned on (Tail, AUTO, Low, High).
Page 252 8310-00...
Page 254: Front Fog Lamp
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 Rear Fog Lamp (for EU) Rear fog lamp The rear fog lamp comes on when the rear...
Page 255: Turn Signal Lamp
(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 The turn signal lamp goes out when the steering wheel angle (same direction with turning direction)
Page 256 8310-00...
Page 257: Back-Up Lamp
(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 Back-up lamp...
Page 258 8310-00...
Page 259: Interior Lamps
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 Glove Box Lamp...
Page 260 8310-00 Door Courtesy Lamp One lamp in each door...
Page 261: Front Room Lamp
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. this switch. pressing this switch. 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.
Page 262 8310-00 (2) Center and Rear Room Lamp OFF position: The lamp does not come on. ON position: The lamp stays on. when the door is opened. The lamp goes out when closing the opened door. The center room lamp comes on when opening a rear door with the DOOR switch pressed in. The center room lamp comes on when opening a rear door.
Page 263: Glove Box Lamp
(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 264 8310-00 (7) Circuit Diagram of Room Lamp...
Page 265: Wiper Control
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 266: Major Changes
3. MAJOR CHANGES Windshield wiper blade Wiper blade design and wiper arm pressure Previous Current Wiper arm pressure: - Wiper blade design changed (blade size is same) Driver side: 20inch Passenger side: 20inch...
Page 267: Wiper And Washer System
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 268 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 269 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 270 3. SYSTEM LAYOUT (INCLUDING RAIN SENSOR) Wiper and washer switch Rain sensor unit Wiper Front wiper Rear wiper Wahser nozzle Front Rear...
Page 271 7810-00 STICS Windshield washer reservoir tank assembly Rear wiper (DPS) Wahser motor Front Rear...
Page 272 4. WIPER AND WASHER OPERATION 1) Windshield Wiper Control Function The wiper operates for 1 cycle when pushing up the lever. The lever will return to the "OFF" position when released. Stop the operation. Wiper speed controls automatically according to the vehicle speed or amount of rain (rain sensing wiper).
Page 273 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 274 (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 275 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 276 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 277 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 278 (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. When the AUTO washer switch is pressed on with IGN ON and INT/AUTO switch OFF, the washer The auto washer switch signal is overridden during washer coupled wiper operation.
Page 279 7810-00...
Page 280: Rear Wiper Switch
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 281 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 position and turn off the wiper and washer. Rear washer motor control The rear washer motor is operated only when the rear washer switch is activated with the ignition key ON.
Page 282 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 283 7810-00 (1) Rain sensor coupled wiper operation (LIN) System layout...
Page 284 (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 285 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 286 (4) Sensitivity control (instant wiping) 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 287 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 288 (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. When the wiper speed control switch is turned to step 3 from step 4, the wiper motor operates one cycle at low speed if STICS receives a faulty sensor signal (S_COMMFAULT) from rain sensor unit with IGN ON and INT/AUTO switch ON.
Page 289 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 290 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 291: System Layout And Overview
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 292 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 293 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 294 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 295: Auto Light Control
8611-09 3) Sensitivity Control (Instant Wiping) 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 296 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 297 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 298: Operation Mode Of Rain Sensing Wiper System
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 299: Specification
8790-04 1. SPECIFICATION Description Specification Rated voltage DC 13.5V (IGN voltage) Operating voltage DC 9.0V ~ 16.0V Operating temperature Storage temperature Maximum humidity Maximum resistance voltage Insulating resistance No heat & fire due to current leak Max. permissible current Unit: 200mA or less (DC 13.5V) Sensor: 30mA (DC 13.5V) 2.
Page 300: Major Changes
3. MAJOR CHANGES PAS sensor holding type Number of Rear PAS sensors Left Center (LH) Center (RH) Right Left Center Right PAS Unit...
Page 302 1. OVERVIEW 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. 2.
Page 303 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 304: Operating Process
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 305 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 30~40cm Stays ON 50~80cm...
Page 306 (2) Vertical Detection Range Front Rear 0~Bottom of bumper (Range From bottom of bumper Height (Range C) Detection No detectable Detection area Tolerance (3) Horizontal Detection Range...
Page 307 8790-04 2) Function Operating conditions IGN ON Operations position. The front PAS ON/OFF switch turns on and off the front PAS sensors. The front PAS sensors are turned off when the vehicle speed exceeds 15km/h. (1) Self-Diagnosis (Buzzer indication) Starts the self-diagnosis mode when turning the ignition on Fail conditions of self-diagnosis a.
Page 308 Rear PAS system...
Page 309: Operation Mode
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 310 Operation of self-diagnosis If the vehicle speed exceeds 15km/h, the front sensors are turned off. If it goes below 10km/h, the When turning on the ignition, the self-diagnosis is performed, but no buzzer output.
Page 311: Circuit Diagram
8790-04 5. CIRCUIT DIAGRAM...
Page 312: Flow Chart
6. FLOW CHART Front + Rear PAS System...
Page 313 8790-04 Rear PAS System...
Page 314: Specification
8910-05 1. SPECIFICATION Unit Description Specification Voltage DC 14.4V Audio Operating voltage DC 10.8V~16.0V Output 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 America...
Page 315 Unit Description Specification Micro pole antenna Audio Operating current max. 150mA Operating voltage DC 10.5V ~ 16V Operating temperature Storage temperature Input/Output impedance...
Page 316: Major Changes
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 317 1. LAYOUT Audio Radio USB/AUX Bluetooth hands-free Audio Remote Control Switches Front Door Front Door Speaker Audio Assembly Tweeter Speaker...
Page 318 8910-05 Micro Pole Antenna USB/AUX Hands-free Rear Door Speaker Microphone...
Page 319 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 SCAN/INFO button BAND/AS button SETTING button Display window (LCD) RDS setup Disc Play button Disc Eject button Disc slot...
Page 320: Specifications
8510-00 1. SPECIFICATIONS Unit Description Specification Rated voltage Current consumption MAX 3.5A Frequency Horn HIGH Sound level Operating voltage 12V~15V Rated voltage Maximum operating current Cigarette lighter Isolated resistance Return time Rated voltage Power outlet Maximum operating current Isolated resistance Rated voltage Operating voltage 8V~ 16V...
Page 321 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 322 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 323 2) Exterior Electric Accessories Siren (Theft Deterrent Alarm) RH Horn (Low) LH Horn (High)
Page 324: Operating Process
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 325 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 326: Digital Clock
8510-00 3) Digital Clock (1) Adjustment Hour button SET button Minute button How to change the time on digital clock 12-hour, press this button for more than 3 seconds. if this button is pressed. and one hour will be added to the hour indicator if this button is pressed. 4) Siren (Theft Deterrent Alarm) (1) Operating Condition This horn sounds once when the vehicle is...
Page 327: General Information
1. GENERAL INFORMATION Automatic transaxle (DSI M78) Tip switch on steering wheel Shift down Shift up 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 toruqe converter with an integral...
Page 328 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 Gear Shift) The shiftable gear can be adjusted by moving this switch to forward and Mode Switch...
Page 329: Features And Specifications
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 Capacity Approx. 9.5 L Transmission fluid Change interval Check the fluid at every 30,000 km or 1 year, and change it if necessary.
Page 330 3650-01 2) Appearance 4WD Automatic Transmission Oil cooler return Torque converter Oil cooler outlet Servo Adapter housing Inhibiter switch 2WD Automatic Transmission...
Page 331 3) Sectional Diagram...
Page 332: Shift Pattern Diagram
3650-01 4) Shift Pattern Diagram Vehicle speed(Km/h) Output shaft speed(rpm)
Page 333: Tightening Torque
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 334 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 335 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 336: Cooling System
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. 3) Shift Strategy Gear Shift Transmission gear change is controlled by the TCU.
Page 337: Mode Descriptions
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 338: Kickdown Function
3650-01 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. When maximum engine rpm is reached the transmission will upshift automatically regardless of the driver selected limit.
Page 339: Limp Home Mode
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 340: Electronic Control System
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 341 3) Transmission Control Monitoring System TCU monitors all input and output signals to identify possible failures. If a fault is detected, TCU Monitoring the Supply Voltage If the battery voltage is too high or too low, the TCU sets the DTC. Monitoring the Supply Voltage to Solenoid TCU monitors the circuits for open or short to ground or supply.
Page 342 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 343 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. Low Range Driving Mode When the vehicle is in 4L driving mode, the transmission uses a different shift mode to optimize the low range driving.
Page 344: Can Network
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 345: Power Flow
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 346 3650-01 Hydraulic Circuit Diagram...
Page 347 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 348 3650-01 1st Gear (M) (3.53:1)
Page 349 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 Connecting Components...
Page 350 3650-01 1st Gear (D) (3.53:1)
Page 351 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 352 3650-01 2nd Gear (D) (2.14:1)
Page 353 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 354 3650-01 2nd Gear (D) Lock-Up...
Page 355 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 356 3650-01 3rd Gear (D) (1.48:1)
Page 357 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 Control S1 and S2 ON C1 shift valve open (S1 OFF), C1 clutch engaged by drive oil...
Page 358 3650-01 4th gear (D) & 4th gear (D) in Limp home mode (1.16:1)
Page 359 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 Connecting Components...
Page 360 3650-01 5th gear (D) (0.87:1)
Page 361 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 Connecting Components...
Page 362 3650-01 6th gear (D) (0.68:1)
Page 363 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 Connecting Components...
Page 364 3650-01 Reverse gear (R) (3.09:1)
Page 365 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 366 3650-01 Reverse (R) Limp Home Mode...
Page 367 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 368 3650-01 Park...
Page 369 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 370 3650-01 Neutral...
Page 371: Specifications
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 372 Item W5A580(2WD)/W5A400(4WD) M/P, S/P solenoid Resistance Operating distance 0.6mm Operating current 0 ~ 1A Lockup solenoid Resistance Operating distance 0.2mm Operating current 1.5 ~ 2.0A Operating range 3rd to 5th gears RPM sensor Resistance HALL type Operating voltae Start lockout switch Switch contact ON(D position) Switch contact...
Page 373: Tightening Torque
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 36 ~ 44...
Page 374: Major Changes
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 375 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 DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the torque converter.
Page 377: Power Flow
3650-01 2. POWER FLOW 1) Power Flow B1 C1 C2 B3 C3 B2 1) Selector program switch: "S" mode 2) Selector program switch: "W" mode 3) Overrun...
Page 378 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 Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced...
Page 379 3650-01 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 Center ring gear: Clockwise rotation...
Page 380 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 Output shaft: Clockwise rotation...
Page 381 3650-01 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) Center ring gear: Clockwise rotation by C3 activation...
Page 382 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 Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation...
Page 383 3650-01 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 Front sun gear: Locked by one-way clutch F1 Front planetary gear carrier: Clockwise rotation (reduced speed)
Page 384 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) Rear ring gear: Clockwise rotation Rear planetary gear carrier and center ring gear: Locked by brake B3...
Page 385: Circuit Diagram
3650-01 3. CIRCUIT DIAGRAM...
Page 387: Specification
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 388: Special Service Tools
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 389 3170-01 Part No. & Name Appearance Description Part No.: SSM00203- Install the counter shaft front roller bearing Name: Counter shaft bearing installer Support the counter shaft when removing the Part No.: roller bearing with a puller T88310011A-9 Name: Bearing support...
Page 390: Tightening Torque
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 391 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 Gasket Spring - Guide...
Page 392 3162-00 Main shaft...
Page 393 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 394 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 Gear - Counter shaft...
Page 395 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 396 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 & 2nd Pin - Spring Bushing Lever assembly - Shaft 5th &...
Page 397 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 398 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 399: Gear Ratio
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 400: Power Flow
2. POWER FLOW 1st speed 2nd speed...
Page 401 3170-01 3rd speed 4th speed...
Page 402 5th speed 6th speed...
Page 403 3170-01 Reverse gear...
Page 404: Shifting Mechanism
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 405: General Specifications
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 2.475...
Page 406 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 407: System Components
3170-01 2. SYSTEM COMPONENTS 1) Gear Combinations 2) Shift Fork and Rail Combinations...
Page 408: Sectional View
3) Sectional View...
Page 409 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 410 IDI Engine equipped vehicle - 4WD...
Page 411 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 412 IDI Engine equipped vehicle - 2WD...
Page 413 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 414: Front View And Rear View
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 415 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 TGS bushing...
Page 416: Power Flows
6) Power Flows 1st gear Counter shaft 2nd gear...
Page 417 3170-01 7) Power Flows (Cont'd) 3rd gear 4th gear...
Page 418 8) Power Flows (Cont'd) 5th gear Reverse gear...
Page 419: Interlock System
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 420 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 421: Backup Lamp Switch
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 422 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 423 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 424 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 425 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 426 1. Oil filler plug 2. Air vent Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm...
Page 427: Circuit Diagram (Backup Lamp)
3170-01 4. CIRCUIT DIAGRAM (BACKUP LAMP)
Page 428 4120-01 1. SPECIFICATIONS 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 1.4L...
Page 429 4122-01 1. SPECIAL TOOLS AND EQUIPMENT...
Page 430 3260-01 1. SPECIFICATIONS...
Page 431 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 432 3260-01 2. LOCATION Distribution of Driving Force in AWD...
Page 433 3. STRUCTURE 1) Sectional View...
Page 434: Exploded View
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 435: Power Flow
4. POWER FLOW Distribution of Front Output Torque Distribution of Rear Output Torque...
Page 436 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 437 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 438 3240-01 1. SPECIFICATIONS...
Page 439 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 440 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 441: 4Wd Operation Overview
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 442 3240-01 2. POWER FLOW System Layout Instrument Panel 4WD Switch Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output...
Page 443: Mode Selection
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 444 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. Releasing the 4L Mode When selecting 4H mode, 4L drive mode is released and 4H mode is resumed.
Page 445 4H Mode (4WD Drive - High Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel)
Page 446 3240-01 4L Mode (4WD Drive - Low Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel)
Page 447: Circuit Diagram
3. CIRCUIT DIAGRAM...
Page 448 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 M/T: inner spline...
Page 449 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 450 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 451 2. LAYOUT Front axle Front locking hub system (IWE) Front propeller shaft Part-time transfer case Rear propeller shaft Rear axle...
Page 452: System Layout
3240-01 3. SYSTEM LAYOUT...
Page 453 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 454 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 455 5. POWER FLOW 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 456 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 457 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 458 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 459: Specification
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) Front propeller shaft length * outer diameter (mm) (at compressed condition) Rear propeller shaft length *...
Page 460 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 461: Wheel Alignment
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 462: Layout And Components
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 463 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 464 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 466 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 467 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 Shock absorber upper bolt/nut...
Page 468: Troubleshooting
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 469 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 470 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 471 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 472 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 473 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. Toe-in When viewed from the top, the distance between the tire centers is smaller in the front than in the rear.
Page 474 2) Camber The angle between the center line of the tire and the vertical line when viewed from the front of the vehicle Camber Positive camber: Top of the tire is tilted outward The axle is not bent when it is loaded. Advantages: The force required to operate the steering wheel is reduced due to smaller contact area (or load area) of the tire.
Page 475 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. Caster Caster: With considering the height difference between the wheel centers of the front and...
Page 477: Specification
4850-01 1. SPECIFICATION Unit Description Specification Front brake Type Ventilated disc Outer diameter of disc Inner diameter of caliper cylinder Thickness of disc 28 mm (wear limit: 25.4 mm) Area of brake pad Pad wear indicator Mechanical type Rear brake Type Solid disc (5-Link)
Page 478 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 Replace...
Page 479 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 480 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 481 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 482: Air Bleeding
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 483 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 484 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 485 4850-01 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 Plunger specified value, adjust the length. rod lock nut 179 mm Specified value (A)
Page 486 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). 3 ~ 8 mm Specified value (A) If the free play is below the specified value,...
Page 487 4850-01 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 488 Color 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%. It will cause the vapor lock frequently.
Page 489 4850-01 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. Disc Thickness Measure the disc thickness at over ten points.
Page 490 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 491 4850-01 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. If any of measured points is below the wear limit, replace the brake disc with new one.
Page 492 Check the brake force with below procedures: Count the number of the clicks (notches) when pulling up the parking brake with 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 493 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 494 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 496: System Layout
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 497 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 498: Sectional Diagram
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 499 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 500: Hydraulic Circuit
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 501 4850-01 5. CIRCUIT DIAGRAM OF STOP LAMP...
Page 502 4892-01 1. SPECIFICATIONS Specification Description Remark HECU Clock frequency: 28 MHz CPU: MCU60 (32bit) Memory: 128~256 kb Switch orifice Active type Output: 7~14 mA Wheel speed sensor None Steering wheel angle sensor Sensor cluster None Longitudinal G sensor 4WD only (integrated in ABS HECU) Pressure sensor None 1) Specifications of Active Wheel Speed Sensor...
Page 503: System Overview
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 505: Components And Layout
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 506 4892-01 HECU (Hydraulic & Electronic Control Unit) Diagnostic Connector Rear Active Wheel Speed Sensor It is installed on the rear axle.
Page 507 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 508: Abs Warning Lamp
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 509: System Operation
5. SYSTEM OPERATION 1) Block Diagram of ABS HECU...
Page 510 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 511 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 512 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 513 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 514 4892-01 4) ABS Control Pattern 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 515: Hydraulic Circuit Diagram
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 516 4892-01 7. HYDRAULIC CIRCUIT DIAGRAM IN EACH OPERATION 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. The speed of the wheel that hydraulic pressure is delivered reduces gradually . As hydraulic pressure on each wheel increases, the wheel tends to lock.
Page 517 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. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is opened.
Page 518 4892-01 8. ELECRTRIC CIRCUIT DIAGRAM...
Page 519: Specification
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 520 2) Specification of Steering Wheel Angle Sensor Description Specification Remark Operating voltage 9 to 16 V Maximum output current 10mA Maximum detection angle speed Operating temperature Supplying voltage 9 to 16 V (battery voltage) Output voltage (HI) approx. 3.50 V (3.0 to 4.1 V) Output voltage (LO) approx.
Page 521: Terms And Acronyms
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 522: Operation Of Components
3) Components Component ABS/EBD HECU Front wheel speed sensor Available Available Rear wheel speed sensor ABS warning lamp EBD indicator G-sensor 2WD: Not available, Not available 4WD: Available Sensor cluster (Yaw-rate sensor, Lateral/Longitudinal G sensor) Not available Available ESP warning lamp & indicator ESP OFF switch and indicator Steering wheel angle sensor 4) Operation of Components...
Page 523 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 524 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 525 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 526 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 527 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 528 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 529 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 530 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 531 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 532 (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 533 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 534 4) Input and Output Diagram of ESP unit...
Page 535 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 536 (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 537 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 538 (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 539 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 540: Operation
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 541 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 542 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 543 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 544 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 545 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 546: Operating Description
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 547 4892-01 The percentage for gradient as below: * 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. (2) HDC (Hill Descent Control) System Non-Operation Conditions The HDC stops its operation when any of conditions below occurs: When HDC switch is turned OFF Gearshift lever has passed neutral (N) position.
Page 548 (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 549 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 550 (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. Therefore, avoid using the HDC system on level roads.
Page 551: Circuit Diagram
4892-01 5. CIRCUIT DIAGRAM (ABS/ESP)
Page 552 ESP OFF switch...
Page 553: Specifications
4610-00 1. SPECIFICATIONS Description Specification Type 4-spoke type Steering wheel Outer diameter (mm) (mm) Type Rack and pinion type Steering gear box Inner Steering angle Outer Type Vane type Maximum pressure (kgf/cm2) Oil pump Pulley size (mm) Operating temperature Tilting angle Down Minimum turning radius...
Page 554 2. TIGHTENING TORQUE Description Steering column Steering column mounting bolt (upper) 19.6 ~ 24.5 shaft Steering column mounting bolt (lower) 17.6 ~ 24.5 Steering wheel and steering column shaft 39.2 ~ 59.8 lock nut Steering column and lower shaft connection 24.5 ~ 29.4 bolt.
Page 555: Special Service Tools
4610-00 3. SPECIAL SERVICE TOOLS Part Number & Name Description Removing the steering wheel 661 589 00 33 00 (L 99 46 001 0A) Steering wheel puller Removing the upper and lower end from front 661 589 13 33 00 suspension (W 99 44 002 0A) Ball joint puller...
Page 556 4. TROUBLESHOOTING Problem Possible Cause Action Movements of steering Unregular wear or binding of steering ball Lubricate or replace feels heavy joint due to lack of lubrication or foreign material insertion Damaged or defective steering gear Replace the steering gear assembly Incorrect steering pinion preload Adjust Defective steering shaft join...
Page 557 4610-00 Problem Possible Cause Action Excessive vibration of Broken steering linkage Replace steering wheel Looseness of steering gear box Retighten (shimming) Broken or binding of steering ball joint Replace Worn or damaged front wheel bearing Replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace...
Page 558: Inspection And Maintenance
5. INSPECTION AND MAINTENANCE Gear Preload Check Preload is the term used in mechanical engineering to describe the load applied to a fastener merely as a result of being fastened (and before any external loads are applied) Place the wheels at straight ahead direction.
Page 559 4610-00 Free Play Check Start the engine and place the wheels at straight ahead direction. Turn the steering wheel until the tires starts to move and measure the distance on the circumference of the steering wheel. Free play 30mm If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage.
Page 560 Oil Level Check Check the fluid level on a level ground with the engine turned off. The fluid level should be between the MIN and MAX marks on the reservoir cap gauge. Place the vehicle on a level ground and start the engine and let it run at idle speed.
Page 561 4610-00 Air Bleeding The air bleeding should be done after servicing the power steering system and when the difference between two measurements (cooled and normal temperature) is prominent. Lift up the vehicle very carefully. Turn the steering wheel to its both ends several times and add the oil up to MAX line in the steering oil reservoir.
Page 562 Oil Pump Pressure Check Check the oil pump pressure to locate any defect in oil pump. Before checking the pressure, check the oil level and belt tension. Prepare the empty container to collect the spilled oil during the service. Unscrew the pressure line fitting in power steering pump.
Page 563 4610-00 Measure the oil pressure with the gauge valve fully open. 3 ~ 5bar Pressure at no load If the pump pressure is in specified range, the pump is normal. If not, replace the power steering pump Turn the steering wheel righ or left until it stops with the engine idling ans valve fully open.
Page 564 1. SYSTEM DESCRIPTION The power steering has been designed to make the wheel move more easily than in a manual steering system. The hydraulic power assists the process utilizing hydraulic fluid. The fluid increases pressure in the power steering pump and aids the movement of the steering mechanism.
Page 565: System Layout
4610-00 2. SYSTEM LAYOUT The steering pump is driven by the engine power through a belt. This pump circulates the power steering oil from the reservoir -> steering pump -> oil supply pipe -> steering gear box -> oil return pipe -> reservoir to perform steering operations Return hose &...
Page 566 Oil Flows during Right Turn Oil reservoir To piston pipe From piston pipe Steering pump Piston Piston pipe...
Page 567: Specifications
4620-01 1. SPECIFICATIONS 1) Specifications Description Specification Voltage Rating DC 12V Current Rating 1.0A Resistance...
Page 568 1. OVERVIEW The speed-sensitive power-assisted steering system can automatically adjust the boosts according to the speed changes, automatically induct the high-speed or low-speed status, and relatively adjust the reasonable steering boosts, enhance the operation precision, reduce the driving pressure of drivers. No matter for steering, parking or reversing, it becomes much easier. The adjustable safety steering column attached possesses the functions of electrically adjusting height and transverse position, has brought much more abundant and comfortable spaces for legs, and has provided the great convenience to get in or out the car.
Page 569 4620-01 2. COMPONENTS SSPS Warning Lamp Location of Power Steering Location of SSPS Solenoid Location of SSPS Control Uni Pump Valve Power Steering Pump SSPS Solenoid Valve SSPS Control Unit...
Page 570 Steering Gear Box Tie rod end SSPS Solenoid Valve Tie rod Bellows SSPS solenoid valve Valve assembly Feed tube Mounting bracket Cylinder tube Rack housing Adjusting plug...
Page 571: Operating Process
4620-01 3. OPERATING PROCESS 1) Input/Output of ECPS Control Unit IG Power Solenoid Valve SSPS Meter cluster Ground Control (SSPS warning lamp) Unit Meter Cluster Trouble Diagnosis (Vehicle Speed) 2) ECPS Configuration...
Page 572 PCV (Pressure Control Valve) This valve controls the hydraulic pressure supplied to reaction device by moving the spool valve according to the changes of solenoid valve. Reaction device This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV.
Page 573 4620-01 The shaft operation force of solenoid rod is reduced due to the reduction of output current from SSPS control unit. The coil spring pulls the PCV spool toward solenoid valve to open it. The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to reaction plunger.
Page 574: System Control
4) System Control ECPS system, according to the vehicle speed, enables to achieve proper steering characteristics by controlling hydraulic pressure to reaction plunger located in input shaft of power steering gear box. In other words, ECPS control unit enhances the parking conveniences by controlling duty type current control.
Page 575 4620-01 During high speed driving, the control unit supplies weak electric current to solenoid valve. Then, the spool located PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C port ) through B port. As a result, the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier.
Page 576: Circuit Diagram
4. CIRCUIT DIAGRAM...
Page 577: Wheel Module
4190-00 1. SPECIFICATIONS 1) Wheel Module Description Specification Remark 0~6.375bar Pressure measuring range 1 bar = approx. 14.5 psi (0~92.43psi) Pressure measuring tolerance Temperature measuring range Temperature measuring tolerance Transmit frequency 433.92 MHz Lithium battery (approx. 3.0~3.2V) Subject to operating Battery life 160,000 km or 10 years conditions...
Page 578 2. SPECIAL SERVICE TOOLS The tightening torque for wheel module is 1.4 Nm. To tighten the bolts for wheel module without any damage, you must use the special service tool as below. Torque wrench (0.1~5.0 Nm) Torx socket T-10 Tire valve remover/installer How To Use Torque Wrench Removing/Installing Valve Insert...
Page 579 4190-00 3. CAUTIONS 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 Tire Pressure Indicated Initial Engine Start Front Tire Pressures Front Tire Pressures Rear Tire Pressures Rear Tire Pressures...
Page 580 Use only the TPMS wheel approved by SYMC for replacement. Even though the replacement wheel has same size with factory installed wheel, TPMA may not be usable due to interference on rim. External View for Wheel Module Internal View for Wheel Module Do not use any tire sealant if the vehicle is equipped with a TPMS.
Page 582 1. OVERVIEW As an additional safety feature, this vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates an abnormal tire pressure telltale when one or more of tires are significantly under-inflated or over-inflated.Driving on a significantly under-inflatedtire causes the tire to overheat and canlead to tire failure.
Page 583 4190-00 Location of Wheel Module Wheel Module Sensor Wheel Module Assembly Location of TPMS ECU TPMS ECU...
Page 584: Block Diagram
3. BLOCK DIAGRAM...
Page 585 4190-00 4. WARNING LAMP AND INDICATOR Meter Cluster TPMS Warning Lamp This warning lamp comes on when the ignition switch is turned This warning lamp comes on and stays on when there is a problem with the TPMS. Tire Pressure Warning Lamp This warning lamp comes on when the ignition switch is turned (Global Warning) This warning lamp blinks (0.4s ON/OFF) for 70 seconds and...
Page 586 5. 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 on Error in TPMS system Yellow Yellow Comes on immediately Affected tire symbol Defective wheel module Yellow...
Page 587 4190-00 Tire Pressure Indicator Tire Pressure Indicator (Changed from ODO mode to Tire pressure display mode) In ODO mode, the symbol for abnormal tire In tire pressure display mode, the symbol for comes on in yellow. abnormal tire comes on in yellow and the other symbols come on in green.
Page 588 Low Tire Pressure A, C (Blinks (0.4 s ON/OFF) for 70 seconds and then stays on) Slowly decreasing pressure from specified pressure Meets the warning lamp ON condition 1 Warning lamp ON Warning lamp OFF (Hysteresis range) Condition 1: continuous driving for 10 minutes (tire pressure: 24~26 psi (low), vehicle speed: 20 km/h or higher)
Page 589: Tire Pressure Display
4190-00 6. TIRE PRESSURE DISPLAY LCD display Trip switch...
Page 590 7. TIRE PRESSURE INDICATION PROCEDURE The TPMS ECU receives the tire pressure value from the wheel module with radio frequency at every 30 seconds and sends the signal to meter cluster via CAN line to show it to driver. To reduce the battery current consumption, in normal driving conditions, each wheel module sends the tire pressure and temperature with its own ID (Identification) to TPMS ECU at every 30 seconds.
Page 591: Tire Inflation Procedure
4190-00 8. TIRE INFLATION PROCEDURE 1) Overview A tire equipped with wheel module should be inflated in a unique method other than conventional one. As the tire pressure on tire pressure gauge and could be different from the value displayed on meter cluster, the tire pressure should be checked and adjusted after specific period (transmitting time for wheel module).
Page 592 Tire Inflation and Inspection for Tire Pressure Inflate the air into the tire according to the specified procedure. Tire Inflation Procedure Inflate the air into tire (32 psi) Drive the vehicle for more than 10 minutes (over 20 km/h) Normal Abnormal Check if TPMS warning lamp or...
Page 593 4190-00 Caution When Inflating If the tire pressure is 10 psi lower than the specified value, remove the valve insert from the wheel module valve body and replace it with new one. Then, inflate the air into the tire.
Page 594: Specifications
4170-34 1. SPECIFICATIONS Description Specification Tire EU,GEN : EU,GEN : 235/75R/16, 255/70R/16, 255/60R18, 16inch/18inch 255/60R18(BR) Tire Tire inflation pressure EU,GEN : EU,GEN : 235/75R/16, 255/70R/16, 255/60R18, 32psi 16inch/18inch 255/60R18(BR) Wheel EU,GEN : EU,GEN : 7.0J * 16 , 7.5J * 18(TYPE A) , 32psi 16inch/18inch 7.5J * 18(DIAMOND CUT)
Page 595: Trouble Diagnosis
3. TROUBLE DIAGNOSIS Problem Possible Cause Action Uneven tire wear Incorrect tire pressure Adjust Unbalanced wheel Adjust Improper location change of tire Change tire location in specified interval Incorrect toe adjustmen Adjust Incorrect wheel bearing preload adjustment Adjust Malfunction of brake syste Replace Tire squeal, Too low tire pressure...
Page 596: Appearance Check
4170-34 4. INSPECTION 1) Appearance Check Symptom Possible Cause Wear at tread edge Insufficient tire inflation pressure or overload Inside Outside Wear at tread center Excessive tire inflation pressure Inside Outside Excessive wear in the outer side of the tread than in the inner side Excessive camber or deflection of knuckle arm Inside...
Page 597 Symptom Possible Cause Blade type wear from outer side toward inner side of the tread Excessive toe-in, Deflection of knuckle arm, Inside Difference in tie rod length Outside between left and right sides Blade type wear from inner side toward outer side of the tread Excessive toe-in, Deflection of knuckle arm, Inside...
Page 598 4170-34 2) Typical Inspection Tread Inspect the tread condition on the tire surface and various damages resulting from the foreign materials, crack, stone or nail etc. If there is any damage in the tire, repair or replace it. Wear limit Measure the depth of the tire tread.
Page 599 Tire inflation pressure Tire inflation pressure Specified value 32psi Check the tire inflation pressure by Proper Proper Over inspecting the tread width. inflation inflation inflation Maintaining the specified tire ressure is essential for comfortable riding, driving safety, and long tire life. Incorrect Tread width Tread width Tread width...
Page 600 4170-34 Wheel balance Check the wheel balance when the wheel is unbalanced or the tire is repaired. The total weight of the wheel weight should not exceed 150 g. Ensure that the balance weight installed is not projected over 3mm from the wheel surface.
Page 601 1. OVERVIEW A radial tire uses a cord angle of 90 degrees. That is, the cord material runs in a radial or direct line from one bead to the other across the tread. In addition, a radial tire has a belt overwrap under the tread surface to provide greater structural stability.
Page 602 4170-34 Location of Components Spare Tire Tools Warning Triangle Jack Wheel wrench Jack connection...
Page 603 Structure of Tire Tread This thick layer of rubber provides the interface between the tire and the road. Wear-resistant rubber is used to protect the carcass and belt against fractures and impacts and to deliver a long driving life. Shoulder Located between the tread and sidewall, the shoulder rubber is the thickest so that the design must allow for the easy diffusion of heat generated within the tire while driving.
Page 604 4170-34 Tire Unit Indication Aspect ratio (%) = Nominal section height (H) / Nominal section width (W) X 100 Tire Inflation Pressure (32 psi) Proper inflation Excessive inflation pressure Low inflation pressure pressure Tread width Tread width Tread width The contact area between the The contact area between The contact area between the ground and tire faces the...
Page 605 2. ABNORMAL TIRE SYMPTOM Standing Wave 32psi Specified tire inflation pressure During driving, the rotating tire repeats deformation and restoring movement in is tread. This happens when the tire pressure is low in high speed driving. However, when the wheel rotating speed is fast, the tire is deformed even before it is restored to its original shape and the trembling wave appears on the tread portion.
Page 606 4170-34 Hydro Planing Vehicle speed = 80 km/h No Hydro planning Partial Hydro planning Full Hydro planing When the vehicle is driven on a road surface covered with water at high speed, tires do not contact with the road surface but rotate floating on a thin film of water. It causes brake failure, lower traction force and losing the steering performance.
Page 607: Wheel Balance
3. WHEEL BALANCE If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic.
Page 608 4170-34 4. WHEEL ALIGNMENT Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tire life and ensures straight and true tracking along a straight and level road. In automotive engineering, toe, also known as tracking, is the symmetric angle that each wheel makes with the longitudinal axis of the...
Page 609 Caster is the angle to which the steering pivot axis is tilted forward or rearward from vertical, as viewed from the side. If the pivot axis is tilted backward (that is, the top pivot is positioned farther rearward than the bottom pivot), then the caster is positive;...
Page 610 4170-34 5. FUNCTIONS OF TIRE Supporting the Vehicle Weight Transferring the Driving Force & Braking Force to Road Even friction coefficient road Uneven friction coefficient road Driving Force Braking Force Absorbing the Impact from Road...
Page 611: Specifications
6822-11 1. SPECIFICATIONS Description FATC Rated voltage DC 12V Operating voltage DC 9~16V Current consumption Operating temperature Output current from air mix door motor 0.4A Air conditioner control panel Output current from high relay Base current for power transistor Output current from air source motor 0.55A Output current from mode motor 0.55A...
Page 612 Description FATC Heating type Air heating type Material BaTiO3 Weight 500g...
Page 614 1. SYSTEM LAYOUT (EXTERNAL) Expansion Valve Controls the refrigerant volume and sends it to evaporator. PWM Electric Fan Cools the radiator and condenser down. Condenser Installed on the front of vehicle and converts the gaseous refrigerant to liquid refrigerant by condensing it.
Page 615 6822-11 A/C Hose &Pipe Lines A/C Compressor Receiver drier & Refrigerant Pressure Sensor Absorbs the moisture from the refrigerant and accumulates it for supplying. AQS Sensor/Ambient Temperature Sensor Measures the air contamination value and ambient temperature and sends the data to FATC controller.
Page 616 2. SYSTEM LAYOUT (INTERNAL) Sun Sensor Heater & A/C Module A/C Control Automatic Control Mode Door Actuator Air Mix Actuator...
Page 617 6822-11 Duct Temperature Sensor Air Source Actuator Power Transistor Thermo Amplifier A/C Filter Blower Motor...
Page 618: Ventilation System
3. VENTILATION SYSTEM 1) Location 2) Duct Layout...
Page 619 6822-11 4. BLOCK DIAGRAM Below diagram shows the input/output mapping between the components of FATC A/C and A/C controller briefly. A/C Compressor OFF Conditions For approx. 4 seconds after starting the engine Engine speed: 650 rpm or lower Engine speed: 4,500 rpm or higher...
Page 620: Basic Operating Principle
5. A/C COOLING CYCLE 1) Basic Operating Principle (1) System flow "Compression -> Condensation -> Expansion -> Evaporation" (2) Functions Condition: Gas Function: Circulates the refrigerant and increases the pressure and temperature for easier evaporation. Condition: Gas/Liquid Function: Cools and condenses the refrigerant by using ambient air to liquefy it under high pressure.
Page 621 6822-11 Condition: Liquefied gas/Gas Function: Cools the air by absorbing the heat from the air around the evaporator. (3) Description for Each Cycle The evaporated refrigerant in the evaporator enters to the compressor. And the refrigerant gas is compressed until it can be liquefied at ambient temperature. Thus, the low refrigerant pressure is maintained so that the liquid refrigerant can be evaporated The high pressure and high temperature gas (refrigerant) from the compressor is cooled down by the fresh air entered into the condenser.
Page 622 Air Conditioner: Compressor, PWM Electric Fan, Air Mix Motor, Sun Sensor, Coolant Temperature Sensor, AQS Sensor, Thermo Amplifier...
Page 623 6810-18 2/2 Motor (Mode, Fresh/Recirculation)
Page 625: Warnings For Airbag
When the engine starts, the air bag warning lamp comes on for a system check. It goes out after 3 to 7 seconds when the system is normal. If this warning lamp stays ON, then the system may be defective. Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation.
Page 626: Major Replacement Parts After Air Bag Deployment
Wash it out with cold and clean water and consult the doctor if irritation continues. When any repairs are needed for the steering wheel, or when an accident occured without the air bag deployment, have the air bag system checked by Ssangyong Dealer or Ssangyong Authorized Service Operation.
Page 628 1. OVERVIEW The air bag unit (SDM) includes the lateral G sensor and longitudinal G sensor. The side air bag sensor is installed in both B pillars. The front air bag module, side air bag module and seat belt pretensioner are installed for each seat.
Page 629 8810-00 Air Bag Warning Lamp (Meter Cluster) Seat Belt Pretensioner Side Air Bag Module Side Air Bag Sensor Assembly...
Page 630: Operating Conditions
3. OPERATING CONDITIONS 1) Front Air Bag System The air bag deploys when: A front collision occurs, which occupants cannot be protected by seat belt. The air bag can deploy when: Underbody impact from the road surface, impact against the curb at a very high speed, or dropping impact onto the road surface with a large angle occurs.
Page 631: Side Airbag System
8810-00 2) Side Air Bag System Driver's Passenger's The curtain air bags are installed to the upper end of both doors. The air bags provide head protection for the front and rear outboard occupants in a side collision. The air bag deploys when: a severe oblique collision occurs with a specific severity, angle, speed, and position.
Page 632: Operation Process
4. OPERATION PROCESS 1) Air Bag System Block Diagram The overall air bag operation process and its functions and roles are broadly explained in this block diagram. This diagram summarizes and highlights the functions adopted by Ssangyoung Motors.
Page 633 8810-00...
Page 634 5. DEPLOYING CONDITIONS Once the ignition starts, the SDM starts to diagnose the air bag system during the ignition process.If the system is OK, the SDM is armed for a specific impact on the vehicle. The ignition time takes about 6 sec. 1) Front Air Bag Deploying Conditions When a Frontal Impact Occurs Impact to Front side...
Page 635: Air Bag Deployment Signal Output (Crash Out)
8810-00 6. DEPLOYMENT 1) Air Bag System Deployment (Firing Loop) According to the collision deceleration rate that each collision G sensor reads, the air bag unit sends out about 2~4 or higher Amp current. This current generates some heat, which fires the detonator in the inflator.
Page 636 Deployment signal Door unlock relay (Crash out) Cautions for Door Lock/Unlock Control 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"...
Page 637: Air Bag Warning Lamp Operational Conditions
8810-00 7. AIR BAG WARNING LAMP OPERATIONAL CONDITIONS The air bag warning lamp on the instrument panel has a few operational conditions. The following are the conditions: When Turning the Ignition Switch to ON Position Initially The air bag unit performs a turn-on test when the ignition is turned on initially. The air bag unit flashes the air bag warning lamp 6 times at 1 Hz interval.
Page 638: Circuit Diagram
8. CIRCUIT DIAGRAM 8810-01 Air Bag (including Side Air Bag)
Page 639 4170-00 1. WARNINGS FOR POWER SEAT Adjust the driver's seat before driving. Make sure that the seat is firmly secured after adjusting. Never drive the vehicle with the head restraint removed or lowered excessively. Otherwise, your neck, spine or other parts of the body can be severely injured in the event of an accident.
Page 640: Major Changes
3. MAJOR CHANGES 1) Front Headrest Front Headrest Swing type tilting Sliding type tilting Changed the design of headrest. 2) Front Seat Assembly Front Seat Assembly Changed the design of seatback and seat cushion. Changed the design of headrest.
Page 641 4170-00 3) Front Seat Back Board Front Seat Back Board Changed the design of seat back board and seat back pocket. 4) Front Seat Cover Shield Front Seat Cover Shield Integrated type Split type Changed the design of seat cover shield.
Page 642 5) Front Seat Frame Cover Front Seat Frame Cover Changed the design of seat frame covers (front & rear). 6) Rear Center Armrest Assembly Rear Center Armrest Changed the location and appearance of armrest band.
Page 643 4170-00 1) Adjustment Height Adjustment of Headrest How to operate To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (A) on top of the seatback and push the headrest down. Forward and Backward Adjustment of Headrest How to operate...
Page 644 Seat Slide Adjustment (Power Seat) Seat Slide Adjustment (Manual Seat) How to operate How to operate To move the seat forward or backward, push To move the seat forward or backward, pull the seat slide switch to desired direction. and hold the seat slide lever up and move the seat as desired.
Page 645 4170-00 Seat Cushion Angle Adjustment (Power Seat Seat Height & Cushion Angle Adjustment (Manual Seat) How to operate How to operate To adjust the seat cushion angle, raise or To adjust the angle and height of the front or lower the seat cushion angle adjusting switch rear section of the seat cushion, rotate the to desired direction.
Page 646 Seat Heater ON Operating conditions IGN ON / Engine running If the engine is cranking during the heater operation, the seat heater stops the operation for cranking period. How to operate The seat heater has 5 heating levels. Turning clockwise: Higher heating level Turning counterclockwise: Lower heating level Operating process the signals from the seat heater switch.
Page 647: Position Memory Setting
4170-00 3) Position Memory Setting Seat position memory function Seat Position Memory Switch The position memory is available for up to three drivers. Each driver can set his/ her mirror positions. The information will individually be stored in the integrated computer.
Page 648 Easy access function Easy Access Switch This system is designed to provide the driver sufficient space to access and exit. Operating conditions Easy access switch ON Operating process When turning the IGN ON and OFF with the Easy Access switch pressed in, The SPWM The moving distance of the seat is based on when the seat is located at its front end.
Page 649 4170-00 1) Adjustment Height Adjustment of Headrest How to operate To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (A) on top of the seatback and push the headrest down. Forward and Backward Adjustment of Headrest How to operate...
Page 650 Seat Slide Adjustment (Power Seat) Seat Slide Adjustment (Manual Seat) How to operate How to operate To move the seat forward or backward, push To move the seat forward or backward, pull the seat slide switch to desired direction. and hold the seat slide lever up and move the seat as desired.
Page 651 4170-00 Seat Heater ON Operating conditions IGN ON / Engine running If the engine is cranking during the heater operation, the seat heater stops the operation for cranking period. How to operate The seat heater has 5 heating levels. Turning clockwise: Higher heating level Turning counterclockwise: Lower heating level Operating process the signals from the seat heater switch.
Page 652 3. SECOND ROW SEAT ASSEMBLY 1) Adjustment Headrest Adjustment To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (A) on top of seatback and push the headrest down. Second Row Seat Heating switch The heating switches for the rear seats are located on the rear...
Page 653 4170-00 4. THIRD ROW SEAT ASSEMBLY 1) Adjustment Headrest Adjustment To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (A) on top of seatback and push the headrest down. Seatback Folding Pull up the folding lever to fold down...
Page 654: Circuit Diagram
5. CIRCUIT DIAGRAM Power Seat/Seat Position Memory...
Page 655 4170-00 Outside Rearview Mirror, Folding...
Page 657 4170-00...
Page 659 4170-00...
Page 661: Cautions For Operation
7340-01 1. CAUTIONS WHEN WORKING Wear clean work clothes and gloves. Any unauthorized modification or operational test is not allowed since the sunroof motor and control unit are preset at the factory. Pay attention not to drop the sunroof assembly when removing it and do not keep it right up. 2.
Page 662: Major Changes
3. MAJOR CHANGES 1) Sunroof Switch Sunroof Switch Changed the appearance of sunroof switch.
Page 663 7340-01 1. COMPONENTS AND LAYOUT OPEN TILT Sunroof Assembly Sunroof Motor Assembly Overhead Console Assembly Sunroof Control Unit (Sunroof Switch)
Page 664: Operating Process
2. OPERATING PROCESS 1) Sunroof switch Sunroof switch The sunroof switches are included in the overhead console assembly. CLOSE Closes the sunroof. OPEN Opens the sunroof. Sunroof glass Sun shade blind Sunroof glass The sunroof glass can be opened automatically and can be tilted by the switch operation.. Sun shade blind The sun shade blind can be closed or opened manually to block sunlight when the sunroof function is not in use.
Page 665 7340-01 2) Sunroof Sliding Opening/Closing Push up the switch briefly: 2-step auto sliding open Sunroof operation has two steps; if you push the switch briefly, the sunroof is opened by its first operating stroke (approx. 326 mm). If you push it again, the sunroof is opened completely.
Page 666 3) Sunroof Tilt Up/Down Tilt Up Pull down the switch The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof closed. Tilt Down Push up the switch The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted up.
Page 667: Emergency Operation
7340-01 4) Sunroof Safety Function (Anti-Trap) To prevent any body parts from being trapped by the sliding sunroof, an Anti-Pinch Function automatically opens the sunroof when an object is trapped. However, when the anti-trap function has been activated consecutively 3 times, the auto closing mode will be changed to the manual operation mode and then resume its function..
Page 668 3. CIRCUIT DIAGRAM 7304-03 Sunroof...
Page 669 7610-00 1. MAJOR CHANGES 1) Center Fascia Panel Center fascia panel Old model New model Changed design 2) Sun Visor Retainer Sun Visor Retainer Old model New model Changed design...
Page 670 5110-00 1. SPECIFICATIONS Description Specification Hood Type Gas lifter type Front door Structure Frame door Window regulator type Wire-drum Locking device Pin-fork device Rear door Structure Frame door Window regulator type Wire-drum Locking device Pin-fork device Tailgate Type Gas lifter type Thickness of glass Windshield Front door glass...
Page 671 2. MAJOR CHANGES 1) Hood Panel Hood Panel Changed the design Hood Insulator Changed the design to eliminate the interference...
Page 672: Radiator Grille
5110-00 2) Radiator Grille Radiator Grille Changed the design and location 3) Front Bumper Front Bumper Changed the design...
Page 673 4) Outside Rearview Mirror Outside Rearview Mirror Introduced the LED side repeater and changed the design 5) Door Garnish Door Garnish Deleted the front and rear garnish...
Page 674 5110-00 6) Wheel Arch Garnish Wheel Arch Garnish Old (Front) New (Front) Old (Rear) New (Rear) Changed the design 7) Center Lower Step Center Lower Step Changed the design...
Page 675 8) Side Sill Garnish Side Sill Garnish Split type Integrated type 9) Side Outer Rear Panel Side Outer Rear Panel Changed the design of rear combination lamp...
Page 676: Tailgate Glass
5110-00 10) Tailgate Glass Tailgate Glass Added the window open lever for flip-up glass and changed the location of rear wiper 11) Rear Spoiler Rear Spoiler Introduced the wing type rear spoiler...
Page 677: Rear Bumper
12) Tailgate Lower Garnish Tailgate Lower Garnish Changed the design 13) Rear Bumper Rear Bumper Changed the design...
Page 678 5110-01 1. MAJOR EXTERNAL DIMENSIONS General dimensions Unit: mm Top view Side view Front view Rear view...
Page 679 Detailed dimensions Head lamp (low) Side repeater Head lamp (high) License plate lamp Tail lamp Turn signal lamp (rear lamp) Turn signal lamp Backup lamp Front fog lamp Extra stop lamp Stop lamp Reflex reflector Tail lamp...
Page 680 5110-01...
Page 681: Jack Points
2. JACK POINTS Front: Double wishbone Rear: 5-link...
Page 682 5110-01 3. UNDER COATING APPLICATIONS...