SSANGYONG Kyron Repair Manual
  1. Manuals
  2. Brands
  3. SSANGYONG Manuals
  4. Automobile
  5. KYRON 2006
  6. Repair manual

SSANGYONG Kyron Repair Manual

Hide thumbs Also See for Kyron:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Manual, User Manual
GENERAL INFORMATION
00
TABLE OF CONTENTS
DIMENSIONS ........................................................... 3
SPECIFICATIONS .................................................... 4
VEHICLE IDENTIFICATION ...................................... 6
MAINTENANCE SCHEDULE ................................... 9
RECOMMENDED FLUIDS AND LUBRICANTS ...... 11

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Kyron and is the answer not in the manual?

Questions and answers

Related Manuals for SSANGYONG Kyron

Summary of Contents for SSANGYONG Kyron

  • Page 1 GENERAL INFORMATION TABLE OF CONTENTS DIMENSIONS ............3 SPECIFICATIONS ............ 4 VEHICLE IDENTIFICATION ........6 MAINTENANCE SCHEDULE ........9 RECOMMENDED FLUIDS AND LUBRICANTS ..11...
  • Page 3 DIMENSIONS Unit: mm Top View Side View Front View Rear View * ( ) : Optional GENERAL INFORMATION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 4 1.536 1.536 1.000 1.000 0.807 0.807 Reverse 3.919 3.919 Automatic Model Electronic, 5-speed Electronic, 5-speed Transmission Operating type Floor change type Floor change type * ( ) Optional GENERAL INFORMATION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 5 12 - 2.2 Starter capacity (V-kW) Alternator capacity (V-A) With PTC: 12 - 140 With PTC: 12 - 140 (With FFH: 12 - 115) (With FFH: 12 - 115) GENERAL INFORMATION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 6: Vehicle Identification

    Engine Number (D20DT) Engine Number (D27DT) The engine number is stamped on the lower area of cylinder block in the intake manifold side. GENERAL INFORMATION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 7: Vehicle Identification Number

    Vehicle identification number (VIN) is is on the right front axle upper frame. [KPTS0A1KS5P 122357] K .. Nation (K: Korea) P .. Maker Identification (P: Ssangyong Motor Company) T .. Vehicle Type (T: Passenger car - 4WD) S .. Line Models (S: Kyron) 0 ..

  • Page 8: Engine Serial Number

    The transmisson label is affixed on the right area of trans- mission housing. 6. Transfer Case Number The transfer case label is affixed on the transfer case housing. GENERAL INFORMATION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 9: Maintenance Schedule

    MAINTENANCE SCHEDULE General * Use only approved Ssangyong genuine parts. Daily Weekly Descriptions Service Interval Check Check Engine Oil and Oil Filter Initial change: 5,000 km, change every 10,000 km or 12 months – (But, shorten the service interval under severe conditions) Coolant Change every 60,000 km or 3 years.
  • Page 10 EU ONLY * Use only approved Ssangyong genuine parts. Daily Weekly Descriptions Service Interval Check Check Engine Oil and Oil Filter Change every 15,000 km or 12 months (But, shorten the – service interval under severe conditions) Coolant Change every 60,000 km or 3 years. And, inspect and –...

  • Page 11: Recommended Fluids And Lubricants

    Power Steering Fluid NOTICE • Use only Ssangyong recommended fluids and lubricants. • Do not mix any different types or brands of oils or fluids. This may cause damages. • Keep the specified levels when adding or replacing the fluids.
  • Page 12 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 13: Table Of Contents

    AUTOMATIC TRANSMISSION (DC 5-SPEED) 3650 / 3660 / 3110 TABLE OF CONTENTS GENERAL INFORMATION ...... 2 SPECIAL TOOLS AND EQUIPMENT ..68 1. Overview .............. 2 VALVE BODY .......... 72 AUTOMATIC TRANSMISSION HYDRAULIC CIRCUIT ......80 (DC 5-SPEED) .......... 4 1.

  • Page 14: General Information

    This function improves shifting quality significantly. And, the driver can select “S” (Standard) mode or “W” (Winter) mode according to the driving conditions. Instrument Panel TCU Assembly TCCU AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 15 The shiftable gear is up by by one step as the lever one step as the lever is is moved to left (-) moved to right (+) direction. direction. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 16: Automatic Transmission (Dc 5-Speed)

    3650 AUTOMATIC TRANSMISSION (DC 5-SPEED) 1. APPEARANCE Left Side With Torque Converter Without Torque Converter Rear View AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 17: Structure And Specifications

    16. Freewheel F1 (Front planetary gear set) 5. Disc clutch C1 11. Parking lock gear 17. Stator shaft 6. Disc clutch C2 12. Intermediate shaft 18. Converter lockup clutch AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 18 Operating range 3rd to 5th gears Speed sensor Type HALL type Operating voltage Start lockout switch Switch contact ON (D, R position) Switch contact OFF (P, N position) AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 19 Single side friction plate Disc clutch Double side friction plate Single side friction plate Single side friction plate Disc brake Double side friction plate Double side friction plate AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 20 ( ), the 4 → 3 shift is done in shaded area (93% of pedal position). 4th gear: 1.000 5th gear: 0.833 Rev. 1st gear: 3.147 Rev. 2nd gear: 1.93 AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 21 Lockup Mode (Open/Slipping) WINTER Mode 5rd GEAR OPEN 5rd GEAR SLIPPING 4rd GEAR OPEN 4rd GEAR SLIPPING 3rd GEAR OPEN 3rd GEAR SLIPPING PEDAL VALUE (%) PEDAL VALUE (%) AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 22 → Compensates the shifting quality according to play and wear Torque converter Flywheel lockup clutch Torque Automatic Final drive Output Engine torque converter transmission gear torque Multiple disc Multiple disc clutch brake AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 23: Power Flow

    C1 (Disk clutch) C2 (Disk clutch) C3 (Disk clutch) assembly assembly assembly Shifting Elements Gear 1) Selector program switch: S mode 2) Selector program switch: W mode 3) Overrun AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 24 4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed 5. Center ring gear: Clockwise rotation 6. Center sun gear: Locked by B2, Rotation with reduced speed 7. Output shaft: Clockwise rotation Gear Lockup clutch 3) Overrun AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 25 4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed 5. Center ring gear: Clockwise rotation 6. Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed 7. Output shaft: Clockwise rotation Gear 3) Overrun AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 26 3. Center ring gear: Clockwise rotation by clutch 2 activation (direct connection) 4. Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed 5. Output shaft: Clockwise rotation Gear AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 27 7. Center sun gear: Clockwise rotation by C3 activation 8. Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection) 9. Output shaft: Clockwise rotation Gear AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 28 6. Center sun gear: Clockwise rotation with increased speed by clutch C3 activation 7. Center planetary gear carrier: Clockwise rotation (increased speed) 8. Output shaft: Clockwise rotation (increased speed) Gear 3) Overrun AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 29 7. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) 8. Center ring gear: Locked by B3 9. Center planetary gear carrier: Counterclockwise rotation (reduced speed) 10. Output shaft: Counterclockwise rotation Gear R (S) 3) Overrun AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 30 6. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) 7. Center planetary gear carrier: Counterclockwise rotation (reduced speed) 8. Output shaft: Counterclockwise rotation Gear R (W) AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 31: Function And Description

    ECU, TCU, instrument panel etc. CAN HI Brake switch signal Ground Self diagnosis connector Selector lever position indicator comes on when tail lamp is turned ON Tail lamp relay AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 32 TCU terminal A2 (29) Ignition switch Tail lamp relay Self diagnostic 10 Brake switch B1 (41) B2 (40) Selector lever control unit Backup lamp Instrument panel, HECU, ECU AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 33 (-) moved to right (+) direction. direction. WARNING Shift Lever Lock Release • Turn the ignition key to OFF position before doing this operation. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 34 2. When fully (85% or more) depressing the accelerator pedal. When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via CAN communication. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 35 The transmission range lever and gear selector lever (P → R → N → D) should be positioned in “N” position. Tightening torque: 4 ~ 8 Nm Tightening torque: 4 ~ 8 Nm Tightening torque: 4 ~ 8 Nm AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 36: Torque Converter

    The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 37 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 38 The rest of the lubricating oil is directed via the throttle “a” into the torque converter in order to cool the torque converter lockup clutch. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 39: Planetary Gear Set

    Direction reversal and step-down ratio Planet carrier locked Sun gear driving (clockwise) Planet gears driven (counterclockwise) Ring gear driven (counterclockwise) Gear ratio: teeth of sun gear / teeth of ring gear AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 40: Multiple-Disc Clutch

    (H1) of the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c).Sun gear (M1) and sun gear (H1) turn at the same speed. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 41: Freewheel

    The outer race (1) slides over the locking elements (3) with negligible friction. If the rotation of the outer race (1) changes to direction “B”, the locking elements (3) stand up and lock the outer and inner races (1, 2) together. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 42: Others

    If the vehicle rolls faster, the shape of the teeth prevents the parking lock pawl (4) from engaging. 1. Detent plate 4. Parking lock pawl 2. Spring 5. Guide sleeve 3. Cone 6. Parking lock gear AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 43 (arrow) back into the oil chamber. Reduction of power losses and prevention of fluid loss from the transmission at high fluid level. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 44 Approx. 8 (initial filling) verse order of removal. Specification Fuchs ATF 3353 or Shell ATF 3353 NOTICE • The oil temperature should be checked at “D” or “R” position. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 45: Removal And Installation

    2. Remove the center console upper cover and disconnect the cigarette lighter. Remove the selector lever cover 3. Separate the selector lever pin with a flat blade screwdriver. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 46 15 ~ 23 Nm 5. Disconnect the selector lever connector, unscrew the mounting bolts (three hexagon bolts), and remove the selector lever assembly. Disconnect Connector Remove Bolts (3) AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 47 3650 6. Install in the reverse order of removal. Make sure the selector lever and the shift lever are at the same position. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 48: Front And Rear Propeller Shaft

    1. Drain the automatic transmission fluid. 2. Disconnect the negative cable from battery. Tightening torque: 81 ~ 89 Nm Front Propeller Shaft (Axle Side) Tightening torque: 70 ~ 80 Nm Front Propeller Shaft AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 49 Rear Propeller Shaft (Axle Side) Tightening torque: 81 ~ 89 Nm Tightening torque: 70 ~ 80 Nm Rear Propeller Shaft Mounting Bracket Tightening torque: 85 ~ 95 Nm Rear Propeller Shaft AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 50: Transmission Assembly

    3. Remove the protective cover from the service hole for torque converter mounting bolts. Remove six torque con- verter mounting bolts while aligning them with service hole by rotating the crankshaft bolt. Torque converter mounting bolt Service hall protective cover AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 51 6. Install in the reverse order of removal. NOTICE • Apply a small amount of transmission oil on the drive flange of torque converter before installation. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 52 • Be careful not to damage the O-ring when remov- ing the dipstick gauge. Oil Cooling Pipe (Outlet) Tightening torque: 25 ~ 35 Nm Oil Cooling Pipe (inlet) Tightening torque: 25 ~ 35 Nm Oil Dipstick Gauge AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 53 Transmission Mounting Insulator and Bracket Tightening torque: 28 ~ 47 Nm Transfer Case Assembly Cross Member Assembly Tightening torque: 28 ~ 47 Nm Tightening torque: 85 ~ 95 Nm AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 54: Replacing The O-Ring On Parking Pawl Guide Sleeve

    • Once the O-rings have been removed on the parking pawl guide sleeve and the guide bushing, replace them with new ones. Connected to parking lock gear Spring Guide bushing Rubber O-ring Rubber O-ring Parking pawl guide Sleeve Snap ring Parking lock Snap ring lever AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 55 Tightening torque 200 Nm * Bend the collar nut to lock it during installation. 3. Remove the snap ring on the parking pawl guide sleeve in the transmission housing. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 56 5. Push out the parking pawl guide bushing from inside with a proper tool. 6. Pull up the parking lock lever and remove the parking guide sleeve, parking lock lever and spring. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 57 Guide bushing NOTICE • Keep clean when installing the O-ring. Open the package of new O-ring just prior to installation. • Especially, do not work with cotton gloves wearing. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 58: Disassembly And Reassembly (Dc 5-Speed A/T)

    5-6. Electric kit 5-13. Bolts 5. Valve body 5-7. Solenoid valve 6. Oil pan 5-1. Valve body assembly 5-8. Lifting solenoid valve 7. Magnet 5-2. Body assembly 5-9. Solenoid valve AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 59 Tightening torque 4 Nm 2. Unscrew the oil pan (6) fixing bolts and remove the oil pan. Installation Notice Tightening torque 8 Nm 3. Remove the oil filter. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 60 4. Unscrew the bolts and remove the valve body from trans- mission housing. Installation Notice Tightening torque 8 Nm 5. Disassemble and reassemble the valve body assembly. NOTE • Refer to Valve Body (page 72) section. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 61 Disassembly and Reassembly 1. Install the transmission assembly on the workbench. 2. Remove the rear extension housing from transmission housing. Installation Notice Tightening torque 30 ~ 35 Nm AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 62 * Bend the collar nut to lock it during installation. 5. Remove the rear oil seal ring. 6. Remove the circlip with a circlip pliers and remove the washer. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 63 8. Unscrew the socket bolts separate the transmission housing from converter housing. Installation Notice Tightening torque 20 Nm NOTE • Gently rock the transmission housing to make the re- moval process easier. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 64 3650 Converter Housing Assembly Clutch C3 Clutch C2 Clutch C1 Brake B1 Oil Pump AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 65 2. Remove the clutch C2 from converter housing assembly. 3. Remove the clutch C1 from converter housing assembly. 4. Remove the brake B1. 1) Remove the bolts on brake B1. Installation Notice Tightening torque 16 Nm AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 66 • Install two bolts on the opposite side of oil pump hous- ing and tap the surface of oil pump with plastic ham- mer to remove it from converter housing. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 67 • Lubricate the pump gears (1, 2) before installation. • Place the pump gear (2) into pump housing and install the pump gear (1) onto the pump housing chamber. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 68 3650 Transmission Housing Assembly Parking Lock Gear Brake B2 Brake B3 Snap Ring Components of Selector Lever AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 69 B3 while compressing it. • Check each disc for wear and burnt out. 4. Remove the fixing bolts for brake B2 from transmission housing. Installation Notice Tightening torque 16 Nm AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 70 7. Remove the fixing bolts for range selector lever. Installation Notice Tightening torque 8 Nm NOTICE • Check the sealing ring for damage. 8. Remove the range selector lever, rod and detent plate. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 71 3650 9. Remove the snap rings from parking lock pawl. 10. Remove the pin from transmission housing. 11. Remove the parking lock pawl from transmission housing. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 72 3650 Components of Each Assembly Clutch C1 Clutch C2 Clutch C3 AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 73 A. Oil pressure bore 23. Snap ring Clutch C3 24. Outer multiple-disc carrier 25. Sealing ring 26. Piston 27. Spring plate 28. Disc spring 29. Snap rig 30. Multiple-disc pack AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 74 14. Piston disc spring 7. Snap ring 15. Spring plate 16. Snap ring 17. Piston guides in B2 and B3 18. O-ring 19. Multiple-disc pack 20. Snap ring 21. Disc spring AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 75 8. Rear gear set 19. Circlip 9. Thrust washer 10. Clutch C3 11. Rear hollow shaft C. Oil outlet port in clutch C3 D. Oil inlet port in clutch C3 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 76 • Measure the clearance between ball bearing (2) and circlip. Install the appropriate size of circlip (2.0, 2.1, 2.2 mm). 4. Install the radial sealing with a special tool. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 77: Valve Body

    C. 3-4 shift group D. Clutch lockup control valve, shift valve B2 Rear Section Filter Plastic valve Valve ball (steel) Dowel pin Filter Valve ball (plastic) AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 78 7. 3-4 command valve 3. 2-3 overlap control valve 8. 3-4 shift pressure shift valve 4. Lubricating pressure control valve 9. 3-4 overlap control valve 5. Operating pressure control valve AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 79 Installation Notice Tightening torque 14 Nm NOTICE • Check the valves for damage and replace them, if necessary. 6. Install in the reverse order of removal. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 80: Special Tools And Equipment

    Fixing plate 140 589 12 15 00 (P99360041C) Installation of sealing ring Drift punch 001 589 50 33 00 (P99420041B) Removal and installation of transmission housing ball bearing Puller AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 81 140 589 13 43 00 (P99360021C) Removal and installation of B1, B2 and B3 pistons Piston puller 126 589 02 09 00 Removal and installation of collar nut for output shaft Socket AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 82 Name and Part Number Application 128 589 04 31 00 (W99360242C) Measuring the clearance between ball bearing and Measuring bridge parking lock gear Compressor Compressing clutch and disc brake AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 83 126 589 12 63 00 (W99360282A) 210 589 00 71 00 (P99360012C) Funnel Hand pipe 140 589 15 21 00 140 589 49 63 00 Dipstick gauge Filling pipe AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 84: Valve Body

    D. Modulating pressure control solenoid valve 4. O-ring B. 3-4 shift solenoid valve 10. Solenoid valve 5. O-ring E. Lockup PWM solenoid valve 6. Shift plate F. 2-3 shift solenoid valve AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 85 T (Time) 1 cycle time: approx 20 ms Circuit Diagram B3 (38) 3-4 shift S/V 2-3 shift S/V 1-2, 4-5 shift S/V B12 (14) B10 (16) B11 (15) AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 86 Working current 0 ~ 1.2 A Operating distance 0.6 mm 5.0 ± 0.3 Ω (23°C) Resistance Line pressure Regulated pressure Regulated pressure Drain line Line pressure Drain line AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 87 3650 Circuit Diagram B3 (38) B4 (37) B5 (36) AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 88 The lockup clutch operates in 3rd, 4th and 5th gear step by step in order to reduce shift shocks. Operating range 3, 4, 5 Circuit Diagram B3 (38) Lockup S/V B9 (17) AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 89: Speed Sensor

    Below diagram shows the • • R (W mode) detection of speed sensor. Circuit Diagram B6 (35) B13 (13) Speed Speed B14 (12) sensor sensor B8 (33) AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 90 The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil temperature, shift operations can be optimized in all temperature ranges. Circuit Diagram Start lock out switch B7 (34) AD converter B8 (33) Oil temperature sensor AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 91 Circuit Diagram Start lock out switch B7 (34) AD converter B8 (33) Oil temperature sensor Start Relay A12 (7) Start motor AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 92: Hydraulic Circuit

    3650 HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT DIAGRAM AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 93 25. 2-3 command valve 26. 2-3 holding pressure shift valve 27. B 2 shift valve 50. Oil pump 51. Oil cooler 52. Oil pan 53. Oil filter 54. Oil sump AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 94: Oil Pressure

    At the operating pressure control valve, excess fluid is diverted to the lubricating pressure control valve (1) and, from there, regulated for transmission lubrication use (including torque converter). AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 95 The shift valve pressure converts the control valve pressure (p-RV) to shift valve pressure. Then it supplies oil to command valve, lockup solenoid valve, and shift pressure control solenoid valves. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 96 1. Clutch C3, 3-4 pressure overlap control valve 2. Brake B2, 3-4 shift solenoid valve 3. Brake B3 4. Command valve 5. Holding pressure shift valve 6. 3-4 shift solenoid valve AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 97: Hydraulic Circuit

    The shift valve B2 (27) is held in the upper position and the 3-4 command valve (6) moves towards the right. At the end face of the 3-4 shift pressure shift valve (7), the operating pressure (p-A) is replaced by shift valve pressure (p-SV). AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 98 (27). With the shift valve B2 (27) in the upper position, shift pressure (p-S) travels behind the piston B2 (B2a) and simultaneously to the opposite face of the piston B2 (B2b). The brake B2 begins to activate. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 99 B2 (B2b) drops to a residual pressure. The 3-4 command valve (6) moves to the left. The operating pressure (p-A) travels via the holding pressure shift valve (5) and the 3-4 command valve (6) to the piston of brake B2 (B2a). AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 100 B1 via the holding pressure shift valve (15). The clutch C1 is unpressurized. The operating pressure from brake B1 acts against the holding pressure shift valve (15) and the end face of 1-2/4-5 shift pressure shift valve (16). AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 101 (18) and reduces the overlap pressure controlled by the pressure overlap control valve (18). It will shift at a corresponding pressure on the holding pressure shift valve (15). AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 102 The operating pressure (p-A) is now applied to clutch C1 via the holding pressure shift valve (15) and the command valve (14). The brake B1 is disengaged (unpressurized). The spring of the shift pressure shift valve (16) moves it into base position. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 103: Adapter Plug

    7 mm bolts. To prevent oil leakage, two O-rings are installed on the plug. 1. Remove the heat shield for adapter plug wire next to exhaust tube. 2. Turn the adapter plug lock counterclockwise and disconnect the plug connector. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 104 • Do not apply an excessive force to remove the adapter plug. It may cause an internal damage to electrci kit. 4. Place an empty container under the adapter plug and remove the adapter plug. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 105: Valve Body

    1-2/4-5 Shift pressure 3-4 shift solenoid pressure solenoid valve valve solenoid valve Shift pressure solenoid valve Valve body Electric kit 2-3 shift Lock-up PWM solenoid valve solenoid valve AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 106 1. Remove the oil pan drain plug and drain the oil completely. 2. Unscrew the six oil pan bolts (T30) and carefully lower the oil pan (6). 3. Carefully remove the oil filter. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 107 3650 4. Unscrew the fixing bolts (T30). 5. Carefully remove the valve body from transmission housing. Valve Body Assembly AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 108 Installation Notice Tightening torque 4 Nm 2. Unscrew the oil pan bolts and remove the oil pan. Installation Notice Tightening torque 8 Nm 3. Remove the oil filter. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 109 Installation Notice Tightening torque 8 Nm NOTICE • The length of socket bolts vary. Be careful not to mix 5-2. Remove the solenoid valves from the valve body. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 110 5-3. Remove the electronic control module from the shift plate. NOTICE • Correctly align the electronic control module onto the shift plate by using two central pins when installing. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 111: Tcu (Transmission Control Unit)

    The transmission is automatically controlled to compensate durability and wear. The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are permanently saved and the diagnosis is partially available. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 112 P/N starting recognition W/S mode signal Selector lever indication Mileage TCU(EGS) ground Power ground * Refer to the circuit diagram for the detailed wiring connection and related pin number. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 113 2. If the shift operation cannot be activated, the driver must reset the system as follows: 1) Stop the vehicle. 2) Stop the engine. 3) In most cases, it is reset when the engine is started and the vehicle operate normally. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 114 Selector lever position and internal fault exists) Odometer (I/P) ATF Temperature Kick-down status Circuit Diagram A18 (1) Self diagnostic 11 B1 (41) B2 (40) Instrument panel Selector lever unit AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 115 13-pin plug No.10 Each solenoid valve voltage 13-pin plug No.6 CAN LOW ECM, HECU, selector lever unit, instrument panel CAN HIGH ECM, HECU, selector lever unit, instrument panel AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 116: Trouble Code And Diagnosis

    2. Turn the ignition switch to “ON” position. 3. Select [TROUBLE CODE] in [FUNCTION SELECTION] screen and press [ENTER]. 4. Select [KYRON] in [VEHICLE SELECTION] screen and press and press [ENTER]. 5. Select [TCU] in [CONTROL UNIT SELECTION] screen and press [ENTER].

  • Page 117: Dtc (Diagnosis Trouble Code) Of Dc5At

    - Check again after TCU coding. P2011 Faulty TCU variant coding - Self-diagnosis with IGN ON. - When the TCU coding is faulty. - Check again after TCU coding. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 118 - Triggered mechanical emergency mode when the defective is detected. • Fixed at 2nd gear in “D” range. - Check the related harness for open, short and contact. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 119 - Triggered emergency mode when the defective is detected. • Electrical error : Fixed at 2nd gear in “D” range. - Check the related harness for open, short and contact. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 120 CAN: Faulty brake system communica- - Check CAN communication line H and L. tion - Check ABS/ESP unit. - Check the related harness for open, short and contact. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 121 • Check the air gap between tooth wheel and wheel speed sensor. (Air gap: 0.309 ~ 0.958 mm) • Check the numbers of tooth wheel: 48 - Check the related harness for open, short and contact. AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 122 CAN: No engine rpm signal - Check CAN communication line H and L. P240A - Check engine ECU. - Check the related harness for open, short and contact. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 123 Abnormal solenoid valve supply - Check solenoid supply voltage. voltage P2603 Abnormal speed sensor supply - Check speed sensor supply voltage. voltage • TCU connector terminals B13 (13) : 6V AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 124: Removal And Installation Of Tcu

    2. Slide the drive’s seat and fold up the carpet. 3. Unscrew the two bolts (10 mm) on TCU. Installation Notice Tightening torque 10 Nm 4. Disconnect the TCU connect and remove the TCU. AUTO TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 125 MANUAL TRANSMISSION 3170 TABLE OF CONTENTS GENERAL INFORMATION ........3 1. Overview and characteristics of manual transmission ... 3 2. Manual transmission system ..........5 MANUAL TRANSMISSION ........10 1. Location ................10 2. System components ............11 3. Shifting mechanism ............19 4.

  • Page 127: General Information

    5. The clutch release system is available to use CSC 3. To improve the shifting performance, 3-piece double (Concentric Slave Cylinder) or Fork type according cone is used for 1/2 shift. to the vehicle model. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 128 5. Neutral switch 30 ~ 40 Nm 6. Shift top cover bolt (12 mm) 17 ~ 26 Nm 7. Concentric slave cylinder adapter bolt 10 ~ 16 Nm MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 129: Manual Transmission System

    3170 2. MANUAL TRANSMISSION SYSTEM Neutral Switch 0.5 mm N (Neutral) Switch 0.5 mm Outside N Switch Inside N Switch MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 130 6) When the gear has been smoothly shifted and the vehicle speed exceeds 3km/h, it returns to the previous operation interval of the engine RPM. In case of Kyron, the N switch signal is transmitted to the instrument panel, and then the instrument panel transmits it to the engine ECU through the CAN communication.
  • Page 131 In this case, the HECU emits an abnormal noise and the brake pedal may feel very rigid, but this is a normal occurrence resulted from the HDC operation. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 132 However, it may recognize a sharp turn or * For the specific information, please refer to the ABS/ rough road as a downhill with a inclination exceeding 10%, and the HDC may operate. ESP section. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 133 Variant Coding Related to N Switch Kyron’s N Switch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires. Thus, if you set the variant coding in the engine ECU, you must do it differently, and you must set the variant coding differently according to the vehicle category and specification as below.

  • Page 134: Manual Transmission

    1. LOCATION Transfer case Oil filler plug Center cross member & transmission insulater mounting Oil drain plug Trasmission housing bolt T/M assembly (14 mm - 11) T/M Assembly MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 135: System Components

    R Idle Reverse Counter 3rd gear 4th gear gear shaft Shift Fork and Rail Combinations Transmission Interlock adapter plate 3/4 rail 5/R rail 1/2 rail Reverse Fork plate MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 136 3170 Sectional View MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 137 33. Retainer ring (3 & 4th) 69. Shift lever 34. Adapter dowel pin 70. Semi-remote lever assembly 35. Reverse idler shaft 71. Pin spring 36. Dowel pin 72. Pin spring MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 138 8. Interlock bolt (tightening torque: 40 ~ 50 Nm) 9. Shift lever (8) Bond-592 loctite 10. Interlock plate (6) Bond-592 loctite 11. Shift rail (1 & 2nd) 12. Spring pin (6 x 25) MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 139 5. Air vent (tightening torque: 20 ~ 35 Nm) 13. Rolling plunger 6. Lock washer 14. Return spring 7. TGS bushing 15. Spring plug (tightening torque: 70 ~ 100 Nm) 8. Outer spring pin MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 140: Power Flows

    3170 Power Flows 1st gear Counter shaft Reverse gear gear gear gear gear gear Reverse gear gear gear gear gear gear MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 141 3170 Power Flows (Cont’d) Reverse gear gear gear gear gear gear Reverse gear gear gear gear gear gear MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 142 3170 Power Flows (Cont’d) Reverse gear gear gear gear gear gear Reverse gear Reverse gear gear gear gear gear Reverse gear idler gear MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 143: Shifting Mechanism

    (1/2 & 3/4 lock) Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward. Neutral 5/R select 5/R shift 5th gear disengaged MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 144 Set ball 2. Gear jump out locking device Hub spline Sleeve spline It prevents the shift lever is beyond the correct shift position while shifting. Clutch gear spline MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 145 It is normal open type switch. Its circuit is formed when the reverse gear is selected. NOTICE Installation Notice • Sealant: Bond-592-Loctite • Tightening torque: 30 Nm ~ 40 Nm MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 146 • Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve. • The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery). MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 147 Spline area of sleeve Spline area of synchronizer ring Synchronizer ring [3rd step] Sleeve Gear spline area Synchronizer key Spline area of sleeve Spline area of synchronizer ring MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 148 • For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 m) • For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 m) MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 149 Transmission oil: ATF DEXRON III Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease Oil level Oil drain screw NOTICE • Sealant on oil drain screw during installation: Bond-592 Loctite • Tightening torque: 40 ~ 50 Nm MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 150: Diagnostic Information And Procedures

    Worn or damaged synchronizer. Check worn or damaged synchronizer parts and replace if necessary. Worn or damaged gears. Check worn or damaged gears and replace if necessary. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 151 Too much oil. Check oil level. Loose bolts at sealing faces. Tighten as specified. Improperly applied sealant. Clean leaking surfaces. Reapply sealant. Worn or damaged oil seal. Replace oil seal. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 152 Slip Yoke Seal Speedometer Drive / Driven Gears Speedometer Driven Gear Housing Input Shaft Seal 1 - 2 Synchronizer Assembly 3 - 4 Synchronizer Assembly 5th Synchronizer Assembly MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 153 • The oil replacement should be done at the quali- • If the oil level is up to the bottom line (5 ~ 7 mm) fied and authorized service station. of plug hole, it is OK. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 154: Removal And Installation

    Oil drain plug Transmission housing T/M assembly mounting bolt (14 mm - 11EA) Removal and Installation Preceding Work: Disconnect the battery negative cable and remove the center console. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 155 4. Unscrew four bolts (17 mm) and separate the rear and front propeller shafts connected to transfer case output shaft. Compress the propeller shaft and bind to torsion bar not to disturb the operation. Tightening torque: Tightening torque: 81 ~ 89 Nm 81 ~ 89 Nm MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 156 (14 mm, 2) at both sides and remove the mounting insulator bracket. Mounting Insulator Bracket Tightening torque: 28 ~ 47 Nm Tightening torque: 28 ~ 47 Nm MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 157 • When installing the transfer case, make sure that the bolts are facing correct direction. • From transmission side (upper: 8), From transfer case side (lower: 3) 9. Disconnect the clutch oil hose from adapter. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 158 10. Support the transmission housing with a hydraulic jack and unscrew eleven transmission bolts (17 mm). (Tightening torque: 50 ~ 60 Nm) 11. Carefully lower the hydraulic jack with transmission assembly. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 159 • SAT clutch cover can not be re-installed if disassembled. SST is needed for re-vse. • Refer to the P.11 at the of this book clutch section. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 160: Disassembly And Reassembly

    (4) with a wrench (12 mm) to remove the top cover. NOTE • Be careful not to lose the disassembled components. 4. Pull out the spring pin (6 x 25) and remove the offset lever. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 161 Be careful not to drop them. 7. Remove the rear ball bearing with a puller and remove the speedometer driven gear. 8. Remove the 5/R shift fork spring pin (6 x 28). MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 162 • Be careful not to stiffen the retainer ring. 9. Spread the retainer ring and remove the 5th counter gear with a puller. 10. Remove the counter reverse spacer. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 163 • Be careful not to lose or mix the spring pins. 14. Remove the 5th gear needle bearings (2). NOTICE • Be careful not to lose or mix the needle bearings. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 164 • Store the ring with the relevant gear to prevent in- correct installation. 17. Remove the 5/R synchronizer hub assembly, the re- verse gear and the shift fork at a time. 18. Remove the counter reverse gear. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 165 22. Remove the gear assembly from the housing. NOTICE • Do not forcefully remove the gear assembly. It may damage the level grooves resulting in incorrect installation. Carefully remove the gear assembly. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 166 • Do not use general bearing puller. 26. Remove the 3/4 gear retainer ring. NOTICE • Be careful not to lose or mix the retainer ring. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 167 28. Loose the 1/2 gear and hub and double synchronizer sleeve with a press. 29. Remove the reverse gear inner race. 30. Remove the main taper roller bearing. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 168 33. Remove the 1/2 gear synchronizer hub along with double synchronizer sleeve. 34. Remove the synchronizer inner intermediate cone and outer ring in 2nd gear side. Synchronizer Synchronizer Synchronizer outer ring intermediate inner ring cone MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 169 3170 35. Remove the 2nd gear and needle bearing. 36. Remove the oil seal from the extension housing. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 170 5. Check the following components for wear: 1) Selector arm 2) Interlock plate 3) 1/2 and 3/4 shift fork 4) Shift shaft 5) Detent/guide plate and offset lever 6) Each shift lever shift fork MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 171 7) Counter shaft front and rear bearing 7. Check the gear sets for wear in teeth surface. 8. Check the gear sets for excessive wear, crack and break and replace if needed. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 172 11. Check the speed gear clutch and synchronizer sleeve for damage in teeth surface. 12. Check the engagement of synchronizer sleeve and speed gear clutch. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 173 NOTICE Groove • 1/2 gear double synchronizer sleeve doesn’t have a step at edge, however, 3/4 and 5/R gears have it. No step MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 174 2nd gear. 5. Install the synchronizer outer ring, intermediate cone and inner ring in turns. 6. Install the 1st gear. 7. Install the 1st gear needle bearing. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 175 • The reverse gear inner race has a step at edge. 11. Place the output shaft assembly with the 1st gear facing downward and install the 3rd gear needle bearing. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 176 • 3/4 gear synchronizer sleeve have a step at edge. Place the groove in hub to face the 3rd gear and align the synchronizer key and the synchronizer ring groove in 3rd gear. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 177 • Apply the force on the inner race other than other points. 17. Install the input shaft along with the 4th synchronizer ring. Place the input shaft to face downward on the work bench. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 178 21. Install the reverse gear needle bearing. NOTICE • The reverse gear needle bearing has two bearing rows and the others consist of two bearings. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 179 25. Install the 5/R gear retainer ring. NOTICE • Adjust the end play between retainer ring and hub to a range of 0.0 to 0.5 mm by using a feeler gauge. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 180 • Place the counter reverse gear with a longer protru- sion facing to the adapter. 27. Install the counter reverse spacer. 28. Install the 5th synchronizer ring. 29. Install two 5th gear needle bearings in line. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 181 31. Install the 5th counter gear by using a press. At this time, place it with a longer protrusion area facing to the adapter. 32. Install the counter 5th gear retainer ring. 33. Install the locking ball. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 182 36. Install the inner race of counter roller bearing by using a press. NOTICE • Place it with a protrusion area facing to the 5th gear. 37. Place the gear assembly on a workbench in parallel. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 183 Also, the 3/4 shift fork is chamfered, but 1/ 2 and 5/R aren’t. 41. Install the 3/4 shift fork and shift rail while aligning the grooves. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 184 NOTICE • Align the 1/2 gear shift lug and interlock plate mating surface. 45. Partially engage the 5/R gear shift fork to the shift rail. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 185 • Place the spring pin with the pin slot facing to the shaft. 49. Install the spring pin into the 1/2 shift fork. NOTICE • Place the spring pin with the pin slot facing to the shaft. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 186 52. Install the stopper plate on the 3/4 shift rail and insert the spring pin. (intermediate size: t= 6 x 25) NOTICE • Place the spring pin with the pin slot facing to the shaft. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 187 56. Apply the sealant to the extension housing. Press down the extension housing against the adapter. NOTICE • Sealant: Silicon sealant -bulk #732 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 188 • Make sure that the gear is at neutral position. If not, the interlock bolt cannot be inserted into the inter- lock plate hole. Installation Notice Sealant Bond 592 loctite Tightening torque 40 ~ 50 Nm MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 189 61. Apply the grease to the top cover and install four bolts (12 mm). NOTICE • Make sure that the gear is at neutral position. Installation Notice Sealant Silicon sealant -bulk #732 Tightening torque 17 ~ 26 Nm MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 190 BACKUP LAMP SWITCH Remove the backup lamp switch with 24 mm wrench. Apply the sealant when installing. NOTICE Tightening torque Sealant Bond-592 LOCTITE Tightening torque 30 ~ 40 Nm MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 191: Inspection/Maintenance

    • The shim adjustment is necessary when replacing the housings, counter gear, input shaft and output shaft. 2. Separate the front fork cover from the housing. 3. Remove the input spacer. MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 192 Apply a proper force to the counter gear and input shaft so that the end plays for bearings are maximized. 7. Tighten the adjusting bolt on the special tool to hold the bearings. MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 193 (14 mm). Measure the starting torque after installation. Installation Notice Starting torque 20 ~ 25 Nm Sealant Silicon sealant -bulk#732 Tightening torque 17 ~ 26 Nm MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 194: Special Tools And Equipment

    Bearing puller Pressing of the bearing and gear W 99 31 002 1B Pressure pipe Providing a space to input W 99 31 003 1B shaft bearing Insert key MANUAL TRANSMISSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 195 W 99 31 006 1B bearing end play Dial gauge holder Removal of 5/R synchronizer W 99 31 007 1B hub assembly, reverse gear Drift and shift fork at one time MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 196 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 197 PART TIME TRANSFER CASE & LOCKING HUB SYSTEM 3240 / 3410 TABLE OF CONTENTS GENERAL ..........2 REMOVAL AND INSTALLATION ... 26 1. Overview .............. 2 1. Components location ........26 2. Removal and installation of IWE (Integrated PART TIME TRANSFER CASE ....3 Wheel End) ............

  • Page 198: General

    (for 4L: stop vehicle first). The warning lamp warns the driver when the system is defective. The 4WD system integrated in KYRON does not have big difference in comparison to the conven- tional part time transfer case, but the changes in comparison to the conventional transfer case are as follows: 1.

  • Page 199: Part Time Transfer Case

    Front axle Front locking hub system (IWE) Front propeller shaft Transmission Part time transfer case Rear propeller shaft Rear axle (IRS type) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 200 Oil drain plug (Tightening torque: 19 ~ 30 Nm) Damper Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 201: System Layout And Functions

    Vacuum line Solenoid valve Atmo- Atmo- sphere sphere Transfer case FL Locking hub FR Locking hub Magnetic clutch Motor Front output shaft PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 202: Locking Hub System

    The vacuum locking hub that is applied to Kyron uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator.
  • Page 203 The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 204 4WD mode, the hub actuator is interlocked to the drive shaft end gear and the front hub end gear. Drive shaft end gear PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 205 Unlike the conventional systems, the vacuum pressure to the front wheel end operates only within the actuator. Supplying vacuum pressure Atmosphere PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 206 Locking hub actuator: pulled out when releasing vacuum pressure Drive shaft Front wheel end Front hub end gear is not invisible (4WD mode engaged) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 207 3240 Front Wheel End in Vehicle with 4WD Front Wheel End in Vehicle without 4WD PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 208 2. Connect vacuum gauge to vacuum line of hub actuator. Vacuum gauge Solenoid valve Connect vacuum gauge to vacuum line of front hub actuator. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 209 (gauge indication: 0) with a vacuum pressure gauge, the drive shaft should be rotated along with the wheel. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 210 If the vacuum pressure is maintained, the If the vacuum pressure is not maintained, actuator hub component condition is OK. replace the actuator with a new one. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 211: Transfer Case

    Front flange 1 pin connector (For magnetic clutch power supply) * Delete power supply terminal and ground for conventional speed sensor. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 212 Connect to rear propeller shaft 2H-4H Shift fork (Lockup fork) 4H-4L Shift fork (Reduction shift fork) Shift motor Connect to front propeller shaft PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 213 Connector Shape and Function Magnetic Clutch Coil Power Supply Connector The transfer case integrated in KYRON doesn’t have an internal speed sensor and receives the speed signal from ABS/ESP HECU or the instrument panel (Non-ABS vehicle) via CAN communication. Therefore, there are not extra terminals for speed sensor power supply and ground.
  • Page 214 Position 3 Position encoder Position 4 ground (Return position) 2WD/4WD switch HIGH/LOW switch CAN HIGH K-Line (Self diagnosis) CAN LOW Hub solenoid PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 215 3240 Transfer Case Circuit Diagram PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 216: Power Flow

    Locking Hub Solenoid Locking Hub Operation (Internal vacuum released) Transfer Front Propeller Shaft Rear Propeller Shaft Front Axle Rear Axle Front Wheel Rear Wheel PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 217: H Mode (2Wd)

    (Front Wheel) Power Flow Transmission Rear Wheel Output Shaft Transfer Case Input Shaft Rear Propeller Shaft Rear Axle ↓ Output Shaft Rear Wheel PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 218: H Mode (4Wd - High Speed)

    T/C Output Shaft Clutch 4WD-HI Locking Hub Solenoid Operation Engagement of Front Drive Shaft and Locking Hub Rear Propeller Front Wheel Drive Shaft PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 219: L Mode (4Wd - Low Speed)

    Locking Hub Solenoid Output Shaft Magnetic clutch Operation Engagement of Front Drive Rear Propeller Shaft and Locking Hub Shaft Front Wheel Drive PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 220: Trouble Shooting

    If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition switch is turned to “OFF” before shifting completes, TCCU continues monitoring for input and output required for the shifting. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 221: Maintenance And Repair

    2. Do not use an impact wrench to remove or tighten the oil level plug or drain plug since this will damage the threads in the plug. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 222: Removal And Installation

    Rear propeller shaft Drain plug (Tightening torque: 19 ~ 30 Nm) Damper Front propeller shaft Filler plug (Tightening torque: 19 ~ 30 Nm) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 223 3240 Exploded View PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 224 63. Hexagon cap screw 31. Shift shaft 64. Electric motor assembly 32. Retaining ring 65. Oil seal 33. Transfer case assembly 66. Pipe plug PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 225 81 ~ 89 Nm (T/C ) Tightening torque 70 ~ 80 Nm (Axle) 3. Disconnect the air hose from the transfer case. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 226 • When installing the transfer case, make sure that the bolts are facing correct direction. From transmission side (upper: 8), From transfer case side (lower: 3) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 227 3240 7. When installing, keep the tightening torque and install in reverse order of removal. Side View Front View PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 228 2. Unscrew the bolts and remove the transfer case motor with bracket. Motor connector Magnetic coil clutch connector NOTICE • Remove two nuts to separate the bracket and motor. Bracket mounting nut PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 229 NOTICE • To do that, install a new shift motor on the same lo- cation that the used shift motor was on. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 230: Removal And Installation Of Iwe (Integrated Wheel End)

    1. Unscrew the two bolts (19 mm) and set the removed brake caliper on the frame. Tightening torque: (85 ~ 105 Nm) 2. Unscrew the two screws and remove the brake disc. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 231 5. Slightly pull the wheel end hub until the wheel speed sensor is visible. Unscrew the mounting bolt (5 mm) and remove the wheel speed sensor. Tightening torque: (6 ~ 8 Nm) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 232 3240 6. Disconnect the wheel speed sensor and the cable. Disconnect connector Wheel speed sensor PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 233 3. Pull out the steering gear linkage lock pin from the knuckle. Unscrew the mounting nut (19 mm) and remove the tie rod end. Lock pin Tightening torque: (110 ~ 130 Nm) PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 234 4. Unscrew the lower arm mounting nut (22 mm). Tightening torque: (140 ~ 160 Nm) 5. Remove the knuckle between upper arm and lower arm with special tool. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 235 (8 ~ 12 Nm) Structure of Hub Actuator Vacuum tube Vent tube Detail Shift seal Clutch ring Shift fork Housing Piston Diaphragm Spring PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 236 * Completely clean the parts and apply the grease them before installation. Be careful not to damage the internal seal ring of the hub actuator. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 237: Special Tools And Equipment

    Pliers DW 220 - 080 (W 99 31 005 0B) Installation of oil seal to transmission case Oil seal installer PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 238: Tccu (Transfer Case Control Unit)

    5. The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU. Location TCCU Pin Arrangement PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 239 Ignition power Input Power supply terminal when ignition switch is ON Solenoid power Output Locking hub system applied to KYRON makes difference in related supply to the conventional part time system and the vacuum supply in operating process. Ground Battery PART TIME TRANSFER CASE &...

  • Page 240: System Operation

    5) The “4WD CHECK” warning lamp comes on when the system is defective. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 241 4H from 4L 2) Operation diagram of “4H” indicator when changing the switch to 4L from 2H/4H 0.3 seconds PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 242 The motor stops when the encoder related to troubles are detected during shift operation. It moves toward LOW- HIGH direction for 5 seconds so that the motor is not left in unidentified position. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 243: Trouble Diagnosis Test

    2. When the system detects a fault in shift motor for over 0.8 seconds, the “4WD CHECK” warning lamp comes on and the trouble code is stored into the memory. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 244: Self-Diagnosis Test

    4. After repairing, erase the defective code stored in TCCU. NOTICE • Before replacing the malfunction parts with defective code, check the wires and connectors for looseness. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 245: Diagnostic Trouble Code

    - When no shifting operation from 4L to 4H, even though the shift conditions are satisfied and no error. - Replace TCCU if necessary. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 246 Abnormal CAN neutral signal P1815 - No neutral signal from automatic transmission over 1 second through CAN. - Check CAN communication line. - Check TCU. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 247 10 Nm 3. Disconnect the TCCU connect and remove the TCCU. NOTICE • Be careful not to apply any impact to TCCU body. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 248 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 249 CLUTCH 3010 TABLE OF CONTENTS GENERAL..............3 1. Function and overview ............3 2. Specifications ............... 8 3. Trouble diagnosis ..............9 4. Maintenance ............... 10 CLUTCH ASSEMBLY ..........12 1. Removal and installation ............. 12 2. Special tools ane epuipment ..........22...

  • Page 251: General

    This system provides higher efficiency than conventional clutch system, and its durability is superior. 1) Clutch master cylinder (mounted on clutch pedal) 2) Concentric slave cylinder pipe (mounted inside of transmission) CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 252 B. Clutch Assembly C. Concentric Slave Cylinder Cross Sectional View of Clutch Assembly 1. Transmission housing 3. Clutch disc cover assembly 5. Washer 2. Clutch disc assembly 4. Bolt 6. Bolt CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 253 The clutch release chamber keeps the oil pressure in the clutch hose and pipe stable and also helps the oil pressure to transfer quickly and generates the remaining pressure in the hose and pipe when the clutch is operated. Chamber assembly Pipe CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 254 The advantages of using the diaphragm spring: the pressure varies only a little even when the clutch disc facing is considerably worn out, its structure is simple, and the pedal effort is small. CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 255 3010 Mounting on Dash Panel Models without ABS/ESP Models with ABS/ESP Clutch pipe Clutch pipe mounting clip mounting clip Tube (Master Tube (Master cylinder-oil chamber) cylinder-oil chamber) chamber chamber CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 256: Specifications

    Master cylinder bolt 8 ~ 18 Nm Fulcrum (clutch pedal bushing) bolt/nut 16 ~ 22 Nm Clutch pedal bracket mounting bolt 8 ~ 18 Nm Stopper bolt 16 ~ 22 Nm CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 257: Trouble Diagnosis

    Worn or damaged concentric slave cylinder Replace Clutch When disengaging Faulty installation of clutch assembly or bearing Repair noisy Damaged pilot bushing Replace Clutch pedal is partially depressed and vehicle speed is reduced CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 258: Maintenance

    • This work has to be done by two service persons. • After bleeding, check the clutch system for operation and noise. • Use only the Ssangyong genuine clutch fluid, and check the clutch fluid level in reservoir. Clutch fluid...
  • Page 259 Installation of Special Zig Remove the transmission and place the zig set (4 pieces) between the clutch cover and diaphram spring around (refer to the picture). * P/No: D9930 - 0010C CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 260: Clutch Assembly

    8. Concentric slave pipe 3. Clutch hydraulic pipe 9. Concentric slave cylinder 4. Clutch fluid chamber 10. Clutch cover 5. Clutch hydraulic hose 11. Clutch disc 6. Adapter A-A : Connection CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 261 NOTICE • Do not remove the bolts at a time, or clutch cover may be damaged or deformed. Installation Notice Tightening torque 24 ± 3 Nm CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 262 4. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc. NOTICE • Be careful not to drop the pressure plate and clutch disc. T/M installation mark Clutch disc Pressure plate CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 263 • Do not re-use the used clutch fluid. • Apply a small amount of clutch fluid on the internal components such as piston. • Replace parts if necessary. Keep the specified tightening torque. CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 264 4. Disconnect the clutch master cylinder push rod from the clutch pedal and remove the clutch master cylinder. 5. Install in the reverse order of removal and check “air bleeding and clutch pedal operation” after installation. CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 265 3. Unscrew the mounting nut (12 mm) and remove the pedal Stud bolt (1EA) box assembly. Installation Notice Tightening torque 8 ~ 18 Nm Hexagon flange nut Push rod on master cylinder Clutch pedal mounting hole Pedal box assembly CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 266 4. Check the fulcrum bolt and the bushing for wear, the pedal for bending and the spring for damage. CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 267 • Clutch pipes are reusable. However, you must check the pipes for damages and cracks. Chamber and Pipe Master cylinder Oil chamber Primary oil pipe Secondary clutch fluid pipe Concentric slave cylinder adapter CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 268: Inspection And Maintenance

    Wear limit 0.3 mm 3. Clutch Disc Run-Out 1) Measure the clutch disc run-out and if it is out of limit, replace the disc. Run-out limit Within 0.7 mm CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 269 • The excessively worn components should be replaced. 5. Concentric Slave Cylinder 1) Check any heat damage, abnormal noise, poor rotation and wear of the concentric slave cylinder bearing. CLUTCH CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 270: Special Tools Ane Epuipment

    3010 2. SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application Support diaphram spring when D9930 - 0010C disassembled Zig set - diaphram spring CLUTCH CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 271 AXLE 4120 / 4210 / 4220 TABLE OF CONTENTS GENERAL ..............3 1. Overview ................3 FRONT AXLE ............5 FRONT AXLE ASSEMBLY ........6 REMOVAL AND INSTALLATION ......8 5-LINK TYPE REAR AXLE ........15 1. Location ................15 2.

  • Page 273: General

    The below figures for rear axle show the rear axle with the independent type suspension (4WD, A/T). Front Axle Rear Axle IRDA (Independent Rear Drive Axle) AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 274 1.5 L 1.9 L Capacity ← Length 448.0 mm 412 mm 469.0 mm ← Width 681.9 mm 292 mm 1717.7 mm ← Weight 45 kg 30 kg 100 kg AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 275: Front Axle

    Knuckle From vacuum pump To air Cap & lock nut Tightening torque: 28 ~ 32 Nm Axle shaft Tire fixing bolt Tightening torque: 120 ~ 140 Nm Brake disc AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 276: Front Axle Assembly

    Brake disc Knuckle Front wheel speed sensor cable Brake disc Disc dust cover Axle Shaft Assembly Front disc assembly Wheel speed sensor & cable Axle shaft assembly Locking hub actuator AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 277 Axle mounting bolt axle bolt Axle mounting Axle mounting Axle mounting bolt lower bushing lower bushing Axle mounting upper bushing Axle mounting Axle lower bushing mounting bracket Axle mounting bracket AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 278: Removal And Installation

    1. Removal of the front tire Remove the front tire wheel caps. Unscrew five wheel nuts (21 mm) in diagonal direction and remove tires. Installation Notice Tightening torque 120 ~ 140 Nm Wheel cap AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 279 3. Brake disc caliper Unscrew two mounting bolts (19 mm) and remove the brake disc caliper. Set the removed caliper on the vehicle frame. Installation Notice Tightening torque 85 ~ 105 Nm AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 280: Axle Shaft

    Tie rod end (2) Tightening torque: Tightening torque: 150 ~ 170 Nm 110 ~ 130 Nm 3. Loosen the upper arm (1) and the tie rod end (2) and remove the assembly. AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 281 4120 4. Remove the axle shaft. Components Boot band Shaft Boot band Seal Boot (in-board) Drive shaft Boot band Ball joint Boot (out-board) Boot band Housing (in-board) AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 282 95 ~ 142 Nm 3. Unscrew the four bolts (17 mm) on the axle housing and remove the axle mounting bracket. Installation Notice Tightening torque 80 ~ 100 Nm AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 283 Otherwise, it cannot be removed due to interruption. 5. Place a safety jack under the axle housing and remove the axle mounting bolts (22 mm). Installation Notice Tightening torque 95 ~ 142 Nm AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 284 Axle mounting bolt Axle mount- ing bolt Axle mounting Axle mounting Axle mounting lower bushing lower bushing upper bushing Axle mounting lower bushing Axle mount- Axle mounting ing bracket bracket AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 285: 5-Link Type Rear Axle

    4120 5-LINK TYPE REAR AXLE 1. LOCATION AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 286 4120 Components Axle Shaft Disc type Axle Housing Axle Yoke Rear Axle Axle Housing Axle Shaft Drum Type AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 287 DI engine + M/T (D20DT / D27DT) 4.27 / 3.91 Final gear ratio DI engine + A/T (D20DT / D27DT) 3.54 / 3.31 Capacity 1.9 L Specification SAE 80W/90 or API GL-5 AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 288: Removal And Installation

    Caliper mounting bolt 85 ~ 105 Nm 2. Unscrew the mounting bolt (10 mm) and disconnect the wheel speed sensor cable. Installation Notice Tightening torque 6 ~ 8 Nm AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 289 Adjusting nut 4. Remove the lock pin and disconnect the parking brake cable. Parking brake cable Lock pin 5. Remove the brake disc. AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 290 6. Remove the plastic plug from the axle shaft flange. 7. Unscrew the four flange lock bolts (17 mm) on the axle housing flange and remove the axle shaft. Installation Notice Tightening torque 50 ~ 64 Nm AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 291 Tightening torque: Tightening torque: 6 ~ 8 Nm 6 ~ 8 Nm C. Parking Brake Cable - LH/RH D. Disc Brake Caliper - LH/RH Tightening torque: 85 ~ 105 Nm AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 292 F. Upper arm bolt/nut (22 mm) lizer bar (14 mm - 2 EA: LH/RH) Assembly mark Tightening torque 40 ~ 60 Nm Tightening torque 70 ~ 80 Nm Tightening torque 150 ~ 180 Nm AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 293 4120 3. Carefully lower the safety axle to remove the rear axle assembly from the vehicle frame. Front View Rear View AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 294: Independent Suspension Type Rear Axle

    1. OVERVIEW Introduction Compared to previous models, in addition to existing 5-link suspension, the IRDA (Independent Rear Drive Axle) is adopted for the independent type suspension in this vehicle. AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 295 (steel, aluminum cover) SAE 75W/90 SAE 80W/90 Specification (Synthetic) 1.5 L Capacity 1.9 L 412 mm Length 469.0 mm Width 292 mm 1717.7 mm Weight 30 kg 100 kg AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 296: Exploded View

    44. Output shaft snap ring 29. Differential case side bearing 13. Differential case snap ring 45. Output shaft 14. Differential case side bearing 30. Differential bearing race assembly AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 297 Rear axle assembly Ball joint Boot Rear axle shaft Boot Brake disc Ball joint Back plate Hub bearing Wheel / Tire Parking brake Tightening torque: Lock nut 250 ~ 350 Nm AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 298: Irda (Independent Rear Drive Axle)

    Axle Shaft Assembly Axle shaft Rear axle shaft Hub plane washer Mounting bolt Lock nut (axle side) Tightening torque: Tightening torque: 250 ~ 350 Nm 70 ~ 80 Nm AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 299 Tightening torque: Rear axle 9 ~ 11 Nm bracket Axle Housing Mounting Bracket Bolt Axle Housing Mounting Bolt Tightening torque: 9 ~ 11 Nm Rear axle bracket Rear axle AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 300: Removal And Installation

    2. Make an alignment mark on the flanges of the axle shaft and the axle housing. Unscrew the six bolts (Torx 10 mm) and remove the axle shaft while lowering the axle shaft flange. Tightening torque: 70 ~ 80 Nm Alignment mark Lower the axle shaft. Remove the axle shaft. AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 301 4. Unscrew the mounting bolt (30 mm) and carefully lower the safety jack with axle housing assembly. Tightening torque: 95 ~ 142 Nm Backlash Check Measure the backlash between the drive pinion and ring gear. Specified value 0.15 ~ 0.20 mm AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 302: Trouble Diagnosis

    Replace Worn or damaged universal joint Replace Worn or damaged axle shaft bearing Replace Lack of oil Replenish Heating Insufficient backlash of gears Adjust Excessive preload of bearing Adjust AXLE CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 303 • Gear contacts on the low • Move the ring gear toward flank the drive pinion (toward the • Gear can be damaged or ring gear center line) worn • Noise can be occurred AXLE CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 304 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 305 SUSPENSION 4411 / 4510 / 4520 TABLE OF CONTENTS FRONT SUSPENSION ......2 IRS TYPE REAR SUSPENSION ... 32 1. System overview ..........2 1. Overview ............32 2. System layout ............. 6 2. Specifications ........... 34 3. Removal and installation ........8 3.

  • Page 306: Front Suspension

    It relieves the load delivered from the tire to the knuckle. This enables to absorb the various impacts according to the load shapes and to ensure the drivability. SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 307 Higher spring rates and shorter overall lengths are commonly used to lower the vehicle’s ride height for enhanced appearance and im- proved handling. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 308 This double tube type shock absorber restrains the vibrations by using oil resistance. This provides better drivability even though the structure is complicated. This vehicle uses the gas shock absorber with cylindrical double tube. Time without shock absorber with shock absorber SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 309 12. Upper spring seat 4. Cylinder 13. Rubber 5. Piston 14. Rubber 6. Shock absorber assembly 15. Spacer 7. Spring 16. Washer 8. Yoke 17. Nut 9. Boot 18. Bolt SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 310: System Layout

    Front axle shaft assembly Stabilizer Bar Assembly Steering gear box assembly Lower Arm Assembly Shock Absorber Yoke Lower arm (on knuckle) nut Tightening torque: 140 ~ 160 Nm Knuckle Assembly SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 311 Tightening torque: 180 ~ 190 Nm Lower arm (on shock absorber yoke) nut Tightening torque: 150 ~ 170 Nm Lower arm (end yoke) bolt Tightening torque: 50 ~ 70 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 312: Removal And Installation

    : Remove the split pin first and then remove the mounting nut. Tightening torque: NOTICE 140 ~ 160 Nm • Replace the split pin with a new one when installing. SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 313 : Separate the upper arm from the frame first, and then separate it from the knuckle with a special tool. Upper Arm Assembly Upper arm Bolt / nut Split pin Castle nut SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 314: Coil Spring & Shock Absorber Assembly

    (24 mm) : Unscrew the lower nut of coil spring/shock absorber yoke from the lower arm. Do not com- pletely remove the nut. Tightening torque: 150 ~ 170 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 315 Lock bolt When installing the yoke Tightening torque: to the coil spring/shock 100 ~ 120 Nm absorber, make sure that slot B and protru- sion A are aligned. Yoke SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 316: Stabilizer Bar

    2. Unscrew the two bracket mounting bolts (14 mm) and remove the stabilizer bar assembly. Mounting Stabilizer bar bracket Bushing Tightening torque: 30 ~ 45 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 317 2. Be cautious of the marks on the front stabilizer bar (LH/RH) when installing. LH: yellow mark RH: white mark Stabilizer Bar Assembly Bracket Bracket Stabilizer bar Bushing Bushing Link Link SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 318: Lower Arm

    -0.19° ± 0.3° (the difference between both ends is should be below 30 ' ) Caster 4.4° ± 0.5° (the difference between both ends is should be below 30 ' ) Front Rear SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 319 Interference between camber Interference between camber bolt and steering gear box bolt and steering gear box NOTICE • Be careful not to damage the SSPS solenoid valve connector. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 320 Lower link nut (12 mm) Tightening torque 1. Lower link nut (110 ~ 130 Nm) Lower yoke nut (24 mm) 2. Lower shock absorber yoke nut (150 ~ 170 Nm) SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 321 Re- move the yoke while raising the safety jack with lower arm. 5. Remove the lower arm assembly from the vehicle. Components SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 322 MEMO .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 323: 5-Link (Rigid Type) Rear Suspension

    It is installed between the rear axle and body It enhances the ride comforts and prevents the frame. It relieves the vibrations and impacts deliv- fatigue break of the spring. ered from wheels to vehicle body. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 324: System Layout

    4510 2. SYSTEM LAYOUT Lower Arm (Link) Stabilizer Bar Link Stabilizer Bar Upper Arm (link) Shock Absorber Lateral Rod Axle Housing Coil Spring Seat (Upper) SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 325 150 ~ 180 Nm Lateral rod (22 mm) 165 Nm Shock absorber (lower: 7 mm + 10 mm) 80 ~ 100 Nm Shock absorber (upper: 2 mm) 30 ~ 45 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 326 4510 Location Shock Absorber Assembly Coil Spring Assembly Lateral Rod Assembly SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 327 4510 Stabilizer Assembly Stabilizer Bar Link Upper/Lower Arm Assembly SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 328: Front View

    4510 Installation Drawing Front View Rear View SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 329: Trouble Diagnosis

    Hard steering Insufficient tire pressure Replace Faulty power steering Adjust Steering instability Worn or loosened lower arm bushing Re-tighten or replace Vehicle bottoming Worn or broken coil spring Replace SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 330: Removal And Installation

    4510 4. REMOVAL AND INSTALLATION System Layout Shock absorber Stabilizer bar Upper Rear suspension assembly Stabilizer bar link Lateral rod Coil spring Lower arm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 331 1) Unscrew the lateral rod mounting nut (22 mm) on axle. Installation Notice Tightening torque 165 Nm 2) Unscrew the lateral rod mounting bolt/nut (22 mm) on frame. Installation Notice Tightening torque 165 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 332 Protrusion of upper bolt 7 ~ 12 mm 2) Remove the mounting cap bracket and bushing from the stabilizer bar (LH/RH). Installation Notice Tightening torque 40 ~ 60 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 333 Installation Notice Tightening torque 30 ~ 45 Nm Protrusion of upper bolt 27 mm 2) Remove the lower bolt/nut (17 mm). Installation Notice Tightening torque 80 ~ 100 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 334 150 ~ 180 Nm Tightening torque 150 ~ 180 Nm NOTICE • The fuel tank should be removed before removing the rear left bolts (upper arm and lower arm). SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 335 2) Unscrew lower arm mounting bolt/nut (22 mm) on frame. Installation Notice Tightening torque 150 ~ 180 Nm 3) Unscrew lower arm mounting bolt/nut (22 mm) on axle. Installation Notice Tightening torque 150 ~ 180 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 336: Irs Type Rear Suspension

    It relieves the vibrations and im- pacts delivered from wheels to vehicle body. The spring should be installed as the red mark is over the yel- low mark. Yellow SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 337 It means that this controls the verti- cal load to the vehicle. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 338: Specifications

    Excessive resistance of lower arm ball joint Replace Insufficient tire pressure Replace Faulty power steering Adjust Steering instability Worn or loosened lower arm bushing Re-tighten or replace Vehicle bottoming Worn or broken coil spring Replace SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 339 6. If the measured preload is out of the specified range, retighten the castle nut to the specified torque. 7. If the trouble still exists, replace the wheel bearing with a new one. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 340: Removal And Installation

    11 ~ 13 Nm Stabilizer Bar Stabilizer bar link: Stabilizer bar mounting Stabilizer bar link: 40 ~ 60 Nm bracket bolt: 40 ~ 60 Nm 40 ~ 60 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 341 110 ~ 130 Nm Coil Spring Link Body: 110 ~ 130 Nm Knuckle: 120 ~ 150 Nm Shock Absorber Body: 30 ~ 45 Nm Coil spring link: 60 ~ 80 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 342 Tightening torque: 85 ~ 105 Nm 3. Unscrew the two stabilizer bar mounting bracket bolts (14 mm) from body (frame) and remove the stabilizer bar. Mounting bracket Tightening torque: 40 ~ 60 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 343 5. Tighten the special tool to compress the coil spring. Remove the coil spring and spring seat while pulling down the coil spring link. 6. Unscrew the bolt (10 mm) and remove the parking brake cable and wheel speed sensor. Tightening torque: 6 ~ 8 Nm SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 344 C. Sub frame coil bolt (front - 14 mm) D. Sub frame bolt (rear - 14 mm) Tightening torque: 95 ~ 142 Nm Tightening torque: 95 ~ 142 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 345 4520 8. Lower the safety jack and remove the sub frame from the vehicle. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 346 2. Unscrew the shock absorber lower bolt/nut (bolt: 14 mm / nut: 17 mm) on coil spring link. Tightening torque: 60 ~ 80 Nm 3. Remove the shock absorber from the rear suspension. SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 347 2. Release the compression force of coil spring by loosening the lower shock absorber bolt/nut and remove the coil spring and upper spring seat. Upper spring seat Coil spring Yellow NOTICE • The spring should be installed so that the red mark is over the yellow mark. SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 348 2. Unscrew the bolt/nut (14 mm) on the link and stabilizer bar and remove the stabilizer bar. Also, unscrew the bolt (12 mm) on the knuckle and remove the link. Link mounting nut Tightening torque: 40 ~ 60 Nm Stabilizer bar mounting nut Tightening torque: 40 ~ 60 Nm SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 349 4520 3. Install the stabilizer link. Be cautious of the installing direction. LH/RH Link Link Link mounting mounting Link Link Stabilizer bar Bracket and Bracket and bushing bushing SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 350 (Tightening torque: 40 ~ 60 Nm) Upper Arm (Knuckle Side) 19 mm - 1EA: bolt/nut (Tightening torque: 140 ~ 160 Nm) Upper Arm 19 mm - 1EA: bolt/nut (Tightening torque: 110 ~ 130 Nm) SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 351 Thrust Link on Body Thrust Link on Knuckle 22 mm - 1EA: bolt/nut 19 mm - 1EA: bolt/nut (Tightening torque: 150 ~ 170 Nm) (Tightening torque: 110 ~ 130 Nm) SUSPENSION CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 352 60 ~ 80 Nm Tightening torque: 120 ~ 150 Nm 1. Bolt and nut (lower shock absorber) Bolt and nut (sub frame, 22 mm) 2. Bolt and nut (knuckle, 22 mm) SUSPENSION CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 353 POWER STEERING SYSTEM 4610 / 4620 TABLE OF CONTENTS GENERAL INFORMATION ........3 1. Overview ................3 2. System layout ..............4 SSPS (SPEED SENSING POWER STEERING) ..8 1. General information ...............8 2. Trouble diagnosis ..............15 3. Removal and installation ............. 24...

  • Page 355: General Information

    Maximum pressure (kgf/cm 85 ~ 92 Displacement ( /min) 10.5 Pulley size (mm) Tilt column adjusting angle 4° Down 8° Minimum turning radius Specification ATF Dexron III Capacity POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 356: System Layout

    With SSPS Gear box pipe Power steering Power steering high pressure gear box hose and pipe SSPS Solenoid Valve * cannot be replaced Return hose and pipe POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 357 Pipe bracket bolt (10 mm) Tightening torque: 9 ~ 14 Nm Pipe mounting nut Tightening torque: 20 ~ 26 Nm Gear box mounting bolt Installation Drawing of SSPS POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 358 Tightening torque: Tightening torque: 65 ~ 80 Nm 70 ~ 90 Nm 30 ~ 40 Nm Tightening torque: 45 ~ 50 Nm Steering gear box Tie rod end POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 359 4610 Steering wheel Lower shaft Column shaft Steering gear box POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 360: Ssps (Speed Sensing Power Steering)

    SSPS (Speed Sensitive Power Steering) NOTICE • If the SSPS solenoid valve is defective, the power steering assembly should be replaced. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 361 PCV. the changes of solenoid valve. Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from SSPS control unit. POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 362 Specifications Description Specification Voltage Rating DC 12 V Current Rating 1.0 A 6.7 ± 1 Ω Resistance POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 363 3) The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to reaction plunger. 4) At this time, the reaction plunger transmits the reaction force to V-groove in input shaft to provide heavy steerability. POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 364 3. When a trouble occurs in the system, the SSPS control unit generates a trouble code using fail safe function. Pin No. Function Ignition Power Supply CAN HIGH Solenoid Solenoid Ground Warning Lamp (SSPS) CAN LOW Self Diagnosis Location SSPS unit POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 365 Pinion valve Valve body Balance line Spring Right Filter cylinder Spool Pressure Connector Left cylinder Solenoid valve Plunger Reaction device Steering gear box Reaction line POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 366 Pinion valve Valve body Balance line Spring Right Filter cylinder Spool Pressure B Port Connector Left cylinder Solenoid valve Plunger Reaction device Steering gear box Reaction line POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 367: Trouble Diagnosis

    Current 0.9 ~ 1.1 A (vehicle speed at 0 km/h) Vehicle speed [km/h] POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 368 ~ 7.7 W (at 20°C) during integrity check? Poor contact in SSPS solenoid Check solenoid valve connector valve connector or defective ECU or replace ECU. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 369 4. Check the connectors for poor contact. NOTICE • When the Fail Safe function is activated, the steering wheel operation needs much more force due to no cur- rents to SSPS solenoid. POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 370 4610 Circuit Diagram SSPS Control Unit SSPS Solenoid Diagnosis Cluster "12" "B11" POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 371 Damaged or loosened oil pump drive belt Adjust or replace Loosened oil pump bracket Retighten Loosened oil pump mounting bolt Retighten Air-in system Bleed Faulty oil pump Replace POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 372 Inner 36° 20' Specified value Outer 32° 40' NOTICE • If the free play is out of the specified value, check and adjust the toe-in. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 373 • To prevent internal damage, do not close the gauge valve over 10 seconds. Pump relief valve pressure 89 ~ 97 kg/cm Pump pressure at no load 3 ~ 5 kg/cm POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 374 3. Place the steering wheel at straight ahead direction. 4. Measure the oil level in the power steering oil reservoir. 5. Adjust the oil level between MAX and MIN. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 375 2. This process should be performed to check if air still exists in the power steering system. NOTICE • Position the gear shift lever to “N (M/T)” or “P (A/T)”, and apply the parking brake before starting the engine. POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 376: Removal And Installation

    Preceding Work: Disconnect the negative battery cable. 1. Remove the engine ECU under the floor carpet. 2. Disconnect the SSPS control unit connector and separate the SSPS control unit from engine ECU. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 377 4610 SSPS Control Unit POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 378 Tightening torque: 40 ~ 60 Nm 3. Remove the instrument panel side cover and unscrew the side lock bolt and screws to remove the instrument lower panel. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 379 5. Disconnect the contact coil and connector from the column shaft and remove the contact coil assembly. Contact coil mounting screw Inlet portDisconnect the connector Align the alignment marks when installing POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 380 4610 6. Disconnect connectors and remove the combination switch from the steering column. Unscrew the mounting screws Disconnect the connectors Combination Switch Assembly POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 381 Mounting Bolts (2 EA) Tightening torque: 20 ~ 25 Nm Tightening torque: 20 ~ 25 Nm Lower Shaft Mounting Bolt (1 EA) Tightening torque: 18 ~ 25 Nm POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 382 • Install the lower shaft so that the lock bolt can be in- serted into the point without spline. • Be cautious of the alignment marks. Lower Shaft Assembly POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 383 Ball Joint Puller Tightening torque: 35 ~ 45 Nm 2. Remove the SSPS connector. 3. Unscrew the lower bolts and remove the lower shaft and gear box. POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 384 70 ~ 90 Nm 30 ~ 40 Nm NOTICE • Tighten the center bolt/nut first, and then tighten the left mounting bolt with the specified tightening torque. POWER STEERING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 385 • Plug the openings so that power steering fluid doesn't leak out. Return hose 3. Unscrew the nuts and remove the pump assembly with bracket. Installation Notice Tightening torque 20 ~ 23 Nm POWER STEERING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 386 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 387 ABS/ESP SYSTEM 4890 / 4891 TABLE OF CONTENTS GENERAL INFORMATION ...... 2 ABS SYSTEM ......... 60 1. General information .......... 2 1. General information ........60 2. Specifications ........... 5 2. Configuration of ABS system ......63 3. Brake operation and noise ....... 6 3.

  • Page 388: General Information

    Hand Operated Type Foot Operated Type (Vehicle with Manual Transmission) (Vehicle with Automatic Transmission) ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 389 4890 Sectional Drawing Front Disc Brake Two internal cylinders Rear Disc Brake One internal cylinder ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 390 Location of the wheel speed sensor (rear right wheel) Location of the Sensor Connector Tightening torque: 6 ~ 8 Nm Connector Appearance In vehicle without ABS In vehicle with ABS/ESP ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 391: Specifications

    Manual type - Hand (MT)/Foot (AT) Manual type - Foot φ 190 mm φ 254 mm φ 190 mm I.D. of drum Capacity 0.7 ~ 0.8 Brake fluid Specification DOT4 ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 392: Brake Operation And Noise

    It is also a physical phenomenon and has no relation with the brake performance. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 393: Esp System

    4. ASR (Acceleration Slip Regulation) 5. AYC (Active Yaw Control, Understeer Oversteer control) 6. HBA (Hydraulic Brake Assist System) 7. ARP (Active Rollover Protection) 8. HDC (Hill Descent Control) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 394: General Information Of Esp System

    The transfer case (T/C) installed on this vehicle doesn’t have the internal speed sensing device and receives the speed signal for T/C control from ESP HECU via CAN bus. [Conventional T/C] [New T/C] Without speed sensor With speed sensor ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 395 4890 Cautions When Removing the Front Wheel Speed Sensor The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the conventional approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator.
  • Page 396 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 397 Integrated yaw rate sensor and Behind the center audio in lateral sensor. Also, used for instrument panel sensing G value for HDC (Hill Descent Control). Pressure Sensor Analog Output Under master cylinder ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 398: Principle Of Esp

    ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 399 The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be changed depending on the vehicle driving situations and driving conditions. Operating range Turning Turning ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 400 ESP auto brake Driver foot brake operation ABS brake The slip occurs under ESP operation ABS operation TCS (Engine Control) The slip occurs under ESP operation TCS operation ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 401: Hba (Hydraulic Brake Assist System)

    In this case, only the conventional brake system with booster is activated. Pressure sensor HECU Hydraulic line Operating conditions: 1. Pressure: over 20 bar 2. Pressure changes: over 1500 bar/sec 3. Vehicle speed: over 7 Km/h ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 402: Arp (Active Roll-Over Protection)

    • 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. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 403: Hdc (Hill Descent Control)

    • The G sensor in sensor cluster measures the actual road steepness. However, it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10%, and the HDC may operate. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 404 HDC goes into operation.) Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission) 3) HDC target speed in 4L mode Forward and reverse driving: 3 km/h ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 405 HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 406 HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 407 20: HDC is deactivated. (instrument panel) 2. If the slope level exceeds 20%, HDC function is still activated and the brake pressure is added. Sensor cluster Longitudinal acceleration sensor ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 408 Basically, the brake system’s basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: • Initial ignition ON • HDC system error occurs • Brake system overheat ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 409 • During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and the brake system, but this is a normal condition during the HDC operation. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 410: Components And Locations

    Master cylinder Sensor cluster: Steering wheel angle sensor pressure sensor (Yaw rate + lateral sensor + longitudinal sensor) HECU (Valve body and ECU integrated type) Valve body Motor pump ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 411 ESP OFF switch and Wheel speed sensor HDC switch. Sensor cluster Steering wheel angle sensor Active Wheel Speed Sensor HDC Switch HDC Indicator ESP OFF Switch ABS / ESP Indicator ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 412: Input And Output Diagram

    Pressure sensor 2 Signal Ground In ESP equipped vehicle, the sig- nals from SWAS are sent to ECS ECU. Ground (Pump) SWAS (Steering wheel angle sensor) Ground (Valve) Ground ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 413: Esp System Related Precautions

    5. The warning lamp flashes and warning beep sounds when the ESP is operating When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flashes and beep comes on every 0.1 seconds. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 414: Hydraulic Circuit Diagram

    (NO) (NO) (NO) (NO) outlet outlet outlet outlet valve (NC) valve (NC) valve (NC) valve (NC) Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL) ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 415: Hydraulic Pressure For Each Esp Operating Range

    When the brake is applied under these conditions, the allow fast oil drainage. brake fluid will be sent to each wheel via the separation valve and inlet valve. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 416 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. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 417: Hydraulic Circuit Of Hba (Hydraulic Brake Assist)

    The motor still keeps rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA function cancels and switches to ABS operation. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 418: Components Description

    Rear RH and LH (Rear LH Primary when ESP is applied) Secondary 2. Comparison ESP HECU and ABS/EBD HECU ABS HECU ESP HECU 3. Other components HECU Pump Motor Valve Body ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 419 3. Disconnect the front and rear wheel brake pipes. Tightening torque HECU to each hydraulic line 13 ~ 20 Nm NOTICE • Be careful not to damage the HECU pipes and nut threads when reinstalling. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 420: Pressure Sensor

    4.75 ~ 5.25 V 0.25 ~ 4.75 V (This is linearly changed from 0.5 V (brake not applied) to Output voltage 4.75 V (brake applied)) Output range 0 ~ 170 bar ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 421 HBA operating conditions: 1. Pressure: 20 bar Signal output 2. Pressure changes: over 1500 bar/sec < Secondary < ESP unit > pressure sensor > 3. Vehicle speed: over 7 km/h ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 422 5. Remove the primary and secondary pressure sensors. When installing Tightening torque 33 ~ 37 Nm 6. Install in the reverse order of removal. 7. Bleed the brake system after installation. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 423 (acceleration around the vertical axis of the vehicle) and transmits it through the CAN communication line to the ESP unit, using the electronic signal. Especially, the longitudinal acceleration sensor detects the slope level of the driving road and provides important information for the HDC operation. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 424 0 V (fail safe function). Power supply circuit Yaw rate sensor Lateral sensor Micro controller Longitudinal CAN module sensor < Internal electric circuit of sensor cluster > ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 425 Remove three screws before removal 2. Remove the AV head unit assembly. Remove four screws NOTE • AV head unit may have different connectors according to the specifications. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 426 • The installing direction and location are very impor- tant when installing the sensor cluster. Make sure that there are not any foreign material and interfer- ence with floor carpet on the mounting surface. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 427 - 30 ~ 75°C Working temperature Supplying voltage 9 ~ 16V (battery voltage) Output voltage (HI) Approx. 3.50V (3.0 ~ 4.1V) Output voltage (LO) Approx. 1.50V (1.3 ~ 2.0V) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 428 2 ° High Detects steering wheel ST1 and angle and angular velocity as an average value Center line of steering wheel Detects the center value of steering wheel ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 429 ESP warning lamp blinks minimum of 4 times every 175 milliseconds. ESP operation (including TCS) 175ms ESP warning lamp 175ms Min. 4 times ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 430 • When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP sys- tem will not be turned on. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 431 • When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen- sate the vehicle stability (posture) during ESP operation. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 432 The air bleeding procedure should be started from the rear right wheel. 6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw. 7. Perform the same procedures at each wheel. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 433 CLOSE BLEEDER SCREW. THERE IS FOAMLESS AND BUBBLE FREE BRAKE FLUID SEEN AT THE BLEED SCREW. PRESS “ENTER”. TIME : xxx [Sec] BUBBLE FREE(FOAMLESS) ? (Yes / No) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 434: Abs/Esp Trouble Diagnosis

    - Check the wheel speed sensor connector and HECU connector - Check air gap and tooth wheel mounting (Specified air gap: 0.335 ~ 0.945 mm) - Check the number of teeth (48) in tooth wheel ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 435 - Check the wheel speed sensor connector and HECU connector - Check air gap and tooth wheel mounting (Specified air gap: 0.309 ~ 0.958 mm) - Check the number of teeth (48) in tooth wheel ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 436 - Abnormal signals from yawing sensor - Poor installation of sensor - Defective sensor cluster - Defective or short circuit of CAN communication line Action - Replace the sensor ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 437 Valve - Abnormal supplying voltage to valve solenoid - Internally defective HECU Monitoring Action - Replace the HECU - Check the battery voltage - Check the HECU connector ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 438 - Defective CAN communication line - Misinstallation HECU Action - Check the HECU coding and vehicle coding - Perform vehicle coding - Replace the exact HECU - Check engine ECU variant coding ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 439 - Short to CAN communication line - Overload to CAN communication Action Action - Check the cluster (meter) - Check the CAN communication line - Check the cluster (meter) connector ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 440 ECU is abnormal Cause Communica- - Engine ECU is defective tion - Signal from engine ECU error Monitoring Action - Check engine ECU - Check ECU S/W version ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 441 Operation / Non-operation ESP Control Operation / Non-operation ESP/TCS OFF Switch ON / OFF ABS Control Operation / Non-operation Stop Lamp Switch ON / OFF (O: Applied, X: N/A) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 442 Operation / Non-operation TCS Valve Secondary (*3) Operation / Non-operation ESV Valve Primary (*3) Operation / Non-operation ESV Valve Secondary (*3) Operation / Non-operation Motor Pump Operation / Non-operation ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 443 The steering wheel angle sensor automatically searches for a center position when the vehicle is driving straight forward with 20 km/h of driving speed (no additional diagnostic menu). ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 444 FRONT/LEFT INLET VALVE ---------------------------------------------------- ON(ACTIVE): “YES” KEY OFF(STOP): “NO” KEY OTHER ITEM : “ ” ---------------------------------------------------- ACTIVE TIME : Max. 10 Sec CONDITION : IG. ON or IDLE ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 445 4890 Clearing Code CLEAR VARIANT CODE VEHICLE CODING CLEAR -------------------------------------------------- DO YOU START TO CLEAR? ( YES / NO ) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 446: Abs System

    The transfer case (T/C) installed on this vehicle doesn’t have the internal speed sensing device and receives the speed signal for T/C control from ABS HECU. Conventional Transfer Case New Transfer Case With Speed Sensor Without Speed Sensor ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 447 Cautions When Removing the Front Wheel Speed Sensor The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the conventional approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator.
  • Page 448 Rubber O-ring Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 449: Configuration Of Abs System

    Valve body Front wheel speed sensor (FR) Rear wheel speed ABS HECU sensor (RL) Front wheel speed sensor (FL) B: Plunger C: Can bushing ABS warning lamp Motor pump ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 450: Input And Output Diagram

    Ground (valve and ECU) Currently applied wheel speed sensors are active type and have the PCB with resistance. It measures wheel speed by using current value changing when wheel rotates. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 451: Hydraulic Circuit Of Abs

    This system is similar to the one from the previous model. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 452: Abs Circuit In Each Operation Range

    This may make the driver to feel the brake pedal vibration and some noises. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 453: Components And Location

    6. COMPONENTS AND LOCATION Front LH wheel Primary master cylinder Front RH wheel Secondary master cylinder Rear RH/LH wheel Wheel Speed Sensor - Front (for 4WD) Wheel Speed Sensor - Rear ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 454: Components Description

    ECU, Gore Tex-based plate is used at ECU lower 3) Diagnosis function support cover. The vent hall (arrow) allows air to ventilate but does not allow moisture to penetrate. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 455: Removal And Installation

    4. Disconnect the front and rear wheel brake pipes. Tightening torque HECU - Each hydraulic line 15 ~ 19 Nm NOTICE • Be careful not to damage the HECU pipe and nut thread when reinstall. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 456 7. After reinstallation, add some oil and perform the brake air bleeding. NOTICE • When you install a new HECU to the vehicle, coding is executed automatically. Thus, no additional coding is necessary. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 457 HIGH (vehicle speed: at approx. 2.75 Km/h) : Approx. 7 mA Wheel speed sensor voltage 7.5 ~ 20 V (one rotation per a second at -40 ~ +60) ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 458 1. Disconnect the front wheel speed sensor connector. 2. Remove the front brake disc. Loosen the hub end bolts (do not remove) and disconnect the wheel speed sensor. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 459 • Otherwise, the air gap between the wheel speed sensor and wheel rotor may be out of specified value, and this may cause an incorrect input value to HECU. ABS/ESP SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 460 • Otherwise, the air gap between the wheel speed sensor and wheel rotor may be out of specified value, and this may cause an incorrect input value to HECU. ABS/ESP SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 461 AIR BAG SYSTEM 8810 TABLE OF CONTENTS AIR BAG SYSTEMS (INCLUDING CURTAIN AIR BAGS) .............. 3 1. Overview ................3 2. Locations and related components ........4 3. Air bag system operation process ........6 4. Air bag module and other components ......8 5.

  • Page 463: Air Bag Systems (Including Curtain Air Bags)

    The detonator may explode due to a sudden extra power supplied by the tester. • Before removing or installing any air bag related components, disconnect the negative battery cable. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 464: Locations And Related Components

    2. LOCATIONS AND RELATED COMPONENTS When the curtain air bag (LH) deploys Curtain air bag collision G sensor BPT: Belt Pretensioner When the curtain air bag (RH) deploys AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 465 PAB: Passenger Air Bag AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 466: Air Bag System Operation Process

    Diagnosis Warning Lamp Output Output Diagnose with the K-line The Air Bag Waning Diagnosis and use the 9th diagnosis Lamp on the Instru- Connector connector ment Panel AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 467 Curtain Air Bag (LH) Curtain Air Bag (RH) bag unit. Each sensor measures the G value from its side and trans- mits the decesion to its air bag unit. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 468: Air Bag Module And Other Components

    8810 4. AIR BAG MODULE AND OTHER COMPONENTS This section describes the air bag module installed in Kyron. The module consists of the inflator, the cushion, and the mounting cover. DAB: Driver Air Bag The driver’s air bag is installed inside the steering wheel. If the acceleration sensor (inside the air bag unit) is activated by the deceleration from vehicle collision, the detonation is fired by the electrical signal of the air bag unit.
  • Page 469 (curtain air bags independently operate in case of the side collisions). Front View Rear View Components ±¸¼ºÀåÄ¡ 1. Passenger’s air bag module housing 2. Inflator 3. Air bag cushion 4. Retainer 5. Nut AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 470 When the Curtain Air Bag is Installed Terms of the Curtain Air Bag Nut and bolt Wrapper cover Air bag cushion Gas guide Inflator When the Curtain Air Bag Deploys AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 471 8810 Components Tightening torque: 8 ~ 10 Nm Tightening torque: 8 ~ 10 Nm a - a b - b Sectimal view a-a Sectimal view b-b AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 472 This holds the occupant more securely in the seat. Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side) Tightening torque: 35 ~ 55 Nm Curtain air bag G sensor Belt pretensioner (LH) Belt pretensioner (RH) AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 473 10. Fiber washer 11. Rivet 12. ID label 13. Plastic washer 14. Steel washer 15. D-bolt 16. Label 17. D-bolt 18. Spacer 19. Bush 20. Mini anchor cover AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 474 8810 Air Bag Unit Air bag unit is installed under the AV head unit in center fascia panel. AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 475 As a result, the sensor may have inaccurate judgment and have the air bag deployed inaccurately. Driver’s Side Passenger’s Side Tightening torque: 9 Nm ± 1 Nm Connector Signal Ground terminal AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 476: Electrical Wiring Diagram

    8810 5. ELECTRICAL WIRING DIAGRAM AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 477: Air Bag System Deploy (Firing Loop)

    The detonator may explode due to a sudden extra power supplied by the tester. • Before removing or installing any air bag related components, disconnect the negative battery cable. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 478: Air Bag Deployment Signal Output (Crash Out)

    But, if an unlock request is made by the air bag signal or the remote control key, the request will be accepted. • When the lock and unlock functions are simultaneously requested, the lock will be performed and the unlock will be ignored. AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 479: Air Bag Warning Lamp Operational Conditions

    When, due to an error from outside the system, the intermittent failure signal is received 5 times or less, the air bag warning lamp comes on for about 6 seconds and then, goes off. Ignition Air bag warning 6 seconds lamp AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 480: Reminder For Air Bag Related Component Replacement

    (connectors included), the collision G sensor assembly for the curtain air bag, and the trims and roof headlining for the broken parts. AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 481: Servicing The Air Bag System

    1. Remove the air bag module assembly from steering wheel. 2. Disconnect all connectors and remove the air bag assembly. Release the hook before disconnecting the connector. Components Front View Rear View AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 482 • Turn the contact coil clockwise until it stops and turn it counterclockwise approx. 2.9 ± 0.2 turns to align the “ ” marks. AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 483 (For details, refer to “Body” section.) 1. Remove the lower air duct from the removed instrument panel assembly. 2. Unscrew five nuts on the air bag module (10 mm). AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 484 3. Remove the air bag module assembly from the instrument panel. WARNING • The air bag module cannot be removed. Below pic- ture is only for reference. Components Retainer Air bag cushion Inflator Air bag module housing AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 485 Preceding Work: Disconnect the battery negative cable and remove the instrument panel assembly. (For details, refer to “Body” section.) 1. Disconnect the connector of the curtain air bag while releasing the hook. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 486 8810 2. Remove the handle bracket and then remove the curtain air bag assembly. Components AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 487 1. Center fecia (LH/RH) 3. Passenger’s lower panel 2. Driver’s lower panel 4. Center console 2. Remove the AV head unit assembly. (For details, refer to “AV System” section.) AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 488 3. Unscrew the screws on the instrument panel and remove the relevant components (power socket/shift lever cover). Power Socket Cover Mounting Screw Mounting Screw (Same at Both Sides) AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 489 The detonator may explode due to a sudden extra power supplied by the tester. • Before removing or installing any air bag related components, disconnect the negative battery cable. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 490 • Because the gap between the installation bolt and the sensor is small, grind the bolt-locking socket to around 1.5 mm before mounting the curtain air bag sensor fixation bolt. Components AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 491: Diagnosis

    1354 short to ground • Check passenger air bag wiring. • Check the air bag unit terminals for damage. • Resistance of Firing Loop: below 2 kΩ AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 492 • Check driver curtain air bag wiring. • Check the air bag unit terminals for damage. • Resistance of squib: below 0.6 Ω AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 493 • If the voltage drops below 10.6 V during normal system operation, the trouble code is generated. This trouble code is linked with B1 400, B1 401, B1 402, B1 414. AIR BAG SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 494 Belt pretensioner operation • Replace SDM. 1657 record 2500 Warning lamp error • Check wiring to warning lamp. • Check warning lamp bulb. • Check SDM unit terminal. AIR BAG SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 495 AIR CONDITIONING SYSTEM 6810 / 6910 / 6810 TABLE OF CONTENTS AIR CONDITIONING SYSTEM ....2 FFH (FUEL FIRED HEATER) SYSTEM 61 1. System layout and components ...... 2 1. Overview ............61 2. Ventilation system ..........4 2. FFH layout ............62 3.

  • Page 496: Air Conditioning System

    This sensor is installed at the front bottom source selection and air quality of engine compartment. This changes the system. air source mode by detecting the air pollution. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 497 * A sensor that detects coolant tem- and reserves refrigerant to supply temperature, engine condition and perature and transmits to engine smoothly. driving condition to control the air ECU. conditioner. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 498: Ventilation System

    6810 2. VENTILATION SYSTEM Locations of Vents Air Duct AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 499: Air Conditioner Module Wiring And Layout

    Air source door actuator Power transistor Main wire Air mix door connector actuator Blower motor Intake sensor Active incar sensor (interior temperature sensor) and humidity sensor Air conditioner controller unit AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 500 Coolant Temperature Sensor Mode Door Actuator Intake Sensor Interior Temperature Sensor A/C Controller Unit (Interior Humidity Sensor) Power Transistor/Blower Motor Power transistor Interior temperature and Blower motor humidity sensor AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 501 A/C cable assembly Intake sensor Heater unit case (right) Air mix door actuator Lower duct Heater core Mode door Heater unitcase (left) Mode door link assembly Mode door actuator AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 502 6810 PTC Heater and FFH Heater Layout PTC Heater Assembly Layout FFH Heater Assembly Layout AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 503: Air Conditioner Controller (Unit)

    7. AQS switch 10. A/C switch 2. AUTO switch 5. Mode switch 8. FRE switch 11. VFD (Display) 3. OFF switch 6. Blower switch 9. Defroster switch AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 504 Auto mode Defroster Temperature (ambient A/C operation air temperature, interior Air flow direction set temperature) Fan speed Air recirculation Indicates the ambient Fresh air temperature is displayed AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 505 When pressing the switch again, the air conditioner returns back to normal operations. When pressing the AUTO switch, the defroster mode appears on the VFD until the coolant temperature reaches at a certain level. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 506 6810 Full Automatic Air Conditioner Controller Interior temperature and humidity sensor AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 507 FAN speed 6 FAN speed 7 FAN speed 8 MODE VENT MODE B/L MODE FOOT MODE D/F AUTO (AUTO A/C) OFF (IGN ON) OFF (IGN OFF) TEMPDIAL AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 508 The air flow direction is in DEF mode (below 20°C), D/F mode (20°C~55°C) and AUTO mode (55°C). When the coolant temperature sensor is defective, the heating control function is cancelled after 500 seconds. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 509 COMP Control Air conditioner - Intake air temperature control: COMP OFF when the Blower motor thermo AMP temperature is below 2°C, COMP ON when it is over 4°C. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 510 Vent Mode The air flows towards face and the indicator comes on. Foot Mode The air flows towards floor and the indicator comes on. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 511 Defroster & Foot Mode The air flows towards face and floor and the indicator comes on. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 512: Self Diagnosis (Only For Fatc Air Conditioner)

    Turn the ignition switch to OFF position and press OFF switch for more than 5 seconds within 10 seconds. 1. ÀÚ±â Áø´ÜÁøÀÔ 2) Check LED segments on the vacuum fluorescent display (VFD). 1) Press OFF switch more than 5 seconds. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 513 VDF segments are OK Defective sun sensor Defective ambient temperature sensor Check Air mix door Defective interior temperature sensor Defective humidity sensor Defective duct temperature sensor Defective intake sensor AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 514 3) Sensor failure code Starting self diagnosis blinking (30: no failure) Trouble Code Code Malfunction Remark Code Malfunction Remark Defective VENT Defective B/L 20% FRE FOOT All door OK AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 515 18.5 18.5 18.5 18 18 18 18 18 o o o o o C C C C C Intake air Ambient air Interior air temperature temperature temperature AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 516 43 43 43 43 43 Step 6 Min. temperature Max. temperature compensation value compensation value 7. Canceling the Trouble Diagnosis Turn the AUTO switch ON or turn the ignition key OFF. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 517: System Diagram

    4. When engine speed is below 650 rpm 5. When engine speed is over 4,500 rpm 6. During abrupt acceleration for the vehicle equipped with manual transmission AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 518: Sensors And Actuators

    5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 519 FATC controller. Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 520: Air Quality System (Aqs)

    AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears. Press the AUTO switch AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 521 NOTE • If the AQS switch is pressed in, the AQS function works regardless of air conditioner controller operation. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 522 Mode change (MODE switch) Mode change (MODE switch) AQS OFF 6. The AQS is turned off, 1) When pressing the defroster switch 2) When pressing the recirculation mode switch AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 523 2. Disconnect the AQS sensor connector, unscrew two bolts (10 mm) and remove the AQS sensor assembly. (Install in the reverse order of removal.) AQS sensor Connector AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 524: Air Conditioner Module Sensors And Actuators30

    (standard: approx. 2 V at 25°C) 4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 525 1. Disconnect the connector from the removed A/C module assembly and then remove the bracket screw on heater pipe. 2. Remove the heater pipe bracket and separate the water temperature sensor from bracket. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 526 Max HI 4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the power transistor. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 527 1. Remove the lower instrument panel in front of passenger seat and disconnect the power transistor connector. 2. Unscrew the mounting screws and remove the power transistor. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 528 The air flows towards towards face. towards face towards foot. front windshield and foot. (Vent mode) and foot. (Foot mode) (Defroster and foot (Bi-level mode) mode) Mode door actuator AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 529 • Make sure that the mode door link mounted on the air conditioner module assembly. When installing, if the location of the mode door link is not correct, may not operate properly. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 530 Remove the driver’s instrument lower panel and then disconnect the connection connector of the mode door actuator and the mounting screws (2EA). Remove the in/ex air door actuator. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 531 With the instrument panel assembly removed as shown in the above figure, disconnect the air mix door actuator and unscrew two mounting screws to remove the air mix door actuator. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 532 A12 and A11 on the FATC controller connector. (standard: approx. 12 V) 5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 533 Mounting Bolt at Bottom of A/C Module 2. Separate the upper case and lower case of blower unit and remove the Intake Sensor from the evaporator. Intake Sensor Evaporator AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 534: Removal And Installation

    1. Disconnect the heater hose (A) from the engine compartment and remove the A/C high/low pressure pipe mount- ing nuts. A. Inner/outer heater hose and clamp * Remove the mounting nut and loosen the coolant reservoir. B. A/C joint pipe mounting nut AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 535 2. Unscrew four mounting screws on A/C module assembly (in engine compartment). Behind FFH pump: 3 Behind vaccum pump: 1 3. Carefully remove the A/C module assembly. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 536 6810 A/C Module Mounting Location Mounting locations inside of vehicle Mounting locations on backide of A/C module Front View AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 537 1. With the center fascia panel removed, unscrew two mounting screws from the A/C controller switch assembly. 2. Disconnect the connectors from the A/C controller switch assembly. 3. Remove the A/C controller switch assembly. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 538 Disconnect the sensor connector, unscrew two mounting screws, and remove the sensor from the air conditioner controller switch. Disconnect Connector Active in-car sensor/ Remove Mounting Screw humidity sensor AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 539 Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly. 1. Unscrew the mounting screws (one at each side and four in center area) and remove the front air duct. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 540 2. Unscrew the mounting screws (one at each side) and remove the left and right air ducts. 3. Unscrew the mounting screws (one at each side) and remove the upper air duct. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 541 1. Unscrew two center mounting screws in floor air duct. 2. Unscrew the mounting bolts and remove the air duct. Vehicle with Foot Parking Brake Mounting Screws Lower Air Duct Assembly Vehicle with Hand Parking Brake AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 542 Floor air duct (LH) Floor air duct (RH) Floor air duct 2. Passenger side floor air duct is located under the air conditioner module. Mounting screw AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 543 ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 544 Front Vent Grille Front vent grille is mounted on the instrumetn panel with one screw. Unscrew the mounting screw and pull the vent grille out of the instrument panel. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 545 1. Unscrew the mounting screws with the front air duct removed. Right side vent grille Right side vent grille 2. Pull the vent grille out of instrument panel. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 546: Condenser Assembly

    2. Remove the pipes from the radiator oil cooler for automatic transmission. Installation Notice Tightening torque 25 ~ 35 Nm AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 547 High-pressure Pipe: Compressor Side Low-pressure Pipe: Receiver Dryer Side Tightening torque: 16 ~ 23 Nm Plug the pipe openings with a seal caps after disconnecting the high/ low pressure pipes. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 548 7. Unscrew three mounting bolts (10 mm) and re- 8. Unscrew the mounting bolt (10 mm) and remove move the hood latch mounted on the front end the front support panel. panel and support panel. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 549 9. Unscrew four bolts and remove the radiator mount- 10. Unscrew three mounting bolts (10 mm) and then ing bracket. remove the front end panel. 11. Remove the mounting clips and remove the radiator assembly. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 550 Remove Two Mounting Bolts (10 mm). 13. Unscrew the upper and lower mounting bolts (10 mm) and remove the inter cooler from the radiator. Inter Cooler Assembly AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 551 14. Remove the oil cooler pipes for automatic transmission from the radiator assembly. 15. Unscrew five mounting bolts (10 mm) and remove the air conditioner condenser assembly. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 552 The oil rings on the pressure pipes should 20 ~ 30 Nm be replaced with new ones once removed. 3. Unscrew the mounting bolt and remove the receiver dryer. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 553: Compressor Assembly

    16 ~ 23 Nm bolts and remove the com- Tightening torque: pressor assembly. 16 ~ 23 Nm Tightening torque: 18 ~ 27 Nm Tightening torque: 18 ~ 27 Nm AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 554 Suction hose Heater outlet hose Receiver drier Compressor Liquid hose Discharging hose A/C condenser assembly Joint pipe assembly Liquid pipe Suction hose Receiver drier Liquid hose AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 555: Ffh (Fuel Fired Heater) System

    Therefore, a certain period of FFH operation after stop- ping the engine is not a malfunction. Components Locator Diagnostic connector Ambient temperature switch FFH Fuel pump AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 556: Ffh Layout

    16. Intake hose 5. FFH NO.3 inlet hose 11. Fuel pipe NO.1 17. Clamp 6. FFH NO.2 inlet hose 12. Fuel pipe NO.2 18. FFH NO.1 inlet hose AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 557 15. Bush for flame sensor (graphite) 33. Screw (M4 x 44 TORX / 4x) 16. Control and overheating sensor with cable 34. Controller cable harness 17. O-ring 35. Insulation washer AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 558: Specifications

    In the main fuel tank (fuel) Tolerable ambient temperature Operation - 40°C ~ 80°C Storage -40°C ~ 125°C Weight approx. 2.3 kg (without coolant and water pump & bracket) AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 559: Ffh Operating Process

    LO mode (low output: approx. 2,300 W) from 81°C. When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be met again. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 560 • When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts. • Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures. • Secure all hose connections with hose clamps. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 561 The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 562 9 V ~ 15 V Power consumption 16 W Pumping capacity (0.1 bar) 800 l/h Operating temperature - 40°C ~ 135°C Weight 0.28 kg Characteristic Curve of Water Pump (12 V) AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 563: Function Diagram

    6910 Function Diagram Switching Diagram According to Temperature Changes AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 564: Components And Functions

    Temperature [°C] Specified value Temperature [°C] Resistance [W] 32.54 12.48 8.06 5.33 2.48 1.25 0.67 0.38 19.87 3.60 1.75 0.91 0.50 AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 565 0.62 19.53 4.41 2.34 1.32 Controller The surface heater and cable harness make up one component. 1) Controller 2) Jacket 3) Combustion chamber housing 4) Mounting screw AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 566 4) Seal - combustion chamber / combustion air fan 5) Seal - combustion chamber / heat exchanger Flame Sensor 1) Flame sensor 2) Graphite bush 3) Bush AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 567 1498 1573 1758 1941 2120 2297 2470 Combustion Air Fan 1) Combustion chamber 2) O-ring 3) Rubber seal 4) Combustion air fan 5) Screw Combustion air fan AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 568 4) Seal - combustion chamber / heat exchanger 5) O-ring (for heat exchanger) Heat Exchanger 1) Heat exchanger 2) Jacket 3) Stopper 4) Groove (bottom of heat exchanger) AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 569: Removal And Installation

    • After replacing the FFH related components, fill up the system with fuel. Fuel Pump 3. From Fuel Tank 4. FFH Fuel Pump 1. To FFH 2. Wiring Fuel tank AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 570 3. Unscrew the bracket mounting bolt (10 mm) and remove the fuel pump assembly. NOTICE • Plug the hose opening with a seal cap to prevent oil leakage AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 571 * The ambient temperature switch should be re- moved after removing the headlamp. 1. Remove the ambient temperature sensor from holder. 2. Disconnect sensor connector while pushing the connector pin. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 572 6910 FFH Assembly Preceding Work: Disconnect the negative battery cable. FFH Coolant Circulation Pump Assembly FFH Assembly AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 573 • Plug the hose openings with seal caps to pre- vent oil leakage. 3. Unscrew the hose clamps on the FFH coolant circulation pump and remove the inlet and outlet hoses. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 574 1) Unscrew three mounting nuts at bottom of coolant reservoir. FFH Assembly 2) Unscrew the mounting nuts from the FFH coolant circulation pump. Front Mounting Nut FFH Exhaust Pipe Side AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 575 3. If the fuel is sprayed out, connect the fuel pipe to Picture A FFH assembly and keep the engine running for 1 minute. 4. Connect the ambient temperature switch connector. AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 576: Trouble Diagnosis

    FFH Heater Trouble Diagnosis Precedure Connect Scan-100 to the diagnostic connector located at the lower instrument panel. 1. Select [KYRON] in [VEHICLE SELECTION]. 2. Select “FFH (FUEL FIRED HEATER)” in [CONTROL UNIT SELECTION]. 3. Select the trouble code out of check items.
  • Page 577 Check the ground and short of combustion air fan motor circuit, motor replace if necessary. Abnormal water pump operation Check connector. Overload or short circuit of water pump Check connector. Abnormal output of water pump AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 578 Defective overheating prevention device Watchdog reset Replace controller. Abnormal reset function If too many resets occurs, replace controller ROM error Replace controller. RAM error Replace controller. Defective transistor Replace controller. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 579 • Change or check cooling fan. • Defective cooling fan temperature • Change sensor or check relevant wiring. • Defective temp. sensor, wiring, and lamp cluster AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 580: Ptc (Positive Temperature Coefficient) System

    Tightening torque: 6 ~ 10 Nm PTC Relay and Fuse PTC (Relay 1) PTC Heater 2 (40A) PTC Heater 1 (40A) PTC (Relay 2) PTC Heater 3 (40A) AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 581: Components

    1. Stable output regardless of voltage changes 2. Block the overcurrent with switch effect of PTC element 3. High heating capacity in a moment 4. Excellent durability of heating element against high current AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 582: Ptc Operating Process

    2. Ambient temperature sensor error (wiring short or open) 3. When engine cranking 4. Battery voltage is lower than 11V 5. When preheating the engine (Glow indicator “ON”) AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 583: Electrical Wiring

    6810 Electrical Wiring AIR CONDITIONING SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 584: Removal And Installation

    Preceding Work: Disconnect the negative battery cable and the instrument panel. 1. Disconnect the PTC connector while pulling out it (A). 2. Unscrew two mounting bolts and remove the PTC assembly from the A/C module assembly. AIR CONDITIONING SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 585 8710 TABLE OF CONTENTS RKSTICS (REKES+STICS) / STICS ....... 3 1. Overview ................3 2. Specifications ............... 4 3. Functions and specifications ..........8 4. Trouble shooting ..............18 5. Diagnosis trouble code and help tips ........47 6. Electrical wiring diagrams ........... 49...

  • Page 587: Rkstics (Rekes+Stics) / Stics

    The STICS also includes a diagnosis function that can inspect the error for related devices. Door Lock Relay PAS Buzzer RK STICS Door Lock Relay RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 588: Specifications

    4. Modulation method: FSK (Frequency Shift Keying) 5 Receiving distance: Approx. 10 ~ 15 m (In case there are not obstacles around the system) RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 589 DC 12 V 500 mA (Inducted load) Headlamp relay DC 12 V 750 mA (Inducted load) Front defogger relay DC 12 V 200 mA (Inducted load) RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 590 ON = GND (DATA), OFF = BAT Diagnosis (SCAN-100) ON = GND (DATA), OFF = BAT (KWP2000) Immobilizer ON = GND (DATA), OFF = BAT (KWP2000) RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 591 However, if less than 500 ms, time tolerance will be ± 100 ms. 2. The time indicated in each function does not include chattering processing time from switch input changing point. RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 592: Functions And Specifications

    Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch. When releasing the switch, it returns to “OFF” position. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 593 KEY IN & IGN2 SW WASHER SW WIPER MOTOR PARKING WIPER LOW RELAY T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 594 2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. KEY IN & IGN2 SW REAR WASHER SW REAR WASHER MOTOR RELAY RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 595 T1: over 100 ms T2: 1.0 ± 0.1 sec T3: within 0.3 sec T4: 4 cycles T5: 3 cycles T6: 0.5 ± 0.1 sec RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 596 WASHER MOTOR OUTPUT WIPER MOTOR PARKING WIPER LOW RELAY T1: over 0.6 sec T2: over 100 ms T3: within 0.3 sec T4: 3 cycles RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 597 Volume (Resistance) Rain LIN (Local Interconnect Network) communication Sensor & RKSTICS N.C. Auto (Numerical Control) Light Wiper parking Sensor Wiper LO Wiper HI Wiper Motor RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 598 (auto light sen- windshield and transmits wiping demand signal accord- sor integrated type) ingly RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 599 * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle. SENSITIVITY Rain Detected RAIN SENSOR to RKSTICS WIPER LOW RELAY T1: 1 cycle RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 600 * The wiper motor runs only when the rain sensor requires. IGN (Operation) WIPER PARKING GND (Stop) SENSITIVITY SEN. 2 RKSTICS to RAIN SENSOR RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 601 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in “ON” position and the wiper switch is in “ON” position). SENSITIVITY S_COMMFAULT RAIN SENSOR to RKSTICS WIPER LOW RELAY T1: 1 cycle RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 602: Trouble Shooting

    Check whether the variable resistance knob on the wiper switch is set in “FAST" or "SLOW”. Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 603 (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) Emitter lense Auto light sensor Auto light sensor RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 604 • If the pause time is below 1.0 second, the wipers operate without pause. • If the pause time is over 1.5 seconds, the wipers operate intermittently. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 605 “ON” (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch) (The output stops immediately after turning OFF the switch.) RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 606 3. If the UNLOCK conditions are met, the UNLOCK output should be unconditionally activated. However, if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK, the UNLOCK output is not activated. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 607 T1: 5 sec ± 0.5 sec (*1) DR & PS & RR DOOR LOCK SW & T/GATE LOCK SW, (*2) DR or PS or RR DOOR SW RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 608 OPEN Dr DOOR CLOSE Dr DOR LOCK LOCK LOCK UNLOCK RELAY C/BUZZER T1: 0.8 sec ± 0.1 sec T2: 5 sec ± 0.5 sec RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 609 V1 = 10 Km/h (*1) DOOR OPEN: Dr or Ps or Rr or T/GATE = OPEN CLOSE: Dr & Ps &r Rr & T/GATE = CLOSE RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 610 The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the ignition key to “ON” from “OFF”. After fastening the seat belt, the chime buzzer stops. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 611 Parking Brake: Hand operated type (manual transmission equipped vehicle), Foot operated type (automatic trans- mission equipped vehicle) Hand Operated Type Foot Operated Type (Manual Transmission Equipped Vehicle) (Automatic Transmission Equipped Vehicle) RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 612 RECEIVE REMOTE CONTROL NO SIGNAL UNLOCK UNLOCK OUTPUT FRONT ROOM LAMP T1: 30 sec T2: 2 sec T3: 3 sec T4 : 30 sec RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 613 (3). always comes on while the coupled position. switch is at the other position. RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 614 For diesel and gasoline For diesel engine equipped engine equipped vehicle vehicle Without immobilizer With immobilizer → With key hole illumination → With key hole illumination RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 615 ALT LOW = 9V ± 1V T1: 12 minutes T2: within 10 minutes T3: 6 minutes ON: IGN2 & ALT = ON OFF: IGN2 OR ALT = OFF RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 616 12 minutes. Windshield heated glass switch Press this switch to turn on the windshield heated glass. It will operate for about 12 minutes. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 617 3. The output is “OFF” when inserting the ignition key and turning it to the “ON” position while outputting the headlamp relay. REMOTE NO SIGNAL CONTROL ARMED THEFT MODE DETERRENT OPERATION OTHERS HEADLAMP RELAY PWR HEADLAMP RELAY OUTPUT T1 : 20 sec RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 618 2. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored. CENTRAL LOCK SW LOCK MONITORING UNLOCK DOOR LOCK RELAY DOOR UNLOCK RELAY T1: 0.5 sec T2: 0.5 sec RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 619 RELAY HORN RELAY HAZARD RELAY T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec Door button Panic button RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 620 LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 621 • “LOCK” (or “UNLOCK”) output is ignored if “LOCK” (or “UNLOCK”) output is required while performing the output of “LOCK” (or “UNLOCK”). • If the door lock system outputs “LOCK” and “UNLOCK” simultaneously, only the “LOCK” output can be activated. RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 622 4. This function operates only in armed mode. Tx SIGNAL (REMOTE CON- TROL SIGNAL) WARNING THEFT DETERRENT MODE HORN T1: 27 sec T2: 0.5 sec T3: 1.0 sec RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 623 5) The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key. RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 624 UNLOCK RELAY HAZARD RELAY HORN ARMED MODE OPERATION OTHERS T1: 0.5 sec T2: 1.0 sec T3: 50 ms T4: 1.0 sec T5: 30 sec RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 625 LISHED WARNING THEFT DETER- ARMED RENT STATE NORMAL HAZARD RELAY HORN WARNING OPERATION STATUS OTHERS T1: 0.5 sec T2: 1.0 sec T3: 27 sec RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 626 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” signal and activates the armed mode. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 627 2) The front room lamp comes on for 30 seconds when receiving door unlock signal by the remote control key while the front room lamp coupled switch is pressed. RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 628 Door Close, Hood Close, SENSING Door Lock, T/Gate Close 0.5 ± 0.1 0.5 ± 0.1 0.5 ± 0.1 seconds seconds seconds HAZARD LAMP 50 ms HORN RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 629 2. The horn sounds for 27 seconds when receiving the PANIC message from the remote control key. Pressing PANIC button UNLOCK DOOR LOCK SWITCH LOCK 0.5 sec HORN 0.1 sec 27 sec RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 630 DOOR UNLOCK SIGNAL 0.5 seconds ± 0.1 second Max 30 seconds ± 0.3 seconds UNLOCK DOOR LOCK Auto Door SWITCH Door Unlock Unlock LOCK RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 631: Diagnosis Trouble Code And Help Tips

    The auto washer output is not sent to the front washer (saved as history error). WASHER RELAY The front washer switch receives the input signal for more than 10 seconds (saved as history error). RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 632 When the seat belt switch circuit maintains OPEN (HIGH) in KEY (Only EU) OUT & ARMED MODE while the vehicle speed is over 50 km/h, the system saves it as History error. RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 633 8710 6. ELECTRIC WIRING DIAGRAMS Power/Ground, Chime Bell, Buzzer, Warning Lamp (Brake, Seat Belt, DR Open) RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 634 8710 Central Door Lock Circuit RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 635 8710 Tail Lamp, Hazard, Power Window RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 636 8710 Windshield Heated Glass (Defogger) RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 637 8710 Panic, Auto Light & Rain Sensing, Room Lamp RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 638 8710 FRT Wiper/Washer & RR Washer RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 639 1. Disconnect the connectors from STICS unit and remove the RKSTICS antenna. 1. STICS connector 4. PAS buzzer connector 2. STICS antenna 5. Door lock/unlock relay connector 3. Chime/buzzer connector RKSTICS (REKES + STICS) / STICS CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 640 2. Unscrew two mounting bolts (10 mm - 2EA) and remove the STICS unit. RK-STICS antenna Chime bell Door lock relay PAS buzzer RK-STICS 3. Separate the STICS unit. STICS Unit RKSTICS (REKES + STICS) / STICS CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 641 IMMOBILIZER SYSTEM 7010 TABLE OF CONTENTS IMMOBILIZER SYSTEM .......... 2 1. Overview ................2 2. Basic functions of immobilizer key (REKES function) ..3 3. Other functions in system ...........4 4. Replacement of electronic head part (excluding key plate) ...6 5. REKES operation logic ............7 6.

  • Page 642: Immobilizer System

    ECU. Refer to the information that follows for specific functions and their descriptions. Transponder Battery IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 643: Basic Functions Of Immobilizer Key (Rekes Function)

    The PANIC function oper- ates only in theft deterrent mode. The PANIC function operates only in theft deterrent mode. Specification CR 2032 Quantity IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 644: Other Functions In System

    • When the key is close to any electronic or electric devices such as lightening equipment, security keys or security cards. • When the key is close to a magnetic or metal object or a battery. IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 645: Engine Control Unit

    • The remote engine starter cannot be installed on the vehicle equipped with the immobilizer system. IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 646: Replacement Of Electronic Head Part (Excluding Key Plate)

    Remove the rubber cover on the back of the key assembly. Remove two screws to uncover the key plate. Install the new electronic head assembly on the key plate. IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 647: Rekes Operation Logic

    DOOR LOCK SWITCH UNLOCK SENSOR LOCK Door Close, Hood Close, HAZARD LAMP Door Lock, T/Gate Close 0.5 sec 0.5 sec 0.5 sec ± 0.1 ± 0.1 ± 0.1 HORN IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 648 3. The hazard warning lamps blink once only when the doors are successfully unlocked. PRESS DOOR UNLOCK SWITCH Chattering DOOR UNLOCK time OUTPUT Door Unlock UNLOCK DOOR LOCK SWITCH LOCK SENSING 0.1 sec HAZARD LAMP ± 0.1 IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 649 2. When receiving the PANIC message from the remote control key, the horn sounds for 27 seconds. PRESS PANIC SWITCH UNLOCK DOOR LOCK LOCK SIWTCH 0.5 sec HORN 0.1 sec 27 sec T1: 27 sec IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 650: Dual Rekes Coding

    Therefore, there is a need to code two immobilizer keys. 1. After connecting the scanner and selecting 2. To start to code, press YES in the below KYRON, then select DUAL REKES. screen. This results in clearing the key codings of the old REKES.
  • Page 651 If they do not work, repeat the above dual REKES key coding procedures. IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 652: Immobilizer Coding And Removal Of Immobilizer Unit

    (For details, refer to BODY section.) 2. Remove the steering column shaft assembly. (For details, refer to STEERING section.) 3. Remove the connector from the key switch and disconnect the immobilizer unit. IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 653 KYRON IMMOBILIZER KYRON IMMOBILIZER ENTER TESTER PASSWORD >>>> WARNING <<<< If you start immobilizer coding procedure, value of coded key is cleared. Are you sure? [Yes/No] 11434 Continued IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 654 Turn “ON” ignition key. Turn “OFF” ignition key. After Check the IMMO. System, Retry Coding Procedure. Rest time: 27 seconds Turn “ON” ignition key Press “ENTER” Press “ENTER” ENTER Continued IMMOBILIZER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 655 KYRON IMMOBILIZER KYRON IMMOBILIZER CODING END. Are you sure exit ? Turn “OFF” ignition key, and then [ Yes / No ] Turn “ON” ignition key. Press “ENTER” IMMOBILIZER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 656 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 657 SEAT POSITION WITH MEMORY 7410 TABLE OF CONTENTS SPWM (Seat Position With Memory) UNIT .... 3 1. Overview ................3 2. Components .................4 3. Operations ................5 4. Input/output of SPWM unit ..........8 5. Control and operating conditions ......... 9 6. Removal and installation of seat ........15...

  • Page 659: Spwm (Seat Position With Memory) Unit

    1. Adjusting the power seat’s position with the seat adjusting switch 2. Adjusting the angle of the outside rearview mirrors (OSRVM) 3. Seat memory positions: for 3 persons 4. Folding/Unfolding the outside rearview mirrors SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 660: Components

    Front cushion motor/ sensor Reclining motor/ sensor Rear Seat memory switch cushion motor/ sensor Sliding motor/ sensor Outside rearview mirror folding switch Seat adjusting switch SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 661: Operations

    Seat Position Control Seatback Reclining Adjustment Seat Slide Adjustment Seat Height Adjustment Seat Tilt Adjustment SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 662 4. Within 5 seconds, press the buttons ( ), ( ) or ( ) you want to set. The indicator on the set button blinks 3 times. SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 663 • In the vehicle equipped with manual transmission, the position memory recall is not available if the parking brake is released. • If the position memory recall is successfully completed the buzzer sounds twice. If it failed, the buzzer sounds three times. SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 664: Input/Output Of Spwm Unit

    Outside rearview mirror adjusting switch The changes of each motor are always Power seat control switch monitored by the sensor in the motor. Seat memory switch SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 665: Control And Operating Conditions

    8. The buzzer sounds twice if the memory setting/recalling is completed. 9. The buzzer sounds three times if an error is found in the sensor during the memory recall operation. SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 666 Twice BUZZER MANUAL OPERA- TION SWITCH (SEAT, OUTSIDE REARVIEW MIR- ROR ADJUSTING SWITCH) Over 3 km/h Below 3 km/h VEHICLE SPEED STOP BUTTON RECALL OPERA- TION SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 667: Power Seat

    4. The motor doesn’t operate if the difference between the stored position and the current position is out of the specified range. 1) Sliding: 12 edges (6 pulses) 2) Cushion height: 6 edges (3 pulses) 3) Reclining: 100 mV SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 668 3. Current consumption: Max. 500 mA (not including the load) 4. Operating temperature range: -30°C ~ 75°C 5. Reserve temperature range: -40°C ~ 85°C 6. Parasitic current: Max. 2 mA SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 669 2. Operating voltage: DC 9 ~ 16 V 3. Current consumption: Max. 300 mA (not including the load) 4. Operating temperature range: -30°C ~ 75°C 5. Reserve temperature range: -40°C ~ 85°C SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 670 T : T < T1 , T1 : 13 ± 3 sec , T2 : 30 ± 6 sec , T3 : 1 sec ± 0.1 sec SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 671: Removal And Installation Of Seat

    3. Pull up the seat and disconnect the harness connector. Remove the seat assembly. Release the hook to disconnect the connector. Connector on seat Main connector SEAT POSITION WITH MEMORY CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 672 7410 4. Unscrew the screws (arrows) and remove the protective cover. 5. Disconnect the harness connector and remove the SPWM unit. SPWM unit SEAT POSITION WITH MEMORY CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 673 CLUSTER 8010 TABLE OF CONTENTS INSTRUMENT CLUSTER ........2 1. Descriptions of indicator display ...........2 2. Warning & indicator panel ........... 10 3. Removal and installation of meter cluster ......18 4. Electrical wiring diagrams ........... 21...

  • Page 674: Instrument Cluster

    10. Door ajar warning light 21. Water separator warning light 32. Engine oil pressure warning light 11. Sea belt reminder (passenger’s 22. Seat belt reminder (driver’s seat) seat) 33. Auto cruise indicator CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 675 8010 Configuration Front View Rear View Main Connector Sub Connector No.1 No.10 No.1 No.10 No.11 No.20 No.11 No.20 CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 676 17. LH indicator lamp (+) 17. CAN High 18. Oil pressure 18. AGND (Fuel -) 19. Parking brake signal input (STICS) 19. MGND (Micom -) 20. - 20. IGN CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 677: Warning Lights And Indicators

    If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner and then compare the value on tachometer with the reading from scanner. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 678 Tolerance (Km/h) +10.5 +12.5 +14.5 +2.5 +3.5 +7.5 +8.5 NOTICE • The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range. CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 679 This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 680 When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection. CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 681 0.0 km in Trip A and Trip B. 0.0 ~ 999.9 km Displaying range: TRIP B 0.0 ~ 999.9 km Displaying range: 0 ~ 999999 km CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 682: Warning & Indicator Panel

    If “4WD CHECK” warning light stays on continuously, it may in- the driver fastens the seat belt even dicate that there is something wrong in the transfer case system. during its operation period. CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 683 In this mode, the engine driving force may be decreased sure is dangerously low. or the engine may stall. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 684 Basically, the brake system’s basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: • Initial ignition ON • HDC system error occurs • Brake system overheat CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 685 1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be resumed after approx. 150 ms. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 686 ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP OFF switch for approx. 3.5 seconds. CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 687 NOTICE • When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen- sate the vehicle stability (posture) during ESP operation. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 688 ECU. The engine ECU receives the N switch signal, the vehicle speed, the clutch operating conditions, and the engine coolant temperature and raises the engine speed by 100-200 rpm. This helps the vehicle start smoothly during gear shifting. N Switch Outside Inside CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 689 The wheel speed sensor is connected to the engine ECU (terminal 36), where its signal is processed, and is connected to other related systems through CAN communication. Battery(+) Wheel speed sensor CAN HI Engine Cluster CAN LO CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 690: Removal And Installation Of Meter Cluster

    8010 3. REMOVAL AND INSTALLATION OF METER CLUSTER Preceding Works: Disconnect the negative battery cable. Location Cluster Center Fascia Panel Assembly (LH/RH) Cluster Outside Mirror Switch Bezel Assembly CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 691 2. Remove four instrument panel mounting screws. 3. Disconnect the outside mirror switch bezel connector and remove the meter cluster panel assembly. NOTICE • Be careful not to damage the another components during removal procedures. CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 692 8010 4. Unscrew four cluster mounting screws. 5. Disconnect the connectors from the back of meter cluster and remove the cluster from the instrument panel. CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 693: Electrical Wiring Diagrams

    8010 4. ELECTRICAL WIRING DIAGRAMS Gauge (speed, RPM, fuel, temp), Warning Lamp (fuel, fuel filter, ABS/ ESP, brake, HDC, 4WD) CLUSTER CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 694 8010 Warning Lamp (batt charge, oil, hood, door, eng check, air bag, ssps, seat belt), Turn Signal, Fog Lamp, Hazard CLUSTER CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 695 SWITCHES / ELECTRIC DEVICES 8510 / 7770 / 8610 / 7632 / 7610 TABLE OF CONTENTS SWITCH ARRANGEMENT ......2 SEAT POSITION MEMORY SWITCH ..72 1. Location and functions ........72 CENTER FASCIA & BEZEL SWITCH 2. Switch arrangement ........... 73 ASSEMBLY ..........

  • Page 696: Switch Arrangement

    Driver’s Power Window Switch Driver can controls all door windows (Open/Close/Lock/ Unlock) and doors (Lock/ Unlock) with this switch unit. SWITCHES / ELECTRIC DEVICES CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 697 Room lamp operating switch operating switch T/C Control Switch Audio Remote Control Switch Driver’s Seat POWER Warmer Switch MODE MUTE Passenger’s Seat SEEK Warmer Switch SEEK CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 698: Center Fascia & Bezel Switch Assembly

    1. LOCATION The center fascia switch consists of hazard switch bezel assembly, T/C control switch and seat warmer switch. Center Fascia Assembly [Front View] [Rear View] CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 699: Switch Arrangement

    HDC switch side rearview mirror heated glass switch TRIP switch Windshield heated glass switch Hazard switch T/C Control Switch Driver’s Seat Warmer Switch Passenger’s Seat Warmer Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 700: Functions

    Unit: 0.0 ~ 999.9 km TRIP A 3. The indicators in the switch come on when in use. Unit: 0.0 ~ 999.9 km TRIP B Unit: 0 ~ 999999 km CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 701 4WD system is off after completion of off after completion of defective. mode change. mode change. Driver’s Seat Warmer Switch Passenger’s Seat Warmer Switch Headlight Leveling Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 702: Switches In Hazard & Bezel Switch Assembly

    HDC switch is a Push & Self Return type switch and connected to ABS/ESP HECU terminal. This switch has an illumination lamp connected to the tail lamp circuit. ABS/ESP HECU HDC Switch 1(B) 2(GND) 3(IND) 4(ILL+) 5(ILL-) CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 703 As given in the table above, the HDC warning lamp comes on when: 1) Initial ignition ON 2) HDC system error occurs 3) Brake system overheat CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 704 Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission) 3) HDC target speed in 4L mode Forward and reverse driving: 3 km/h CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 705 HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 706 HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 707 3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6 minutes. 4. It stops when the ignition switch is turned to “OFF”. T/LP RR DEFOGGER SW REPLAY STICS ILL- ILL+ 1(U) 2(GND) 3(IND) 4(ILL+) 5(ILL-) CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 708 T1: 12 min. T2: within 10 min T3: 6 min ON: IGN2 (Key ON) & ALT = ON OFF: IGN2 (Key ON) or ALT = OFF CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 709 3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6 minutes. 4. It stops when the ignition switch is turned to “OFF”. T/LP RR DEFOGGER SW REPLAY STICS ILL- ILL+ 1(U) 2(GND) 3(IND) 4(ILL+) 5(ILL-) CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 710 T1: 12 min. T2: within 10 min. T3: 6 min. ON: IGN2 (Key ON) & ALT = ON OFF: IGN2 (Key ON) or ALT = OFF CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 711: Trip Switch

    TRIP A or TRIP B mode, the trip ODO meter re- sets to zero. Unit: 0 ~ 999999 km CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 712: Hazard Switch

    8510 Hazard Switch Overview Hazard switch is connected to the turn signal lamp circuit. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 713: Center Fascia Switch Bezel Assembly

    4WD LOW is properly working. To avoid damages to the drive train, do not drive your vehicle with excessively high speed in sharply curved road. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 714: Seat Warmer Switch

    • When cleaning the seats, do not use organic solvents such as benzene or thinner. • Do not use this function when the engine is not running. The battery could be discharged. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 715: Removal And Installation Of Hazard & Bezel Switch Assembly

    HDC switch Hazard warning switch Windshield heated glass switch TRIP switch T/C control switch Driver’s seat warmer switch Passenger’s seat warmer switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 716 1. Remove the RH panel from the center fascia panel and unscrew three screws from the center fascia panel. 2. Disconnect the switch connectors and remove the center fascia panel assembly. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 717 3. Remove the hazard switch bezel assembly and miscellaneous switch assembly from the removed center fascia panel. Front View Rear View Remove Three Mounting Screws Remove Four Mounting Screws CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 718 4. Remove each switch from the hazard switch bezel assembly. Front View Side View Rear View 1) Remove the round cover and switches. 2) Remove the hazard switch mounting bracket and remove the hazard switch. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 719 5. Remove each switch from the miscellaneous switch assembly. Front View Rear View Side View Driver’s Seat T/C Control Switch Warmer Switch Passenger’s Seat Warmer Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 720 HDC switch Windshield heated glass TRIP switch switch Hazard warning switch T/C control switch Driver’s seat warmer switch Passenger’s seat warmer switch Headlight leveling switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 721: Outside Rearview Mirror Switch Bezel Assembly

    (regional option). Rear fog lamp switch Front View of Outside Rearview Mirror Bezel Panel Rear View of Outside Rearview Mirror Bezel Panel CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 722: Switch Arrangement

    8510 2. SWITCH ARRANGEMENT Outside Rearview Mirror Folding Switch ESP OFF Switch Outside Rearview Mirror Angle Adjusting Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 723: Switches In Outside Rearview Mirror Switch Bezel Assembly

    It may cause a malfunction of the mirror folding system. To fold the outside rearview mirrors, press the switch. To unfold the mirrors, press it again. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 724 P/W TIME RELAY FOLDING FOLDING UNFOLDING T: T < T1, T1: 13 ± 3 sec, T2: 30 ± 6 sec, T3: 1 Sec ± 0.1 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 725 8510 Electrical Wiring Diagrams CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 726 8510 ESP OFF switch Overview ESP OFF switch is Self return type switch. ESP OFF Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 727 • When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be turned on. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 728 Return to switch signal Reset to normal condition ESP function (including TCS) Cancellation of ESP OFF mode Turning the ESP warning lamp off ESP warning lamp CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 729 • When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen- sate the vehicle stability (posture) during ESP operation. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 730: Removal And Installation

    Preceding Works: Disconnect the negative battery cable. Location Outside rearview mirror folding switch Outside rearview mirror angle adjusting switch ESP OFF switch Rear fog lamp switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 731 2. Disconnect the connector from the outside rearview mirror switch bezel assembly and remove the meter cluster fascia panel. NOTE • To make the operation easier, move down the steering wheel. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 732 3. Remove the switch assembly from the removed meter cluster fascia panel. Front View Rear View 4. Remove the round cover on the switch assembly. Round cover CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 733 5. Remove each switch from the outside rearview mirror switch bezel assembly. Switch Assembly Remove the switch bracket. ESP OFF Switch Outside Rearview Mirror Adjusting Switch Outside Rearview Mirror Folding Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 734 Meter Cluster Fascia Panel Round cover Outside Outside rearview rearview mirror mirror adjusting folding switch switch bracket Fog lamp switch ESP switch Outside rearview mirror adjusting switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 735: Overhead Console Switch

    Passenger’s spot switch the spot switch (A). The passenger’s room lamp comes on if you depress the spot switch (B). Luggage Room Lamp Center Room Lamp CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 736: Components

    Overhead console case Sun roof switch Main room lamp switch Interior light switch Center Room Lamp and Luggage Room Lamp Center Room Lamp Luggage Room Lamp CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 737: Switches In Overhead Console Switch Assembly

    Main room lamp switch (Push ON-OFF type) Driver’s spot lamp switch Passenger’s spot lamp (Push ON-OFF type) switch (Push ON-OFF type) Front room lamp connector Sunroof switch connector CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 738 8510 Sunroof Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 739 8510 Front Room Lamp Main room lamp switch (Push ON-OFF type) Passenger’s spot lamp Driver’s spot lamp switch switch (Push ON-OFF type) (Push ON-OFF type) CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 740 IGN KEY REMINDER SW RECEIVE Tx UNLOCK NO SIGNAL UNLOCK OUTPUT Fr ROOM LAMP T1: 30 sec. T2: 2 sec. T3: 3 sec. T4: 30 sec. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 741 8510 Electrical Wiring Diagram of Room Lamp CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 742 The sunroof switch is a Self return type switch and connected to the power supply terminal and sunroof circuit. For details, refer to “Sunroof” section. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 743 8510 Circuit Diagram of Sunroof CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 744: Removal And Installation Of Overhead Console Switch

    (2 EA). • For details, refer to the “LAMP” section. Mounting Mounting screw screw 2. Remove the overhead console switch assembly and disconnect the connector. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 745 8510 3. Remove the front room lamp switch from the removed overhead console switch assembly. 4. Unscrew three mounting screws and remove the sunroof switch. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 746 8510 Components Sunroof switch Room lamp Lamp main switch Lamp CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 747: Switch Assembly On Driver'sdoor Armrest

    (Sub and RR is not operated by pressing in the main Rear LH door Window Switch switch) Passenger’s Door Window Switch Rear RH Door Window Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 748: Switch Arrangement And Appearance

    0.7 A (actuator voltage) Window lock switch (motor operation) 20 A (restricted current) 10 A (operating voltage) Switch Assembly Front View Rear View Side View Connector CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 749: Power Window Operations

    Power window versions in this vehicle: Auto Down, Auto Down/Up The circuit diagram shows the Auto Down version. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 750: Circuit Diagram Of Power Window

    8510 4. CIRCUIT DIAGRAM OF POWER WINDOW CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 751 30 seconds. ING1 SW OPEN Dr/Ps DOOR SW CLOSE P/WINDOW RELAY T1: 30 sec. T2: OFF during T1 output CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 752: Central Door Lock/Unlock Switch

    However, the door lock switch on driver’s door armrest locks/unlocks all doors with STICS control. This is a same control type with Auto door lock function that locks the doors when the vehicle speed exceeds 50 km/h. Door Lock/Unlock Relay CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 753 PS DOOR LOCK SW UNLOCK OPEN DR/PS DOOR SW CLOSE LOCK RELAY UNLOCK RELAY T1: 0.5 sec T2: 0.5 sec T3: Within 0.5 sec T4: 0.5 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 754 2. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored. CENTRAL LOCK SW LOCK MONITOR- UNLOCK LOCK RELAY UNLOCK RELAY T1: 0.5 sec T2: 0.5 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 755 NO SIGNAL ESCORT LOCK RELAY UNLOCK RELAY HORN RELAY HAZARD RELAY T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 756 1 LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 757 8510 Electrical Wiring Diagram CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 758: Removal And Installation Of Power Window Switch

    6. REMOVAL AND INSTALLATION OF POWER WINDOW SWITCH Preceding Works: Disconnect the negative battery cable. Location Driver’s Door Power Windows Switch Passenger’s Door Power Windows Switch Rear Door Window Switch (LH/RH) CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 759 • Be careful not to damage the door trim. • For more information, refer to the “Body” section. Location Inner door handle assembly Door trim armrest Power Window Switch Assembly CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 760 2. Unscrew ten mounting screws on the inner door handle of the door trim. 3. Remove the inner door handle and the memory seat switch assembly. Switch Assembly Door Trim Armrest CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 761 8510 4. Remove the switch from the memory seat switch assembly. Unscrew two mounting screws and remove the switch. Front View Connector Side View CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 762 2. Unscrew the mounting screws and remove the inner door handle and the memory seat switch assembly from the passenger’s door trim. Door trim armrest Power window switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 763 8510 3. Remove the switch from the power window switch assembly. Front View Connector Side View CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 764 Rear Door Power Window Switch 1. Separate the power window switch assembly with a special tool. 2. Disconnect the switch connector and remove the switch assembly. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 765 8510 3. Remove the switch. Front View Connector Side View CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 766: Seat Position Memory Switch

    3. Wait until they stop moving (The buzzer sounds twice). 4. Within 5 seconds, press the button ( ), ( ) or ) you want to set. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 767: Switch Arrangement

    The driver’s seat position memory switch is installed in door trim and its connector (4 pins) is connected to the SPWM (Seat Position With Memory) unit. Driver’s Seat Memory Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 768: Exploded View

    0 ~ 100 mv STOP 0 ~ 100 mv 2.2K Position 1 0.12 ~ 1.36 mv Position 2 2.12 ~ 2.59 mv Position 3 3.4 ~ 4.15 mv UNIT CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 769: Functions And Operations

    8. The buzzer sounds twice when the memory setting/recalling is completed. 9. The buzzer sounds three times when an error is found from the sensor during the memory recall operation. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 770 1.5 ± 0.2 sec POS SW time times BUZZER Seat & Outside Rearview Mirror Manual Operation OVER 3 Km/h Vehicle Speed BELOW 3 Km/h STOP Recall CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 771: Removal And Installation Of Seat Position Memory Switch

    1. Remove the driver’s door trim. NOTE • For details, refer to the “Body” section. Location Memory seat switch Speaker Power window switch Memory Seat Switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 772 8510 2. Remove the memory seat switch from the door trim. Switch Arrangement Memory switch cover PCB assembly Memory switch button 4-pin Connector Memory switch box CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 773: Electrical Diagram Of Power Seat & Outside Rearview Mirror

    8510 7. ELECTRICAL DIAGRAM OF POWER SEAT & OUTSIDE REARVIEW MIRROR CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 774 8510 CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 775: Audio Remote Control Switch On Steering Wheel

    - Press and hold: Automatic searching for a station. In CD (DVD) player/Cassette tape mode - Press briefly: Replay next/previous track. - Press and hold: Move forward/backward in current tract. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 776: Components

    The remote audio control switch is installed on the the steering wheel. Its rated voltage is 5 V and has three connectors. Main Connector Connector and cable Pin No. Output voltage Audio signal Audio ground Tail lamp power Switch & PCB Switch & PCB CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 777: Circuit Diagram

    8510 3. CIRCUIT DIAGRAM CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 778: Removal And Installation

    8510 4. REMOVAL AND INSTALLATION Preceding Works: Disconnect the negative battery cable. 1. Remove the airbag module assembly from the steering wheel. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 779 8510 2. Unscrew mounting screws at both sides of the removed airbag module and remove the audio remote control switch. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 780: Multifunction Switch

    4 times. Then, the fluid will be sprayed again and the wiper will automati- cally operate 3 times. Front fog lamp switch <For detailed operation logics, refer to “STICS”> CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 781: Functions And Operations

    Headlamps and tail lamps automatically turn on or off based upon the intensity of the sunlight analyzed by the automatic light sensor. All lights are off. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 782 “OFF” position when released. Stop the operation. AUTO Operates automatically ac- cording to the vehicle speed or amount of rain. Continuous wipe, slow operation Continuous wipe, fast operation CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 783 For details, refer to "Rain Sensor" section. Rain & AUTO Light Sensor Wiper Switch AUTO Position AUTO It controls the wiping speed by de- tecting the amount of rain drops. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 784: Operating Range

    Air bag (-) Air bag (+) Sound switch 37 ~ 42 Auto cruise 31 ~ 33 Audio remote control 44 ~ 48 Steering wheel angular sensor CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 785: Connector Pin Arrangement

    21 IG 22 MS Low wiper speed 23 - 24 AW AUTO washer switch 25 IGR 26 RW Rear wiper 27 RWA Rear wiper & washer CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 786: Removal And Installation

    Place the steering wheel to the straight forward direction. Lift up the hook when disconnecting the air bag contact coil connector (A). CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 787 4. Unscrew four screws and remove the air bag contact coil assembly. For installation, align the steering wheel to the installation mark and tighten the nut to the speci- fied tightening torque. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 788 Steering wheel angular sensor 6. Remove the steering wheel angular sensor from the re- moved multifunction switch assembly. Light switch Turn signal & wiper switch CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 789 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 790: Digital Clock

    Blinking cycle of Colon: Once per second 1. Remove the center fascia panel (refer to the “Switch” section). Remove the panel from bottom Disconnect the connector. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 791 8510 2. Disconnect the digital clock connector. 3. Unscrew three mounting screws and remove the digital clock from the center fascia panel. Digital Clock CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 792: Cigarette Lighter

    8510 CIGARETTE LIGHTER Preceding Works: Disconnect the negative battery cable. Cigarette Lighter 1. Remove the center console cover. Remove the panel from bottom CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 793 8510 2. Disconnect the cigarette lighter connector. 3. Remove the cigarette lighter from the cover. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 794: Power Outlet

    1. Remove the power outlet bracket from the center console (passenger side). 2. Disconnect the power outlet connector. 3. Remove the power outlet from the bracket. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 795 1. Remove the rear lower quarter panel (RH) and dis- connect the power outlet connector. 2. Unscrew eight screws and remove the power out- let mounting bracket. 3. Remove the power outlet from the bracket. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 796 8510 Electrical Wiring Diagram of Cigarette and Power Outlet CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 797: Horn (Including Theft Warning Horn)

    8510 HORN (INCLUDING THEFT WARNING HORN) 1. LOCATION Horn Assembly Theft Deterrent Horn Connector Horn Horn Horn Connector Tone Connector adjusting screw CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 798: Electrical Wiring Diagram Of Horn

    Location of theft deterrent horn: Under the battery tray in engine compartment The theft deterrent horn is controlled by STICS in armed mode regardless of horn relay operation. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 799: Stics Control For Theft Deterrent Mode

    Door LOCK: Any of door lock switches (front doors, rear doors, tailgate) output “LOCK” signal. Door UNLOCK: All lock switches (front doors, rear doors, tailgate) output “UNLOCK” signal. CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 800 (Dr) UNLOCK RELAY HAZARD RELAY HORN ARMED MODE OPERATION STATUS OTHERS T1: 0.5 sec T2: 1.0 sec T3: 50 ms T4: 1.0 sec T5: 30 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 801 NO ESTABLISHED TION WARNING THEFT DETER- RENT ARMED STATE NORMAL HAZARD RELAY HORN WARNING OPERATION STATUS OTHERS T1: 0.5 sec T2: 1.0 sec T3: 27 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 802 4. This function operates only in armed mode. PANIC TX SIGNAL (REMOTE CONTROL NO SIGNAL KEY SIGNAL) WARNING THEFT DETERRENT MODE OTHERS HORN T1: 27 sec T2: 0.5 sec T3: 1.0 sec CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 803 8510 Electrical Wiring Diagram of Theft Warning Horn CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 804: Removal And Installation

    1. Disconnect the theft deterrent horn connector and un- screw the mounting bolt (10 mm) to remove the theft warning horn assembly. Horn Theft Warning Horn Connector Connector Tone adjusting screw CHANGED BY SWITCHES / ELECTRIC DEVICES EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 805 AV SYSTEM 8932 / 8930 TABLE OF CONTENTS AV SYSTEM .............. 2 1. AV head unit ............... 2 2. AV system configuration ............. 3 3. Head unit ................6 4. Tuner and DSP amplifier ..........13 5. Subwoofer ................. 15 6.
  • Page 806 DVD + Cassette + Radio DVD title insert slot Cassette 6.5 inch TFT LCD tape slot 2. Tuner 3. DSP amplifier 4. DVD 6 DISC changer 5. Subwoofer AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 807: Av System

    Radio antenna module Steering wheel remote control switch 2. CD + RADIO Audio Head Unit 1. 6 DISC changer + 6 DISC changer CD slot TAPE + RADIO Tape AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 808 TV and AM radio (quarter RH glass) signals and transmits each 2-channel video and audio signals to tuner. Each AMP amplifies receives TV signals and then transmits to tuner. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 809 Tweeter speaker (RR) Center speaker (LH) Subwoofer (without built-in AMP) Woofer is installed at the bottom of passenger’s seat. It enforces mid-low sounds. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 810: Head Unit

    The monitor moves to parking position when turning the ignition switch to OFF position. It moves to the preset position when turning the ignition switch to ON position again. Display when turning on the monitor AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 811 12. - 13. DVDC ON 13. AMP ON 13. - 14. GND 15. ALT D+ 16. Steering wheel remote control 17. Steering wheel remote control GND 18. PARKING SENSOR AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 812 8932 Head Unit Wiring Connector Tuner amplifier changer antenna connector AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 813 When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 814 Automatic replay: Audio CD, DVD title Playback control supported Sub woofer speakers DVD Changer (option) Install 6-discs in the magazine Automatic replay: Audio CD, DVD title Others DSP function, Equalizer function AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 815 Turning OFF/ON the button operating sound (“Beep” sound) Turning OFF/ON the speakers Turning OFF/ON the PBC function Turning OFF/ON the driving restriction Moves to replay mode out from SET/ADJUSTMENT mode Audio OFF AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 816 (driver’s, passenger’s, rear seats, all seats) on the screen (Position setting). To, adjust the balance, use the arrows on the screen. * BALANCE function and POSITION function cannot be used simultaneously. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 817: Tuner And Dsp Amplifier

    8932 4. TUNER AND DSP AMPLIFIER Front View Side View Rear View AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 818 5. CHASSIS GND 6. B+ (BACKUP) 7. RV VIDEO 8. RV GND TV antenna module LH CAN Wiring Radio antenna module TV antenna module RH CAN-HI ANT-ON CAN-LO AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 819: Subwoofer

    8932 5. SUBWOOFER Passenger’s Seat 1. Subwoofer_1 (+) 2. Subwoofer_1 (–) 3. Subwoofer_2 (+) 4. Subwoofer_2 (–) AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 820: Removal And Installation Of Av System

    2. Remove the center fascia panel. 1. Unscrew four mounting screws from the AV head unit and AC control panel. 2. Disconnect the head unit harness connector and the fiber optic cable. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 821 8932 3. Remove the AV head unit. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 822 1. Remove the service cover from the right lower quar- ter panel in the luggage compartment. 2. Remove the OVM tool box. 3. Unscrew eight mounting nuts from the tuner/amplifier deck assembly. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 823 2) Radio antenna cable, TV antenna cables and connectors Radio antenna cable TV antenna cables NOTICE • Use the pliers as shown in figure when disconnecting the TV antenna cables. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 824 5. Unscrew the mounting screws from the removed tuner/amplifier deck assembly and remove the tuner assembly. NOTE • Match the colors when inserting TV antenna cables into the connections. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 825 Unscrew six mounting bolts (10 mm) from the amplifier. Output signal from AV head unit Optical Main connectors sensor input AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 826: Dvd Changer

    DVD Changer Preceding Work: Disconnect the negative battery cable. DVD changer box 1. Remove the glove box lamp and release the locking device to lower the glove box. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 827 3. Unscrew the inner and outer mounting screws from the glove box and remove the lower instrument panel. 4. Open the DVD changer cover. Unscrew the mounting screws and remove the inner cover and outer cover. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 828 5. Remove the DVD changer cover. 6. Unscrew the mounting screws from the DVD changer. 7. Disconnect the fiber optic cable from the DVD changer through the opening of lower instrument panel. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 829 8. Slide out the DVD changer and unscrew the mounting screws from the DVD changer case. 9. Disconnect the harness connector and pull out the DVD changer with case. 10. Separate the case from the DVD changer. AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 830 8932 DVD Changer Front view Connector Fiber optic cable terminal AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 831 Preceding Work: Disconnect the negative battery cable. 1. Remove the center speaker cover. 2. Unscrew the mounting screws and disconnect the harness connector to remove the center speaker. Components Speaker cover Speaker assembly AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 832 Preceding Work: Disconnect the negative battery cable and remove the passenger’s seat. 1. Disconnect the harness connector and unscrew the mounting nuts to remove the sub woofer speaker. Components Connection Volume control lever AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 833 2. Unscrew four mounting screws and disconnect the harness connector to remove the speakers from the front and rear doors. Front door speaker 40W/2Ω Rear door speaker 40W/2Ω AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 834 Preceding Work: Disconnect the negative battery cable and remove the door trim. (For details, refer to “Body” section.) 1. Unscrew the mounting screws (2 EA) from the removed door trim and remove the speaker. AV SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 835 3. Remove the rear quarter upper and lower trims. 4. Remove the rear headlining. Radio antenna module TV antenna module TV antenna module TV antenna connection at tuner Radio antenna connection at tuner AV SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 836 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 837 WIPER & WASHER SYSTEM 7810 / 7820 / 7830 TABLE OF CONTENTS WIPER AND WASHER SYSTEM ......2 1. System layout of wiper and washer (with rain sensor) ..4 2. Wiper & washer related function and specification .... 6 3.

  • Page 838: Wiper And Washer System

    To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone Rear washer hose and roof wiring harness are fixed at the headlining section with silicone. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 839 Washer fluid outlet Passage Counter-current Spray passage Washer fluid inlet It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle. WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 840: System Layout Of Wiper And Washer (With Rain Sensor)

    Washer reservoir tank There is no separate washer res- ervoir tank for the rear washer fluid. The rear washer system uses the front washer fluid reservoir. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 841 Rear nozzle assembly Check valve Rear nozzle STICS STICS STICS receives the rain sensing data from the rain sensor and controls the wiper and washer systems. WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 842: Wiper & Washer Related Function And Specification

    Pull and hold the lever for more than 0.6 seconds : Wiper operates 3 times Wiping stops Washer fluid coupled operation Washer fluid for rear windshield operates once. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 843 “ON”, and it is turned on three times immediately after turning off the washer switch. KEY IN & IGN2 SW WASHER SW WIPER MOTOR PARKING WIPER LOW RELAY T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 844 2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation. KEY IN & IGN2 SW REAR WASHER SW REAR WASHER MOTOR RELAY WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 845 LOW RELAY T1: over 100 ms T2: 1.0 ± 0.1 sec T3: within 0.3 sec T4: 4 cycles T5: 3 cycles T6: 0.5 ± 0.1 sec WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 846 5. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. 6. The auto washer switch input is overridden during the front washer operation. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 847: Wiper And Washer System Related Circuit

    7810 3. WIPER AND WASHER SYSTEM RELATED CIRCUIT STICS WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 848: Removal And Installation

    At this moment, perform the work with the engine hood removed or opened. Wiper blade assembly 2. Close the engine hood and then remove the wiper blade asembly. Driver side Passenger side WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 849 Driver side cowl Passenger side cowl 5. Disconnect the wiper motor connector (1) and front windshield heated wire connector (2) connected to the wiper link assembly. WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 850 7. Unscrew the mounting nut (10 mm - 1EA) and bolts (8 mm - 3EA) from the removed wiper linkage assembly and then remove the wiper motor. Mark the adjustment mark before unscrewing the wiper motor cen- ter mounting nut. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 851 Layout of Front Wiper Assembly Linkage aseembly Wiper motor Passenger seat cowl Driver seat cowl Wiper blade (Passenger side) Wiper blade (driver side) Wiper Motor Assembly Connector WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 852 1. Remove the tailgate upper trim. 5. Lower mounting screw on the 3. Disconnect the mounting 2. Remove the inner tailgate tailgate lower trim clip underside the tailgate. handle. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 853 7810 2. Disconnect the mounting screw and then remove trim and vinyl cover from the tailgate underside. Mounting Piece Position WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 854 4. Remove the wiper blade and then unscrew the wiper motor cap and the mounting nut (17 mm - 1EA). Disconnect the cap Disconnect the nut WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 855 5. Open the tailgate, unscrew the connector and mounting bolts (10 mm - 2EA) and then remove the wiper motor. Rear Wiper Assembly Passenger seat wiper blade assembly Splasher ring-tailgate wiper Mounting nut Spacer ring-tailgate wiper Front Rear wiper motor and linkage assembly Inside Rear WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 856: Reservoir Tank

    2. Remove the tire. Reservoir Tank 1. Remove the front wheel house cover. 2. Remove the washer motor from the reservoir tank and then drain the washer fluid. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 857 Unscrew the washer reservoir tank mounting bolt and then remove it. Disconnect Wiper Motor Connector Upper Mounting Bolt Be careful not to damage when disconnecting Rear hose Front hose Connection Hose on the Wheel House Side WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 858 1. Open the engine hood and then disconnect the hose. Nozzle Side Connection Point 2. Remove the nozzle by pressing the right/left nozzle located at the engine hood as shown in the figure. WIPER & WASHER SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 859 2. Close the tailgate and then remove the nozzle with a flat blade screwdriver or special tool. NOTICE • Be careful not to damage the body and the nozzle. WIPER & WASHER SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 860 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 861 RAIN SENSOR UNIT (WITH AUTO LIGHT SENSOR) 8610 TABLE OF CONTENTS RAIN SENSING SYSTEM (WITH AUTO LIGHT SENSOR) ....... 2 1. System layout and overview ..........2 2. Rain sensor operation ............4 3. Rain sensor related circuit ............5 4. Functions and specifications of rain sensing wiper ....6 5.

  • Page 862: System Layout And Overview

    Horizon autolight sensor Auto light sensor Vertical autolight sensor Enlarged auto light sensor section RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 863 (For example, the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 864: Rain Sensor Operation

    Housing and Receiver Lens Enlarged auto Light Receiver Lens The receiver lens Sensor Section guides the reflected in- frared rays from wind- shield to photodiode. RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 865: Rain Sensor Related Circuit

    INT auto switch IGN 1 Auto washer switch Washer switch Volume (resistance) Rain RK STICS Sensor Figure Parking control Low speed High speed Wiper Motor RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 866: Functions And Specifications Of Rain Sensing Wiper

    LOW relay one cycle only when the rain sensor detects the “Rain Detected” signal. KEY IN & IGN2 INT AUTO Rain detected RAIN SENSOR to RKSTICS WIPER LOW RELAY T1: 1 cycle RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 867 2. The operation data is sent to the rain sensor even during the washer coupled wiper operation. KEY IN & IGN2 AUTO INT AUTO WASHER WIPER P-POS WIPER LOW RELAY Ignore Rain RAIN SENSOR Rain Sensing RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 868 (while the ignition key is in “ON” position). KEY IGN2 AUTO AUTO LIGHT LIGHT RAIN SENSOR TAIL Data TAIL LAMP RELAY HEAD LAMP RELAY RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 869 * The wiper motor runs only when the rain sensor requires. IGN (Operation) WIPER PARKING GND (Stop) SENSITIVITY SEN.2 RKSTICS to RAIN SENSOR RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 870 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in “ON” position and the INT switch is in “ON” position). SENSITIVITY RAIN SENSOR to S_COMMFAULT RKSTICS WIPER LOW RELAY T1 : cycle RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 871: Operation Mode Of Rain Sensing Wiper System

    (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.) RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 872: Functions And Checks Of Rain Sensor

    The wiper operates one cycle when changing the wiping stage (0 → → → → → 1, 1 → → → → → 2, 2 → → → → → 3). RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 873 If the wiper operates, this causes when the sensor is defective or the sensor has the communication problem with STICS. RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 874: Diagnosis Procedures

    4. Check the washer coupled wiper function. 5. Check the high speed. 6. Find the causes for irregular operations (abrupt operations). 7. Check the system with self-diagnosis function. RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 875: Trouble Shooting

    Check whether the variable resistance knob on the wiper switch is set in “FAST" or "SLOW”. Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage. RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 876 2. Disconnect the connector from the rain sensor unit located at the front windshield glass and then lift up the rain sensor unit to disconnect from the glass. RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 877 8610 Components of the Rain Sensor Unit PCB Assembly and Emitter Lens Auto light sensor Emitter lens Housing and Receiver Lens Receiver lens RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 878: Electrical Wiring Diagram

    8610 9. ELECTRICAL WIRING DIAGRAM RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR) CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 879 PARKING AID SYSTEM 8790 TABLE OF CONTENTS PARKING AID SYSTEM (PAS) ........ 2 1. System configuration ............2 2. Component specifications ............. 4 3. Alarm interval ................5 4. Troubleshooting of sensor ............. 5 5. Cautions on parking aid system ..........6 6.

  • Page 880: Parking Aid System (Pas)

    When placing the gear selector lever to “R” position, the designated unit (PAS unit) activates the parking aid sensors to measure the distance to obstacles. Gear Selector Lever (R Position) PAS buzzer STICS PAS piezoelectric buzzer PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 881 8790 Left/Right/Center Sensor Location Center sensor Parking Aid Unit Left sensor Center sensor Connector Right sensor PARKING AID SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 882: Component Specifications

    1) Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm 2) Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 883: Alarm Interval

    Back sonar (RH) Back sonar (LH) 4) Open in power circuit (+, -) Back sonar (center) Warning beeps When failed (also when diagnosing the unit) When normal PARKING AID SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 884: Cautions On Parking Aid System

    5) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). 6) When a high-power radio is turned on. 7) When some accessories are attached in detecting ranges PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 885: Removal And Installation Of Parking Aid

    Preceding Work: Disconnect the negative battery cable and remove the spare tire. Center PAS sensor 1. Disconnect the harness connector and then remove the center sensor by turning the mounting cover. Sensor assembly Connector PARKING AID SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 886 1. Disconnect the center connector and then remove the cover by turning it. LH sensor RH sensor 2. Remove the RH/LH sensor mounting cover and spring and then remove the sensor from the bumper. PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 887 8790 Components of PAS Sensor PAS sensor PAS sensor lower Spring PAS sensor upper mounting cover mounting cover Connector PARKING AID SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 888 When Extended When Compressed 1. Align the sensor lower cover with the sensor 2. Insert the sensor upper cover into the sensor groove. groove. Align Wigh the Groove PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 889 (For removal and installation, refer to the BODY section.) 1. Disconnect the connector and mounting bolts (10 mm - 2EA) and then remove the PAS unit. Connector Disconnection Removal of of connector mounting bolt Connector PARKING AID SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 890: Circuit Diagram

    8790 7. CIRCUIT DIAGRAM PARKING AID SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 891 ELECTRIC SYSTEM 8000 TABLE OF CONTENTS ELECTRIC SYSTEM LAYOUT ........ 2 1. Locations of interior units and sensors ........2 2. Switches, units and sensors in engine compartment ....4 3. Interior switches ..............6 4. Audio & video system ............8 5.

  • Page 892: Electric System Layout

    Door lock relay Chime bell Curtain air bag module Buzzer Sun sensor for PAS TV antenna amplifier RK STICS PAS Unit TCCU and TCU Driver Seat Memory Switch TCCU ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 893 DVD changer Curtain Air Bag Sensor DSP amp Sub woofer TV tuner Interior Temperature and Engine ECU and SSPS Unit Humidity Sensor SSPS unit (under the engine ECU) ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 894: Switches, Units And Sensors In Engine Compartment

    FFH Assembly Receiver Drier and Triple Pressure Switch Horn (RH) AQS Sensor and FFH Ambient Temperature Sensor FFH ambient temperature sensor AQS sensor (ambient temperature sensor integrated type) ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 895 ESP Pressure Sensor / Primary, Secondary ABS (ESP) HECU IWE Vacuum Solenoid Valve (4WD) Hood Contact Switch Horn (LH) (on battery tray) Theft Deterrent Horn (Under the Battery) Fuse and Relay Box ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 896: Interior Switches

    Bezel Assembly on Outside Rearview Mirror Adjusting Switch Outside rearview mirror folding switch ESP OFF switch Outside rearview mirror adjusting switch Seat Position Memory Switch (Driver’s Door) Driver’s Power Window Main Switch ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 897 HDC switch TRIP switch Front defogger switch Hazard switch Center Fascia Switch switch Driver seat warmer switch Passenger’s Power Window Switch Passenger seat warmer switch ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 898: Audio & Video System

    DVD+tape Center speaker AV head unit Sub Woofer Tweeter speaker (LH) Front speaker (LH) Other Audio Head Unit 1. 6-INDASH CD+TAPE+RADIO 2. CD+RADIO CD slot 6-Indash changer Tape ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 899 TV antenna amplifier (RH) Rear speaker (RH) Tuner/Amp Tweeter speaker Radio antenna amplifier AV System DSP integrated amplifier Tweeter TV antenna amplifier (LH) speaker (LH) Rear speaker (LH) Tuner ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 900: Electric Components And Layout

    8000 5. ELECTRIC COMPONENTS AND LAYOUT Wiring Harness Arrangement ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 901 8000 Components Locator ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 902: Fuses And Relays

    The designation and capacity of relays and fuses is shown on the fuse and relay box cover. Fuse and Relay Box in Engine Compartment Fuses and Relays Connector Arrangement ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 903 8000 ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 904 1. Disconnect the negative battery cable, open the fuse and relay box cover in engine compartment, and unscrew the mounting nuts. 2. Lift the fuse and relay box assembly and disconnect connectors behind the assembly. 3. Remove the fuse and relay box assembly. ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 905: Interior Fuse Box

    8000 7. INTERIOR FUSE BOX Fuse and Relay Box (LH) Fuse and Relay Box (RH) ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 906: Driver Side

    8000 Designation and Capacity Driver Side ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 907: Passenger Side

    8000 Passenger Side ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 908: Diagnostic Connector

    Additional cable for CAN module CAN module Additional Devices of Scan-100 Connection of Scan-100 (Diagnosis: EAS, EPB Only) (Including CAN Module and Additional Cable) CAN module CAN module connecting cable ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 909 TGS lever position unit Pin no. 11 Pin no. 12 SSPS Pin no. 13 TCCU Pin no. 14 CAN - LOW Pin no. 15 REKES coding Pin no. 16 Battery + ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 910: Electrical Wiring Diagrams

    8000 9. ELECTRICAL WIRING DIAGRAMS ELECTRIC SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 911 LAMP 8310 / 8320 / 8610 TABLE OF CONTENTS LAMPS ..............2 1. Locations of exterior lamps and specifications ....2 FRONT LAMPS ............6 1. Compositions of front lamps ..........6 2. Aiming and adjustment of front lamp ........8 3.

  • Page 912: Lamps

    EU: one at each side (12V/H27W) Turn Signal Lamp/Stop Lamp Assembly T/Stop Lamp General: LH-1 (12V/27W/8W) EU: LH-1 (12V/P21W/5W) Turn Signal Lamp General: one at each side (12V/27W) EU: one at each side (12V/PY21W) LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 913 General: one at each side (12V/27W/8W) EU: one at each side (12V/P21W/5W) Reversing Lamp General: one at each side (12V/16W) Rear Fog Lamp General: one at each side (12V/P21W) LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 914 30 seconds. When the door open. is closed, the lamp will go off. Glove Box Door Courtesy Lamp 12V/5W - One at glove box 12V/5W - one at each door LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 915 9. The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch is pressed. OPEN Dr or Ps DOOR SW CLOSE IGN KEY REMINDER SW RECEIVE REMOCON UNLOCK NO SIGNAL UNLOCK OUTPUT CENTER ROOM LAMP LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 916: Front Lamps

    High beam bulb Low beam bulb EU: Position lamp Connector Lamp General: Positon lamp and turn signal lamp bulb Front Fog Lamp Fog lamp bulb Connector Lamp and case LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 917 8310 Connection Connector When Installing Positon lamp and turn signal lamp connector Headlamp connector Side Repeater Connector Lamp Lamp cover LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 918: Aiming And Adjustment Of Front Lamp

    Adjustment Direction Low Beam Low Beam 1: Left / 2: Right A: Up / B: Down High Beam High Beam 1: Left / 2: Right A: Up / B: Down LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 919 Unit: mm <단위 : mm> If the focus deviates the “A” point, adjust the headlamp aiming by rotating the aiming screws (Up, Down, Left, Right) in turn with a screwdriver. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 920 The lamp aiming moves down and The lamp aiming moves up and the the light faces downward when the light faces upward when the knob knob is turned counterclockwise. is turned clockwise. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 921: Removal And Installation Of Headlamps

    • Be careful not to damage the headlamp cover when removing it in order of the above number. 3. Disconnect two headlamp connectors (Turn signal lamp/Position lamp, Low beam/High beam). LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 922 Position lamp (EU) Turn signal lamp and Position lamp NOTICE High beam • If the lamp cover rubber ring is damaged Low beam while installing, replace it with new one. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 923 • To make the bulb replacement easier, remove the headlamp assembly. 2. Disconnect the high/low beam connectors from the headlamp assembly. Low Beam Side High Beam Side 3. Remove the clamps. Low Beam Side High Beam Side LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 924 5. Position/turn signal lamp bulb should be removed after removing the headlamp assembly. NOTICE • Use only specified bulb for replacement. • Do not touch the bulb with bare hands when it is hot. You may get burnt. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 925 2. Disconnect the connector and unscrew four mounting screws to remove the front fog lamp assembly. Front View Rear View Fog lamp bulb and connector Lamp and case LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 926 Preceding Work: Disconnection of negative battery cable 1. Push out the side repeater assembly. Rear Front 2. Disconnect the connector and remove the lamp. Connector Lamp (12V/5W) Side repeater cover LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 927 MEMO .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 928: Rear Combination Lamp

    1. COMPOSITION OF REAR COMBINATION LAMP Turn Signal Lamp/Stop Lamp Assembly Turn signal lamp (valve) Bulb holder & connector Stop lamp bulb Combination lamp License Plate Lamp Assembly Connector Bulb Lamp LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 929 8310 High Mounted Stop Lamp Tail Lamp/Back-up Lamp Assembly Bulb holder & Bulb Connector (tail lamp) Bulb • Passenger: Back-up lamp • Driver: RR Fog Lamp Combination lamp LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 930: Removal And Installation Of Rear Combination Lamp

    Preceding Work: Disconnect the negative battery cable. 1. Open the tailgate and unscrew two mounting screws to remove the rear combination lamp assembly. 2. Disconnect the connector and remove the rear combination lamp assembly. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 931 8310 3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs. NOTICE • Use only specified bulb for replacement. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 932 2. Disconnect the connector and remove the rear combination lamp assembly. 3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs. NOTICE • Use only specified bulb for replacement. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 933 1. Remove the upper and lower trim of the tailgate. Disconnect the connectors and unscrew eight mounting nuts (10 mm) to remove the rear garnish assembly. Tailgate Rear Garnish Assembly Inside Outside LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 934 2. Disconnect the bulb and bulb cable from the removed rear garnish assembly and then remove the lamp by pressing (A) section of the lamp. Disconnect the Bulb Connector Remove the Lamp Exploded View Tailgate garnish Connector Lamp LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 935 1. Pry off the license plate lamp with a flat bladed screwdriver. 2. Remove the bulb from the removed license plate lamp. NOTICE • Use only specified bulb for replacement. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 936 It should be replaced with the tailgate upper garnish assembly. 1. Open the tailgate, remove the upper trim and then 2. Disconnect the rear washer nozzle hose. disconnect the high mounted stop lamp connector. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 937 • In the vehicle without tailgate air spoiler, the bulb type high mounted stop lamp is used. It can be re- placed with new one after removing the tailgate upper garnish assembly. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 938: Interior Lamps

    1. COMPOSITION OF INTERIOR LAMPS Front Room Lamp Assembly Front room lamp cover Sunglasses box Front room lamp bulb Interior Room/Luggage Room Lamp Assembly Lamp (lens) luguage room Bulb Front view Rear view LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 939 8310 Glove Box Lamp Assembly Bulb Door Courtesy Lamp Assembly LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 940: Removal And Installation Of Interior Lamps

    Preceding Work: Disconnect the negative battery cable. 1. Open the sunglasses box and remove two front room lamp assembly mounting screws. 2. Disconnect the connector and remove the front room lamp assembly. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 941 • The tab can be damaged when removing the room lamp abnormally. 2. Carefully remove the bulb from the lamp and replace it with new one. NOTICE • Use only specified bulb for replacement. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 942 2. Unscrew the lamp mounting screws (luggage room lamp) and nuts (center room lamp). Center room lamp Luggage room lamp 3. Disconnect the connector and remove the lamp assembly. LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 943 1. Remove the lamp cover and then carefully remove the bulb. Replace it with new one. Center room lamp Luggage room lamp NOTICE • Use only specified bulb for replacement. LAMP CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 944 1. Open the glove box and remove the lamp cover by pressing both sides of the lamp as shown in the figure. 2. Disconnect the connector and remove the lamp assembly. Replace the bulb with new one. 12V-5W LAMP CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 945 SUNROOF SYSTEM 7340 TABLE OF CONTENTS SUNROOF ASSEMBLY ........... 2 1. Components and locations ............2 2. Operation and function ............3 3. Trouble diagnosis ..............6 4. Removal and installation of sunroof assembly ....... 7 5. Circuit diagram ..............21...

  • Page 946: Sunroof Assembly

    7340 SUNROOF ASSEMBLY 1. COMPONENTS AND LOCATIONS Sunroof Motor Sunroof Control Unit (SCU) Sunroof Switch Sunroof Assembly SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 947: Operation And Function

    However, if the force against the sunroof is less than the specified value, the Anti-Trap function doesn't operate. Anti-trap function is built in SCU SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 948 Motor drive B Supply voltage monitor Close position Sensing Tilt Puls input Logic input Slide Controller assembly Motor (HALL I.C & MICROSWITCH) SCU Main Connector Motor Connector (SCU) SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 949 • If the power supply system is in normal conditions, replace the sunroof motor or the sunroof control unit. • Replace the sunroof control unit with new one and check if the sunroof operates properly before replacing the sunroof motor. SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 950: Trouble Diagnosis

    Install sponge to drain hose. body Interference between vehicle body and roof Apply sealant between vehicle body and panel roof panel. Gap and clearance between roof panel and Readjust glass location. glass SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 951: Removal And Installation Of Sunroof Assembly

    LH Main lever LH Retraction bar Breed nail Drain channel Frame assembly Seal - drive tube Tube cable guide Frame assembly Drive tube Sunroof Sunroof control unit motor SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 952: Wind Deflector

    • Work only when the sunroof is open. 2. Unhook the wind deflector side locks at both sides. 3. Unhook the wind deflector bottom locks as shown in figure (A). Wind deflector SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 953 1. Remove the inner side covers at both sides by pushing them rearward. 2. Remove the three mounting bolts (TORX bolts) of the glass panel with a special wrench (25 T). Tightening torque: 5 Nm 3. Remove the glass panel. SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 954 2. Insert the locks of the new outside cover into the mount- ing holes. Sunroof mechanism 3. Push down the outside cover to install into the roof panel and lock it to the sunroof system with a pliers. SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 955 2) Rear gap (0 ~ 1 mm) NOTE • To prevent the wind noise during high speed driv- ing (over 100 km/h), the rear gap should be greater than front gap. Rear Front SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 956 Gap between roof and glass panel should be approx. 5 mm. If this gap is too small, the glass panel may be scratched or the interferencing noise may sound. Gap between roof and glass panel: approx. 5 mm SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 957 1. Remove the two mounting bolts (TORX bolt) at both sides on the drain channel with the glass panel removed. Tightening torque: 1.2 Nm 2. Unhook the locks (A) and remove the drain channel. 3. When installing Hook the locks (B) of the drain channel. SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 958 1. Move the sun shade panel forward and remove the slide blocks of the sun shade panel from the guide rail with a flat bladed screwdriver as shown in the figure. 2. Remove the sun shade panel from the sunroof. SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 959 3. When installing, completely fit the sunroof rail into the slot of sunroof control unit and tighten the screw. NOTICE • Completely fit the sunroof rail into the slot of sunroof control unit. Slot Completely fit the tab. SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 960 2. Unscrew the three mounting bolts (25T) with a special wrench and remove the motor assembly. NOTICE • To make the motor positioning easier, do not operate the motor (even for the testing) before installation. SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 961 Release the clamps and remove hoses. (However, the fastener at rear side of rear hose should be removed.) Rear Hose Front Hose NOTICE • When installing, be careful not to kink, damage and twist the hose. Not allowed SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 962 7340 Note Fastener location of rear drain hose The rear drain hose can be removed after releasing the fasteners. SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 963 Preceding Work: Removal of headlining 1. Disconnect the front and rear drain hoses with the sunroof closed. 2. Unscrew the two bracket mounting bolts (10 mm) at both sides. SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 964 3. Unscrew the mounting bolts (10 mm) at both sides. Installation Notice Tightening torque 6 ~ 10 Nm 4. Remove the sunroof assembly from the vehicle. Sunroof Assembly SUNROOF SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 965: Circuit Diagram

    7340 5. CIRCUIT DIAGRAM SUNROOF SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 966 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 967 SEAT & SEAT BELT 7410 / 7430 TABLE OF CONTENTS SEAT ASSEMBLY ........... 3 1. Seat mounting points ............3 2. Composition of seat .............. 4 3. Removal and installation of seat .......... 11 4. Seat heating ............... 17 5. Seat arrangement ............... 17 SEAT BELT ............

  • Page 969: Seat Assembly

    Tightening torque: 35 ~ 55 Nm Second Row Seat Tightening torque: 35 ~ 55 Nm Third Row Seat Mounting bolts Tightening torque: 35 ~ 55 Nm SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 970: Composition Of Seat

    Reclining Seat cushion angle lever Seat Cushion Motor (Rear) adjusting lever (rear) Sliding motor Seat cushion angle adjusting lever (front) Seat height control switch Sliding lever SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 971 7410 Location of Seat Position With Memory Unit (Bottom of Driver Seat) SPWM unit SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 972 7410 Front Seat (Passenger Seat) Reclining Motor Reclining lever Sliding rail Sliding rail Sliding lever (No seat height control function) Sliding motor SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 973 7410 Functions Switches and Functions of Driver Seat 1. Seat Sliding Adjustment 2. Seat Cushion Height Adjustment 3. Seat Cushion Angle Adjustment 4. Seatback Reclining Adjustment SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 974 To lower the headrest, press the release button (1) on top of seatback and push the headrest down. 2. Seatback Reclining Adjustment 3. Seat Sliding Adjustment SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 975 To change the seatback angle, lean forward slightly and raise the lever. Then, lean back to the desired angle and release the lever. Full Flatting the Second Row Seat SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 976 (A) on top of seatback and push the headrest down. 2. Full flat lever for third row seat Unfolding/Folding of Third Row Seat SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 977: Removal And Installation Of Seat

    3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly. Disconnect the connector Connector (seat side) Main connector SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 978 Installation Notice Tightening torque 35 ~ 55 Nm 3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly. SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 979 Tightening torque: 35 ~ 55 Nm 3. Remove the second row seat from the vehicle. SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 980 2. Unscrew the mounting bolts and remove the third row seat. Tightening Tightening torque: torque: 35 ~ 55 Nm 35 ~ 55 Nm SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 981 1. Slide the front seat forward and unscrew the mounting screws of seat side cover. 2. Disconnect the switch connector and remove the seat side cover. SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 982 7410 3. Remove the power seat switch cover and unscrew the two mounting screws to remove the switch. Composition of Power Seat Switch SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 983: Seat Heating

    Press the button to warm the seat, and press it again to stop the operation. The indicator on the switch comes on during operation. 5. SEAT ARRANGEMENT SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 984: Seat Belt

    Pretensioner: Installed at front seats. The seat belt pretensioner rewinds the seat belt immediately to protect occupant’s face and chest when a strong frontal collision occurs. Seat Belt Seat Belt (3 point type) (3 point type) Seat Belt (2 point type) SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 985 Buckle of 2 point type seat belt Seat Belt (2 Point Type) 2 point type seat belt is installed only in the center seat of second row seat. SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 986: Removal And Installation Of Seat Belt

    1) Press both sides of button (1) and push the bot- tom of D-ring cover (arrow) to release the upper hook (2). 2) Raise the arrow section and remove the D-ring cover. SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 987 35 ~ 55 Nm 5. Carefully lower the seat belt and unscrew the mounting screws and bolts to remove the seat belt. Tightening torque: 35 ~ 55 Nm SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 988 Composition of Front Seat Belt Seat belt anchor bolt Seat belt (35 ~ 55 Nm) Height adjuster D-ring Seat belt mounting bolt (35 ~ 55 Nm) SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 989 35 ~ 55 Nm Tightening torque: 35 ~ 55 Nm Tightening Anchor bolt torque: 35 ~ 55 Nm O-ring bracket Seat belt D-ring D-ring SEAT & SEAT BELT CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 990 Buckle for 3 point second row seat type seat belt in second row seat Fixed Type Buckle (Front Seat) Buckle Cover Buckle mounting bolt: 35 ~ 55 Nm SEAT & SEAT BELT CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 991 AUTO CRUISE SYSTEM TABLE OF CONTENTS AUTO CRUISE ASSEMBLY ........2 1. Cruise control system ............2 2. Curise control switch ............2 3. Removal and installation of cruise control switch ....2 4. Electrical wiring diagrams ............. 3...

  • Page 992: Cruise Control System

    2. Remove the steering wheel air bag and cruise switch cover. 3. Remove the crew with control switch. 4. Remove the control switch 5. Installation should follow the removal procedure in the reverse order. AUTO CRUISE SYSTEM CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 993 4. ELECTRICAL WIRING DIAGRAMS Diesel Gasoline AUTO CRUISE SYSTEM CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 994 MEMO ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 995 BODY INTERIOR 7730 / 7610 / 7330 / 7630 / 7632 / 7850 / 7770 TABLE OF CONTENTS INTERIOR TRIM ............2 1. Locations ................2 INSTRUMENT PANEL ..........4 1. Removal and installation of instrument panel ......4 SUN VISOR ............11 1.

  • Page 996: Interior Trim

    INTERIOR TRIM 1. LOCATIONS Instrument Panel Assembly Center Console (A/T) - Deluxe Type B Pillar Trim (Upper/Lower) C Pillar Trim Rear Quarter Panel Door Trim (Driver Side Door) BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 997 7730 Hand Grip Sun Visor A Pillar Trim Door Trim (Passenger Side Door, Rear Doors) Headlining Assembly BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 998: Instrument Panel

    3) Unscrew the mounting bolts and nuts and Slot Cable remove the undercover and bracket. Guide groove Insert tab Parking brake release lever Guide bracket Parking brake pedal BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 999 9) Remove the steering wheel assembly (steering angle sensor, air bag, air bag contact coil, multifunction 8) Remove the center console assembly and switch). the center fascia lower tray. BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 1000 4) Remove the parking brake lever bracket and fuse/ relay box assembly. 5) Unscrew the meter cluster mounting nuts and lower instrument panel mounting bolts. Parking Brake Lever Driver Side Fuse/ Bracket Relay Box BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 1001 9) Unscrew the mounting nuts and screws from the fuse/ relay box and side instrument panel (at passenger side). 10) Disconnect the GPS antenna connector. 11) Remove the instrument panel assembly. GPS Antena BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 1002 2) Unscrew the mounting bolts from the driver side steering column bracket. 3) Disconnect the main wiring connector (A) 4) Disconnect the center wiring connector and and air bag connector (B). unscrew the mounting bolt. BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 1003 9) Disconnect the main wiring, the optical cable 8) Unscrew the center mounting bolts at both and the SSPS connector etc. on the pas- sides in the instrument panel frame. senger side. BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...
  • Page 1004 7730 10) Remove the instrument panel frame. Instrument Panel and Panel Frame Assembly BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...

  • Page 1005: Sun Visor

    Unscrew the screws and disconnect the vanity mirror lamp connector. Remove the sun visor and sun visor hook. Mounting Screws (3) Vanity Mirror Lamp Connector Sun Visor Components Driver side Passenger side BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 1006: Rear Quarter Trim And Pillar

    C Pillar Assembly B. Side Bolt Rear Quarter Trim Assembly C. Lower Bolt (Tailgate Side) Remove the tailgate scuff trim before removing the lower screw of rear quarter trim. BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 1007 C Pillar Remove the seat belt and unscrew the mount- ing screws to remove the C pillar. D Pillar Be careful not to damage the pillars and fasteners. BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

  • Page 1008: Headlining Assembly

    Luggage room lamp connector Sunroof unit connector Room lamp connector Front room lamp connector Rear washer fluid hose Rear washer fluid hose Rear washer fluid hose Roof wiring connector BODY INTERIOR CHANGED BY KYRON SM - 2005.09 EFFECTIVE DATE AFFECTED VIN...
  • Page 1009 2. Disconnect the connectors and washer fluid hoses from the headlining and remove the fasteners. Fastener Rear Washer Fluid Hose Sunroof Unit Connector Rear Washer Fluid Hose and Roof Wiring Connector * Use only designated special tool when removing the fasteners. BODY INTERIOR CHANGED BY EFFECTIVE DATE KYRON SM - 2005.09 AFFECTED VIN...

Table of Contents

Save PDF