SSANGYONG Rodius 2012.07 Manual
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SSANGYONG Rodius 2012.07 Manual

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Summary of Contents for SSANGYONG Rodius 2012.07

  • Page 118 01-3 0000-00 *( ) : Optional 1. DIMENSIONS Unit: mm Top View Side View Front View Rear View...

  • Page 119: Specifications

    01-4 2. SPECIFICATIONS * ( ) Optional, [ ] 2WD...
  • Page 120 01-5 0000-00 ▶Specifications (Cont'd)

  • Page 121: Vehicle Identification

    01-6 3. VEHICLE IDENTIFICATION Engine Number Visual VIN Label Chassis Number The chassis number is Gasoline Engine: The stamped on the frame behind engine number is stamped the front right tire. on the lower area of cylinder block in exhaust manifold side.

  • Page 122: Maintenance

    01-7 0000-00 4. MAINTENANCE 1) Scheduled Maintenance Services (EU) - Diesel Engine (D20DTR)
  • Page 123 01-8...
  • Page 124 01-9 0000-00...
  • Page 125 01-10 2) Scheduled Maintenance Services (GEN) - Diesel Engine (D20DTR)
  • Page 126 01-11 0000-00...
  • Page 127 01-12...

  • Page 128: Scheduled Maintenance Services (Gasoline Engine)

    01-13 0000-00 3) Scheduled Maintenance Services (Gasoline Engine)
  • Page 129 01-14...
  • Page 130 01-15 0000-00...

  • Page 131: Recommended Fluids And Lubricants

    01-16 5. RECOMMENDED FLUIDS AND LUBRICANTS - Use only Ssangyong recommended fluids and lubricants. - Keep the specified levels when adding or replacing the fluids. - Do not mix any different types or brands of oils or fluids. This may cause damages.

  • Page 132: Jack Points

    01-17 0000-00 6. JACK POINTS Front: Double wishbone Rear: Multi Link...

  • Page 133: Pin Arrangement Of Diagnostic Connector

    01-18 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR The diagnostic connector is located at bottom of instrument panel. It consists of 16 pins. The REKES key should be coded by the scan tool. Diagnostic connector ▶ Connector Pin Pin No. Function STICS "A2"(Coding) Ground Ground...

  • Page 134: Electric Components And Layout

    01-19 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement...

  • Page 135: Components Locator

    01-20 2) Components Locator...

  • Page 136: Tightening Torque Of Standard Bolts

    01-21 0000-00 9. TIGHTENING TORQUE OF STANDARD BOLTS ▶ Tightening Torque By Bolt Specification Metric bolt strength is embossed on the head Determine extra proper tightening torque if of each bolt. The strength of bolt can be tightens with washer or packing. classified as 4T, 7T, 8.8T, 10.9T, 11T and If tightens bolts on the below materials, be 12.9T in general.
  • Page 138 02-2 1. ENGINE COMPARTMENT (DIESEL ENGINE) 2130-13 Coolant Reservoir 1115-00 Engine De-aeration port - Changed housing design and added - Deleted D27DT (Euro4) engine and de-aeration port (engine head to coolant introduced D20DTR (Euro5) engine. reservoir) HFM (Hot Film Air-Mass Sensor) 2330-08 HFM6 HFM7...
  • Page 139 02-3 0000-00 1990-01 Engine Mounting Insulator 2232-01 Fuel Filter Assembly Front RH Front LH Priming pump Water detection Front RH Front LH sensor - Changed design according to installation of new engine - Changed fuel filter Newly Installed Equipment 2112-02 PWM Cooling Fan Electric fan 2330-01...
  • Page 140 02-4 2. CHASSIS I 4012-01 Front Sub Frame Sub frame bushing Changed front axle mounting height Changed stabilizer mounting - Changed sub frame Newly Installed Equipment CDPF (Catalyst & Diesel 2412-02 Particulate Filter) Engine side - Installed CDPF according to Euro 5 regulation 4420-01 Front Stabilizer...
  • Page 141 02-5 0000-00 1990-00 Rear Engine Mount - Changed design 4411-01 Front Suspension Coil spring Upper arm assembly assembly Knuckle assembly Stabilizer bar Lower arm assembly assembly Shock absorber assembly Upper arm Knuckle assembly assembly Lower arm assembly Stabilizer bar assembly - Changed components 3240-01 Transfer Case (T/C)
  • Page 142 02-6 2. CHASSIS II 3650-02 Torque Converter Torsional damper Turbine wheel Stator Impeller - Added torsional damper (reduces booming noise) and increased capacity 4115-01 Knuckle and Hub Assembly (4WD) Knuckle Front axle shaft Locking hub actuator Knuckle Hub assembly Front axle shaft - Changed components (hub, knuckle, hub actuator and front axle shaft) according to new part-time T/C...
  • Page 143 02-7 0000-00 Newly Installed Equipment Wheel and Tire Repair Kit Manual Transmission 4170-07 Wheel 3170-01 4WD (A/T) (A/T, M/T) (A/T, M/T) - Installed 6-speed manual - For 4WD vehicle, installed new wheel transmission Repair kit Sealant Located in left quarter trim - New wheel - Installed tire repair kit Transmission Cross Member...
  • Page 144 02-8 3. OTHERS 8910-05 Audio Assembly -Bluetooth 2 DIN CDP Warning Lamp/Indicator Cluster 8010-10 - Changed some warning lamps and indicators 8410-14 4WD Switch - Changed 4WD switch according to newly installed part-time T/C...

  • Page 145: Engine Layout

    01-3 0000-00 1. ENGINE LAYOUT Front view Rear view Right view Left view...

  • Page 146: Major Components

    01-4 2. MAJOR COMPONENTS ▶ Front view Vacuum pump Camshaft position sensor Oil filter assembly Power steering pump pulley Oil pressure switch Water pump pulley Idler pulley No. 22 Alternator pulley Auto tensioner Idler pulley No. 1 A/C compressor pulley Isolation damper ▶...
  • Page 147 01-5 0000-00 ▶ Right view Front exhaust gas temperature sensor Oil dipstick tube & gauge assembly E-VGT actuator E-VGT turbocharger Coolant screw plug Oil drain plug ▶ Left view Thermostat assembly Variable swirl valve assembly E-EGR valve E-EGR solenoid valve EGR cooler Oil cooler assembly Electronic throttle body...

  • Page 148: Engine Compartment Layout

    Always turn the engine off and allow it to cool before starting the maintenance. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.

  • Page 149: Service Interval

    01-7 0000-00 1) Service Interval Daily Weekly Description Service interval inspection inspection Engine oil & oil Inspection Change every 20,000 km or 12 filter months (The service interval should be shortened under severe conditions) General Change every 15,000 km or 12 months (The service interval should be shortened under severe conditions)
  • Page 150 01-8 2) Specification and Capacity Specification Quality class: Ssangyong genuine engine oil (Total Quartz INEO Engine oil ECS 5W 30, SK ZIC SY 5W 30) or oil Approved by MB Sheet 229.51 Capacity approx. 6.0 litter Specification Ssangyong genuine coolant Anti-Freeze SYC-1025...

  • Page 151: Caution When Servicing The Engine

    01-9 0000-00 4. CAUTION WHEN SERVICING THE ENGINE 1) Cleaness Engine has a lot of precisely machined (grinding, polishing, lapping) surfaces. Thus, there should be great cautions for cleaness when servicing the engine components. Apply the engine oil on the sliding surfaces when assemblying the components. Every component should be disassembled and reassembled in accordance with the correct sequences.

  • Page 152: Lubrication System

    01-10 (3) Cautions before service Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never remove the coolant reservoir cap when the engine and radiator are hot. (4) Lubrication system Prolonged exposure to the engine oil make cause a skin cancer or an irritation. Used engine cotains the hazardous material that may cause the skin cancer.

  • Page 153: Standard Bolts Specifications

    01-11 0000-00 5. STANDARD BOLTS SPECIFICATIONS Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as 4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general. Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 % if necessary.

  • Page 154: Tightening Torque

    01-12 6. TIGHTENING TORQUE Note (total Tightening Numbers of Name Size tightening torque (Nm) fastener torque) M12×82 55±5Nm, Main bearing cap Not-reusable 180˚ M9×52 40±5Nm, Connecting rod cap 50 ~80Nm 90˚+10˚ M6×20 10±1Nm Crankshaft rear seal M8×35 25±2.5Nm Oil pump M10×22 45±5Nm, Drive plate...
  • Page 155 01-13 0000-00 Note (total Numbers of Tightening torque Name Size tightening fastener (Nm) torque) M6×12 10±1Nm Hot water inlet pipe M10×90 (LO) 25±2.5Nm Alternator M10×116 (HI) 46±4.6Nm M8×85 Air conditioner 25~2.5Nm compressor M6×25 10±1Nm Air conditioner bracket M8×35 25±2.5Nm Intake manifold M8×110 25±2.5Nm M8×40...
  • Page 156 01-14 Note (total Tightening Numbers of Name Size tightening torque (Nm) fastener torque) 45±4.5Nm Idler pulley/tensioner pulley 20±2Nm Glow plug M8×25 10±1Nm Vacuum pump M6×40 10±1Nm Timing gear case cover M6×45 10±1Nm M6×50 10±1Nm M6×35 10±1Nm Cylinder head cover M6×16 10±1Nm Oil dipstick gauge cover 25±2.5Nm...

  • Page 157: Coding And Initialization

    01-15 0000-00 7. CODING AND INITIALIZATION 1) Engine Variant Coding Unit Selection Description PTC auxiliary heater For PTC auxiliary heaterequipped vehicle, select"YES". Glow plug Relay (K-line) Select "AQGS". AQGS (CAN) Transmission MT 5-speed Select the appropriate system. MT 6-speed AT 5-speed (DC 5AT) AT 6-speed (DSI 6AT) AT 7-speed (DC 7AT) Select “Refrigerant pressure sensor”.
  • Page 158 01-16 2) Chassis Variant Coding Unit Selection Description Region GENERAL Select the region. EUROPE Select "NO". EAS 2-corner EAS 4-corner Select "NO". Telematics Select "NO". A/T: Select “DURA lever (CAN)”. T/M shift lever DC lever (CAN) M/T: Select “M/T”. DURA lever (CAN) DSI lever (NO-CAN) Select “ABS”...
  • Page 159 01-17 0000-00 Unit Selection Description Sedan/Limousine Sedan (RV) Select "Sedan (RV)". Limousine Vehicle code Rodius Select "Rodius". (Flatform) Rexton Korando C Kyron Korando Sport A/T: Select “DURA lever (CAN)”. Vehicle code D32DT M/T: Select “M/T”. (Engine) D27DT D27DTP D20DT D20DTR D20DT-LOW Select “D20DTR”.

  • Page 160: Engine Assembly

    02-3 0000-00 1. ENGINE ASSEMBLY Unit Description Specification Remark Cylinder head Height 131.9 to 132.1 mm Flatness below 0.1 mm Valve protrusion Intake valve 0.6 to 1.0 mm Exhaust valve 0.6 to 1.0 mm Flatness on Intake manifold 0.08 mm manifold side Exhaust manifold 0.08 mm...
  • Page 161 02-4 2. TIGHTENING TORQUE Bolt Remark Specified torque Component Size Quantity (Total torque) (Nm) M12×82 55±5Nm, Main bearing cap Not re-usable 180˚ M9×52 40±5Nm, Connecting rod cap 50 to 80 Nm 90˚+10˚ M6×20 10±1Nm Crankshaft rear seal 25±2.5Nm Oil pump M8x35 M10×22 45±5Nm,...
  • Page 162 02-5 0000-00 Bolt Specified torque Remark Component Size (Nm) Quantity (Total torque) M6×12 10±1Nm Hot water inlet pipe M10×90 (lower) 25±2.5Nm Alternator M10×116 (upper) 46±4.6Nm M8×85 25±2.5Nm A/C compressor M6×25 10±1Nm A/C bracket M8×35 25±2.5Nm Intake manifold M8×110 25±2.5Nm M8×40 25±2.5Nm Oil filter module M8×20...
  • Page 163 02-6 Bolt Specified torque Remark Component Size Quantity (Nm) (Total torque) 20±2Nm Glow plug M8×25 10±1Nm Vacuum pump M6×40 10±1Nm Timing gear case cover M6×45 10±1Nm M6×50 10±1Nm M6×35 10±1Nm Cylinder head cover M6×16 10±1Nm Oil gauge tube 25±2.5Nm Oil filter cap M8×25 25±2.5Nm Fuel rail...

  • Page 164: Compression Pressure Test

    02-7 0000-00 3. CHECK AND INSPECTION 1) Cylinder (1) Compression pressure test ▶ Specified value Compression ratio 16.5 : 1 at normal operating temperature (80˚C) Test condition Standard 32 bar Compression pressure 18 bar Minimum Differential limit between cylinders Maximum 3 bar The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket).

  • Page 165: Cylinder Pressure Leakage Test

    02-8 Crank the engine for approx. 10 seconds by using the start motor. Record the test result and measure the compression pressure of other cylinders with same manner. If the measured value is out of specified value, perform the cylinder pressure leakage test.
  • Page 166 02-9 0000-00 (3) Piston protrusion check Position the piston at TDC and measure the piston protrusion from crank case mating surface. Specified value 0.475~0.745mm Measure it at both ends of crankshaft.
  • Page 167 02-10 2) Cylinder Head (1) Cylinder head mating surface check ▶ Specified value 131.9 to 132.1 mm Total height "A" 131.9 mm Minimum height after machining 0.1 / 150 Flatness Longitudinal direction Transverse direction 0.15 Parallel deviation of cylinder head below 0.1 mm Peak-to valley of surface Rmax 7 Rz 6.3...
  • Page 168 02-11 0000-00 4. GUIDELINES ON ENGINE SERVICE To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.
  • Page 169 02-12 ▶ Fuel and lubrication system Do not allow the fluid and engine oil to make contact with the body paintwork and hoses. If work on the fluid system such as fuel and oil, working area should be well ventilated and smoking should be prohibited.
  • Page 170 02-13 0000-00 1. BELT LAYOUT It is single drive type and uses FEAD (Front End Accessories Drive) design to make a compact layout. ▶ Components D20DTR Engine (Hydraulic Power Steering) Crankshaft pulley (DDU) Auto tensioner Tensioner pulley Vacuum pump A/C compressor pulley Alternator pulley Water pump pulley Idle pulley #1...

  • Page 171: Sectional Drawing

    02-14 1) Crankshaft Pulley (Isolation Damper) (1) Overview The strut type tensioner automatically adjusts the belt tension to provide the reliability and durability for the system. And, the belt tension is decreased to minimize the friction loss and improve the belt operating noise. (2) Sectional drawing Pulley Axial &...
  • Page 172 02-15 0000-00 (3) Features Rubber damper: Decrease crankshaft torsion Improve belt NHV: Reduce unbalance speed to crankshaft due to irregular combustion Minimize noise: Anti-vibration from crankshaft and belt Post bonded type rubber damper: Improve durability of rubber damper...

  • Page 173: Belt Tensioner

    02-16 2) Belt Tensioner (1) Overview The torque deviation from crankshaft affects the components in belt drive system and the belt movement. The auto tensioner system is to adjust this deviation automatically. In D20DTR engine, one of the mechanical tensioner, pivot damped tensioner is used to keep the damping force, system reliability and durability.

  • Page 174: Vacuum Pump

    02-17 0000-00 2. VACUUM PUMP Vacuum pump generates the vacuum pressure and supplies it to EGR cooler bypass solenoid. This pump is single vane type and displacement is 210 cc/rev. The lubrication oil is supplied through the hole in hollow shaft. ▶...
  • Page 175 02-18 1) Location 2) Operation The vacuum pump is engaged to the exhaust camshaft. Connection between vacuum pump and exhaust camshaft Oil supply and driving Vacuum pump Exhaust camshaft...

  • Page 176: Engine Mounting

    02-19 0000-00 3. ENGINE MOUNTING D20DTR engine uses 3-point mounting type that supports the engine and transmission simultaneously. ▶ Components Front mounting insulator (Right side) Front mounting insulator (Left side) Location Insulator Location Insulator Rear mounting insulator 2WD M/T 2WD A/T 4WD A/T P/N: 31900-21M20 P/N: 31900-21A20...
  • Page 177 02-20 1) Functions Appearance Type and function Front mounting insulator (Left side) Type: Rubber mounting Function: Supports the powertrain Front mounting insulator (Right side) Type: Rubber mounting Function: Supports the powertrain Rear mounting insulato Type: Rubber mounting Function: Supports the powertrain...

  • Page 178: Intake Manifold

    02-21 0000-00 4. INTAKE/EXHAUST MANIFOLD 1) Intake Manifold Intake manifold is installed on the cylinder head with 8 bolts. The variable swirl valve is introduced to improve the EGR gas mixture and turbulence in combustion chamber and to decrease the exhaust gas.

  • Page 179: Cylinder Head Cover

    02-22 5. CYLINDER HEAD COVER AND OIL SEPARATOR 1) Cylinder Head Cover The cylinder head cover is made by high strength plastic to reduce the weight. The multi twist type oil separator improves the oil consumption. ▶ Components Cylinder head cover Cylinder head cover Rear view...

  • Page 180: Oil Separator

    02-23 0000-00 2) Oil Separator (1) Overview Oil separator separates the particle in blow-by gas to minimize the engine oil consumption and reduces the inflow oil from intake system into the combustion chamber. The separated oil returns to oil pan through cylinder head. (2) Layout Oil separator Blow-by outlet hose...

  • Page 181: Cylinder Head

    02-24 6. CYLINDER HEAD Cylinder head contains cam position sensor, vacuum pump, intake manifold, exhaust manifold and valve assembly. Vacuum pump and the high pressure (HP) pump are driven by Camshaft and valves are install in vertical direction. This enables the compact layout in cylinder head assembly. ▶...
  • Page 182 02-25 0000-00 1) Cylinder Head (1) Overview The cylinder is made by gravity casting and the water jacket is integrated type. The cylinder oil passage is drilled and sealed by cap. The Camshaft bearing cap is also made by casting and installed on the cylinder head. (2) Features Location of Expansion Plugs Front...
  • Page 183 02-26 ▶ Closed flow type water jacket (improving cooling performance) 2) Camshaft (1) Overview Hollow type camshaft contains cam, octagon cam, HP pump gear and intake/exhaust gears. Camshaft operates the intake/exhaust valves, vacuum pump and HP pump, and transfers the engine oil to vacuum pump through the internal oil passage.
  • Page 184 02-27 0000-00 3) Valve Assembly (Installed in Cylinder Head) (1) Features Automatic valve clearance adjuster by hydraulic pressure (Maintenance Free) - Hydraulic lash Optimized adjustment of valve clearance reduces the valve noise. Roller type finger follower reduces the friction loss. Vertical installation.
  • Page 185 02-28 4) Cylinder Head Gasket (1) Features Sealing the cylinder gas pressure - Peak pressure: 190 bar Minimizing the distortion of engine structure (cylinder head, block): profile stopper, backland stopper Material: MLS (Multi Layer Steel), Gasket (3 layers) Thickness of gasket: 3 types (1.2 /1.3 /1.4 mm) Thickness marking Ex: 1.3t (2) Thickness of cylinder head gasket...

  • Page 186: Chain Drive

    02-29 0000-00 7. CHAIN AND GEAR DRIVE SYSTEM D20DTR engine uses single stage chain drive system. Timing chain drives the exhaust side and gear drive the intake side. Timing chain is single bush type. Upper chain drives HP pump connected to intake Camshaft by driving exhaust cam shift sprocke, and lower chain drives oil pump to lubricate the engine.
  • Page 187 02-30 (2) Layout Chain upper bush Exhaust camshaft sprocket Type: single bush Chains:112 EA Teeth: 42 EA Tensioner rail Clamping rail Installed between exhaust Camshaft sprocket and Installed between exhaust crankshaft sprocket Camshaft sprocket and crankshaft sprocket Hydraulic tensioner Contains tensioner housing plug, spring and check valve, Mechanical type tensioner and operated by hydraulic...

  • Page 188: Timing Chain

    02-31 0000-00 2) Timing Chain and Gear (1) Timing chain Simple layout: optimized timing, enhanced Single stage layout: minimized chain load The brass link on crankshaft is at symmetric position of that on camshaft. Chain upper bush - Single bush type (112 EA) Chain lower bush - Single bush type (60 EA) (2) Tensioner...

  • Page 189: Guide Rail

    02-32 (3) Mechanical Tensioner Assembly Operating principle - Use only spring tension Tensioner type - Compensation and impact absorbing Static and dynamic force - Spring (4) Guide rail The guide rail is used for optimizing the movement of chain drive system. And it also prevents the chain from contacting each other when the chain is loose, and reduces the chain wear.

  • Page 190: Timing Gear Case Cover

    02-33 0000-00 (5) Timing gear case cover Timing gear case cover (TGCC) Timing gear case cover Oil seal Screw plug...
  • Page 191 02-34 ▶ Features Major function: Protecting the chain drive system, minor function: Shielding the chain noise. Install crankshaft front seal and screw plug on the timing gear case cover. Location of chain tensioner screw plug A671 997 01 46 Crankshaft front seal Do not touch the inner lip of crankshaft front seal.

  • Page 192: Oil Pan

    02-35 0000-00 8. OIL PAN The oil pan in D20DTR engine improves the NVH. Especially, the oil draining is much easier than before. ▶ Components Oil pan sassembly...
  • Page 193 02-36 9. DUAL MASS FLYWHEEL (DMF) & DRIVE PLATE 1) Overview Flywheel is installed on crankshaft. When starting the engine, this functions as follows: Reducing the irregular speed of crankshaft due to unbalanced combustion -> Improving the power train NVH, Improving the driving performance Reducing the clutch noise by using ball bearing...
  • Page 194 02-37 0000-00 3) Operation Compensating the irregular operation of engine: The secondary flywheel operates almost evenly so does not cause gear noises The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more (less pulsation absorbing effect). Transaxle protection function: Reduces the torsional vibration to powertrain (transaxle) by reducing the irregularity of engine.

  • Page 195: Drive Plate

    02-38 4) Features Reduced vibration noise from the powertrain by blocking the torsional vibrations Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation Reduced shifting shocks Smooth acceleration and deceleration 5) Advantages Improved torque response by using 3-stage type spring: Strengthens the torque response in all ranges (low, medium, and high speed) by applying respective spring constant at each range.
  • Page 196 02-39 0000-00 10. PISTON/CRANKSHAFT/CYLINDER BLOCK The crankshaft and the cylinder block convert the compression pressure to the rotating energy. ▶ Components Cylinder block Piston Connecting rod Crankshaft...
  • Page 197 02-40 1) Piston (1) Overview Piston assembly contains piston, #1 ring, #2 ring, oil ring, piston pin and snap ring. The expansion energy from engine is transferred to the crankshaft through connecting rod to convert the linear movement to rotating energy.

  • Page 198: Assembling The Piston

    02-41 0000-00 (3) Functions Piston transfers the combustion energy from engine to connecting rod. Especially in the direct injection engine such as D20DTF, it provides the combustion space and largely effects to the engine performance and exhaust gas. ▶ Piston ring #1 ring (Top ring) : Prevents the high pressurized combustion gas from leaking into crank chamber, and prevents the engine oil getting into combustion chamber.
  • Page 199 02-42 Selecting piston oversize Top of piston Top of cylinder block Piston Cylinder bore Engine Part NO Marking NO. 671 030 06 17 671 037 07 01 671 037 08 01 D20DTF 671 037 09 01 671 037 10 01 671 037 11 01...

  • Page 200: Connecting Rod

    02-43 0000-00 2) Connecting Rod (1) Overview Connecting rod converts the reciprocating movement of piston to the rotating movement of crankshaft. The big end is connected to connecting rod bearing and the crank pin journal, and the small end is connected to the piston pin. (2) Components Piston pin bush Connecting rod...
  • Page 201 02-44 (3) Selection of crankshaft pin journal bearing The connecting rod bearing contains 3 sets of 3 grades in upper and lower sections. Three sets in the table below have nearly same oil clearance (0.015~0.063 mm) of bearing. Identification: Coloe mark on bearing side surface Upper bearing Lower bearing Connecting...
  • Page 202 02-45 0000-00 3) Crankshaft (1) Overview Crankshaft is installed on the cylinder block. (2) Arrangement Upper thrust bearing Crankshaft main bearing upper Crankshaft main bearing upper Crank pin journal Main journal Lower thrust bearing Crankshaft main bearing lower Crankshaft main bearing lower...
  • Page 203 02-46 (3) Selection of crankshaft main bearing Mating surface of crankshaft sprocket Bottom of cylinder block Selection of lower main bearing Selection of upper main bearing Selection of bearing according to pin Mark Color Thickness of main bearing (mm) punch & color Mark Color Thickness of main...

  • Page 204: Cylinder Block

    02-47 0000-00 4) Cylinder Block (1) Overview The major dimensions in D20DTR are similar to D20DTR engine. It has two mounting bosses for knock sensor and meets the requirements for EURO5 regulation. (2) Layout Cylindrical pin Right side Expansion plug Screw plug...
  • Page 205 02-48 Left side Expansion plug (3) Features For simple manufacturing, the crankcase blow-by gas passage and the oil return hole are made by casting on the cylinder block.
  • Page 206 02-49 0000-00 The bottom side of water jacket is desgined as sine wave to strengthen the structure of crankcase. The main flow of coolant starts from outlet port of water pump and goes along the longitudinal direction of engine. The coolant passage from cylinder head to inlet port of water pump is integrated in cylinder head.

  • Page 207: Specifications

    03-3 2210-01 1. SPECIFICATIONS Description Specification Fuel Diesel Fuel filter Type Fuel heater + priming pump + water separator integrated type Filter type Changeable filter element type Change interval every 40,000 km every 45,000 km Water separation every 20,000 km interval every 15,000 km Water accumulating capacity...

  • Page 208: Maintenance And Inspection

    03-4 2. MAINTENANCE AND INSPECTION 1) Maintenance Procedures for DI Engine Fuel System Always keep the workshop and lift clean (especially, from dust). Always keep the tools clean (from oil or foreign materials). Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
  • Page 209 03-5 2210-01 Follow the job procedures. If you find a defective component, replace it with new one. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened tospecified tightening torques during installation.

  • Page 210: Hydraulic System

    03-6 2) Diagnostic Test for Engine Fuel System (1) Overview If a DTC is displayed on the diagnostic device, check the low pressure- and high pressure fuel systems before removing the components. To run the system properly, the electric system must be intact but for the DI engine, the fuel pressure should be measured also when there is a malfunction even after the diagnostic test with a diagnostic device.
  • Page 211 03-7 2210-01 (3) Excessive backleak of injector ▶ Excessive injector backlea Occurs when the injector control valve is not sealed due to the entry of the foreign materials. ▶ Example: Entry of foreign materials Burned out and worn HP pump Mechanical damage inside the injector...
  • Page 212 03-8 (4) Loss of pump pressure/flow ▶ Loss of HP pump pressure/flow Faulty fuel supply line, or damaged or worn pump causes the lack of flow pressure and flow volume ▶ Example: Air in fuel supply line Excessive load on fuel supply line (←400 mBar) Burned out and mechanical worn pump High temperature of fuel supply (>...
  • Page 213 03-9 2210-01 3) DI Engine Fuel System Pressure Test (1) Test device (Tool kit) Device for high pressure Device for low pressure (2) Pre-check Check-tighten fuel supply line Check fuel level in fuel tank Check air in fuel supply line (bubble in fuel supply line or fuel) Check fuel supply line for leaks (low pressure and high pressure) Check that specified fuel is used Check fuel filter for contamination...
  • Page 214 03-10 (3) DI Engine Fuel System Check Procedure If several DTCs are output simultaneously, check the electric wiring for open or short circuit. Check the low pressure fuel system and fuel filter and confirm that there are no abnormalities. Carry out the high pressure fuel system check.
  • Page 215 03-11 2210-01 (4) Fuel System Check Procedure...
  • Page 216 03-12 (5) High Pressure System Pressure Test ▶ Fuel rail pressure test Disconnect the pressure sensor connector (A) and IMV connector (B) from the fuel rail. Connect the pressure tester to the fuel rail pressure sensor connector. Crank the engine 2 times for 5 seconds. Read the highest pressure value displayed on the tester display.
  • Page 217 03-13 2210-01 ▶ How To Use Pressure Tester Press the "TEST" button on the tester to check if the message "TEST?" is displayed. If the button is pressed again at 4 seconds after starting engine cranking, the highest pressure is displayed on the tester. The fuel rail pressure value can be checked using a diagnostic device.
  • Page 218 03-14 (6) Low Pressure System Pressure Test ▶ Inspection procedure All wirings/connectors and fuel lines should be connected and the engine should work properly. Prepare a special tool for low pressure test and clean it thoroughly to prevent foreign materials from entering. Disconnect the key connector for fuel filter connection, and connect both connectors to the fuel filter and hose.
  • Page 219 03-15 2210-01 ▶ Static test for backleak of injector Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool). Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 220 03-16 ▶ Dynamic test for backleak of injector Warm up the engine so that the engine coolant temperature be over 80℃ and star the engine again. Disconnect the injector return hose and cover the openings with caps shaped screw (included in the special tool). Connect the hose of the container for measuring backleak to the return nipple of the injector.
  • Page 221 03-17 2210-01 ▶ HP pump pressure test Prepare a special tool for high pressure test and clean it thoroughly to prevent foreign materials from entering. Disconnect the high pressure fuel supply pipe on the HP pump and install the close rail in the tool kit.

  • Page 222: Cautions For Di Engine

    03-18 3. CAUTIONS FOR DI ENGINE 1) Cautions for DI Engine This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine, warning lights, symptoms when engine malfunctioning, causes and actions. DI Engine Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high power and reduces less emission.
  • Page 223 03-19 2210-01 2) Cleanness (1) Cleanness of DI engine fuel system ▶ Cleanness of DI engine fuel system and service procedures The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1,800 bar. Some components in injector and HP pump are machined at the micrometer 100 μm of preciseness.

  • Page 224: Water In Fuel

    03-20 (2) Di engine and its expected problems and remedies can be caused by water in fuel ▶ System supplement against paraffin separation In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally.

  • Page 225: Fuel Flow Diagram

    03-21 2210-01 1. OVERVIEW The components in fuel system supply the fuel and generate the high pressure to inject the fuel to each injector. They are controlled by the engine ECU. The common rail fuel injection system consists of fuel tank, fuel line, low pressure line which supplies low pressure fuel to the low pressure pump (including high pressure pump), common rail which distributes and accumulates the high pressurized fuel from the fuel pump, high pressure line which connected to the injector, and the engine control unit (ECU) which calculates the...
  • Page 226 03-22 2. SYSTEM LAYOUT AND OPERATION 1) Layout For sensor and actuator control logic, refer to Chapter "Engine Control". Engine ECU (D20DTR) Injector (C3I) Pre-injection, main injection, after-injection by signals from Engine control by various signals HFM sensor Measuring intake air mass and temperature Crankshaft position sensor Fuel tank...
  • Page 227 03-23 2210-01 High pressure pump Accelerator pedal position sensor Plunger type HP pump (1,800 bar) Vane type LP pump (6 bar) Generating high pressurized fuel and supplying it according to Detecting driver's intention for engine rpm, required volume, speed up/down required pressure Fuel filter assembly Supplying clean fuel/fuel...
  • Page 228 03-24 2) Fuel System Flow Diagram The fuel from the fuel tank is supplied to the fuel heater of fuel filter/priming pump and then low pressure generated by the low pressure pump (built into HP pump) is transmitted to the HP pump. The fuel pressure at the HP pump is controlled by the IMV valve, and the maximum allowed pressure is 1,800 bar.
  • Page 229 03-25 2210-01 3) Input/Output devices Refer to Chapter "Engine Control".
  • Page 230 03-26 The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and controls the overall operation of the vehicle. The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio control based on these signals. The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position) sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal depressed (driver's will) by receiving the electrical signals from the accelerator...

  • Page 231: Specifications

    04-3 1719-00 1. SPECIFICATIONS Unit Description Specification Filter type Dry, filter element Initial resistance Max. 300 mmAq Air cleaner element Service interval EU: Change every 20,000 km GEN: Change every 15,000 km Weight 2.36kg Air cleaner assembly -30 ~ 100℃ Operating temperature Radiation over 13,000 Kcal...
  • Page 232 04-4 2. INSPECTION 1) Troubleshooting ▶ When Abnormal Noises are Heard from the Engine Room For the vehicle equipped with DI engine, if a learning noise occurs in each range or other noises occur, the major cause of it is a faulty turbocharger assembly. But an interference issue, poor tightness or loose in the intake and exhaust system also can cause those noises.

  • Page 233: Troubleshooting Sequence

    04-5 1719-00 3) Troubleshooting Sequence The basic checks for intake system are as follows: ▶ Basic Checks for Intake System Make sure to replace or clean the air cleaner element periodically. Otherwise, engine will be derated or work abnormally because of low intake air volume.
  • Page 234 04-6 1. OVERVIEW The intake system for D20DTR engine is equipped with a throttle body which includes a flap. This flap is controlled by an electrical signal to cut off the intake air entering to the engine when the ignition switch is turned off. Because of this, the shape of the intake manifold has been changed and improved HFM sensor is newly adopted to control the intake air volume more precisely.
  • Page 235 04-7 1719-00 1719-02 Swirl control valve Operating variably in accordance with the engine load and rpm.* For more information, refer to Chapter "Engine Control". 1719-01 Intake manifold Passage for variable swirl valve and for intake 1719-16 Electric throttle body * For more information, refer to Chapter "Engine Control".
  • Page 236 04-8 3. INPUT/OUTPUT OF INTAKE SYSTEM For more information, refer to Chapter " Engine Control".

  • Page 237: Operating Process

    04-9 1719-00 4. OPERATING PROCESS ▶ Work Flow...
  • Page 238 04-10 1) Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Squish: Squish is the air flows due to the piston head.
  • Page 239 04-11 1719-00 Engine Swirl valve Amount of Load Remarks speed swirl Low speed, below Increased EGR ratio, better air-fuel Closed Heavy Low load 3,000 rpm mixture (reduce exhaust gas) High speed, over 3,000 Increase charge efficiency, higher Open Light High load engine power The variable swirl valve actuator operates when turning the ignition switch ON/OFF...

  • Page 240: Troubleshooting

    05-3 1729-01 1. TROUBLESHOOTING 1) Work Flow...
  • Page 241 05-4 2. CAUTIONS Do not park the vehicle on flammable materials, such as grass, leaves and carpet. Do not touch the catalyst or the exhaust gas ignition system when the engine is running. If a misfire occurs in the combustion chamber or the emission of pollutant exceeds the specified level, the catalyst can be damaged.
  • Page 242 05-5 1729-01 1. OVERVIEW This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants and noise during that arise during combustion. 2. LAYOUT Exhaust manifold assembly Exhaust front pipe assembly CDPF assembly For more information, refer to Chapter "Engine Control".
  • Page 243 05-6 3. OPERATING PROCESS 1) Exhaust Gas Flow 2) Input & Output Devices...

  • Page 244: Specification

    06-3 1914-01 1. SPECIFICATION Unit Description Specification Max. expansion coefficient Max. turbine speed 226,000rpm Turbocharger 790 ℃ Max. temperature of turbine housing Weight 6.5kg E-VGT actuator Operation duty cycle 250Hz...
  • Page 245 06-4 2. INSPECTION 1) Cautions During Driving The following lists cautions to take during test drive and on the turbocharger vehicle, which must be considered during the operation. It's important not to drastically increase the engine rpm starting the engine. It could make rotation at excessive speed even before the journal bearing is lubricated and when the turbocharger rotates in poor oil supply condition, it could cause damage of bearing seizure within few seconds.
  • Page 246 06-5 1914-01 2) Inspection of Turbocharger When problem occurs with the turbocharger, it could cause engine power decline, excessive discharge of exhaust gas, outbreak of abnormal noise and excessive consumption of oil. On-board Inspection Check the bolts and nuts foe looseness or missing Check the intake and exhaust manifold for looseness or damage Check the oil supply pipe and drain pipe for damages Check the housing for crack and deterioration...
  • Page 247 06-6 3) Inspection of Turbine Thoroughly check the followings. Must absolutely not operate the turbocharger with the compressor outlet and inlet opened as it could damage the turbocharger or be hazardous during inspection. Interference: In case where is trace of interference or smallest damage on the compressor wheel means, most of times, that abrasion has occurred on the journal bearing.
  • Page 248 06-7 1914-01 4) Possible Causes of Defect The following tries to understand the defects that can occur with vehicle installed with the turbocharger and to manage the reasons of such defects. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where adhesive of gaskets has been contaminated into the oil line.
  • Page 249 06-8 Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil line.
  • Page 250 06-9 1914-01 Turbine Side: Inflow of foreign materials from engine Compressor Side: such as air filter, muffler and nut...
  • Page 251 06-10 Defects caused by reasons other than that of the turbocharger.
  • Page 252 06-11 1914-01 3. TROUBLESHOOTING The followings are cautions to take in handling defects of turbocharger, which must be fully aware 1) Cautions After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting condition of vacuum port and modulator, which is connected to the actuator.
  • Page 253 06-12 2) Work Flow for Troubleshooting...
  • Page 254 06-13 1914-01...
  • Page 255 06-14...
  • Page 256 06-15 1914-01...
  • Page 257 06-16...
  • Page 258 06-17 1914-01 1. SYSTEM DESCRIPTION OF E-VGT (Electric-Variable Geometry Turbine) The E-VGT turbocharger has one shaft where at each ends are installed with two turbines having different angles to connect one end of housing to the intake manifold and the other end to the exhaust manifold.
  • Page 259 06-18 1) Features (1) Performance (for EURO V) Enhanced emmission control: By temperature control with CDPF system Target temperature and airflow control (2) E-VGT Actuator (Electric-Actuator) Optimizes the exhaust gas flow rate by controlling the vanes inside the turbine housing with the EActuator.
  • Page 260 06-19 1914-01 2. COMPONENTS * For details about control logic, refer to Chapter “Engine Control”. E-VGT turbocharger Engine ECU (D20DTR) Accelerator pedal position sensor Atmospheric pressure, RPM signal Transfers driver's will to Improves engine power E-VGT duty control accelerate to ECU T-MAP sensor HFM sensor Coolant temperature sensor...

  • Page 261: Input/Output Devices

    06-20 3. INPUT/OUTPUT DEVICES...

  • Page 262: Operating Principles

    06-21 1914-01 4. OPERATING PRINCIPLES The E-VGT is designed to get more improved engine power in all ranges by controlling the turbine as follows: 1) How it Works at Low Speed Normal turbocharger cannot get the turbo effect because the amount of exhaust gas is not enough and the flow speed is slow in a low speed zone, but VGT allows the flow passage of exhaust to narrow, resulting in increasing the flow speed of exhaust gas and running the turbine quickly and powerfully.
  • Page 263 06-22 2) How it Works at High Speed In a high speed zone, the amount of exhaust gas increases and it is accompanied with a great force. Therefore, if the inner diameter of venturi is more widened, the turbine in the turbocharger by the releasing force of abundant exhaust gas can deliver a more increased energy to the compressor.

  • Page 264: Specification

    07-3 1543-00 1. SPECIFICATION Unit Specification Oil pump Lubrication system Gear pump, forced circulation Type Inscribed gear Capacity 63 L at 4,000 rpm 5.8 bar ± 0.3 bar Relief pressure Oil filter Type Full flow/Paper element Engine oil Specified oil SAE 5W30 (approved by MB SHEET 229.51) Capacity (L) Min.: 4.5 L...

  • Page 265: Maintenance

    Recheck the oil level after 5 minutes. Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary. Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.

  • Page 266: System Description

    07-5 1543-00 1. SYSTEM DESCRIPTION 1) Overview The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove heat from the friction part. As the engine runs, frictional heat is generated on each lubrication section. If this condition persists, the bearing can be burned and stuck. In other words, it creates an oil film on each sliding surface to convert solid friction to liquid friction in order to minimize wear and prevent temperature increasing on the friction part.
  • Page 267 07-6 2. FUNCTIONS OF LUBRICATION 1) Lubrication It creates a viscous barrier between moving parts that reduces friction, which means less heat and longer life for those parts. As a lubricant, oil must maintain a protective film to prevent metal- to-metal contact.
  • Page 268 08-3 1520-00 1. SPECIFICATION Description Specification Cooling system Type Water cooling, forced circulation Coolant Capacity approx. 11.5 L 589W x 538H x 27T (over 3,170 cm²) Core size Radiator Flow type Cross flow Type Long life coolant Antifreeze Mixing ratio 50 : 50 (water:antifreeze) Motor type...
  • Page 269 08-4 2. INSPECTION Possible Cause Action Coolant level - Leak from the radiator - Change the radiator - Leak from the coolant auxiliary tank - Change the coolant auxiliary tank too low - Leak from the heater core - Change the heater - Leak from the coolant hose - Reconnect the hose or replace connections...

  • Page 270: Coolant Level Check

    08-5 1520-00 1) Coolant Level Check Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is cooled down. The coolant level should be between the MAX and MIN mark on the coolant reservoir. Check the coolant level.
  • Page 271 08-6 2) Leak Test Release the pressure in the system by loosening the pressure cap of the coolant reservoir slightly. Then, remove the pressure cap completely. Never open the cap until the coolant temperature becomes under 90℃ to prevent any burn. Add the coolant so that the coolant level is between MAX and MIN mark on the coolant auxiliary tank.
  • Page 272 08-7 1520-00 3. CAUTIONS If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity can be decreased resulting in poor circulation in the cooling system which leads to overheated engine. Use of non-recommended coolant could cause damage to the cooling system and overheating of the engine.
  • Page 273 08-8 1. SYSTEM DESCRIPTION 1) Overview Coolant reservoir Water pump Sealing Oil filter module Water pump Impeller vane The water pump is driven by the engine drive belt and supplies the coolant to each area of the engine. Thermostat When the engine coolant reaches 90℃, the thermostat starts to open (fully open at 100℃) and lets the coolant...
  • Page 274 08-9 1520-00 Coolant temperature sensor Measures the coolant temperature and sends the result to the engine ECU. Electric fan Circulates the fresh air forcibly to exchange heat with the radiator core fin. Radiator Releases heat through fins and cools down the hot coolant as the coolant passes through the tube of the radiator core.
  • Page 275 09-3 1451-01 1. SPECIFICATION Unit Description Specification Crankshaft pulley : Alternator pulley 1 : 2.94 Normal output (idling/2200 rpm) 70/140A Alternator Regulator voltage 14.6 V Length 12.5mm Brush Wear limit Type Battery Capacity 90 AH...

  • Page 276: Alternator Output Test

    09-4 2. INSPECTION 1) Alternator Output Test Item How to check DTC set value / Action Disconnect the cable connected to the Pass: If the measured current is B terminal on the alternator. Connect 45 A or higher. one end of the ammeter to the B Fail: If the measured current is terminal and the other end to the cable less than 45 A.
  • Page 277 09-5 1451-01 2) Troubleshooting for Alternator Item Cause Action Overcharged Defective alternator voltage regulator Replace the alternator battery Defective voltage detection wiring Replace the alternator Defective voltage detection wiring Repair or replace Discharged battery Loose alternator drive belt Adjust the belt tension or replace Poor connection of related circuit or Retighten the loose connection or open circuit...

  • Page 278: Checking Battery

    09-6 3) Checking Battery...
  • Page 279 09-7 1451-01 (1) Checking ▶ Using battery tester PASS (11.0 V or more): Explain to the customer that the battery is reusable. Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the customer.
  • Page 280 09-8 (3) Starting with jumper cable If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to start the engine. ▶ Connecting order The positive (+) terminal of the discharged battery The positive (+) terminal of the booster battery The negative (-) terminal of the booster battery Connect one end of the other jumper cable to the body of the discharged vehicle, such as the engine block or a front towing hook.
  • Page 281 09-9 1451-01 (4) Maintenance If the charge warning lamp ( ) on the instrument cluster comes on while driving, there is a malfunction in the charge system including the battery. Therefore, carrying out the system check is needed. Make sure that the battery cables are firmly connected. If the terminals are corroded, clean them with a wire brush or sandpapers.
  • Page 282 09-10 1. SYSTEM DESCRIPTION 1) Overview The charge system is designed to supply electrical energy to the vehicle while driving, and supplies a constant direct current voltage by converting mechanical rotational movement to electrical energy. The voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and adjusts the system voltage according to the electric load and ambient temperature change.

  • Page 283: Operating Process

    09-11 1451-01 2. OPERATING PROCESS 1) Charging Flow...

  • Page 284: Output Characteristics

    09-12 2) Charging The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge, slip ring and brush. ▶ Charging time according to vehicle conditions and environment Specification: Charging a fully depleted high- capacity battery takes twice or more as long as charging a fully depleted battery for small vehicles.

  • Page 285: Circuit Diagram

    09-13 1451-01 3. CIRCUIT DIAGRAM...

  • Page 286: Specifications

    10-3 1413-00 1. SPECIFICATIONS Description Specification Glow plug Rated voltage 4.4 V 1100 °C Max. temperature 1080 °C ~ 1000 °C Operating temperature 23 °C: 0.39 ~ 0.52Ω Resistance Glow plug control unit Operating voltage 6 ~ 16 V -40°C ~ 110°C Operating temperature Dark current Max.
  • Page 287 10-4 1. OVERVIEW The pre-heating system for D20DTR engine has the glow plug to the cylinder head (combustion chamber), and improves the cold start performance and reduces the emission level. The pre-heating resistor (air heater) is used to heat the intake air. This enables the diesel fuel to be ignited in low temperature condition.

  • Page 288: System Operation

    10-5 1413-00 2. SYSTEM OPERATION 1) Input/Output Diagram of Glow Plug Control Unit 2) System Diagram...
  • Page 289 10-6 3) Circuit Diagram...
  • Page 290 10-7 1413-00 4) Operation Glow plug is installed in the cylinder head. It enhances the cold starting performance and reduces the exhaust gas during cold starting. ECU receives the data (engine rpm, coolant temperature, vehicle speed) through CAN lines. Based on the data, GCU controls the pre-glow, cranking and post-glow. It also checks the glow plugs, and sends the result to ECU.
  • Page 291 10-8 (2) Pre-heating time control based on battery voltage GCU monitors the battery voltage. If it is low, GCU extends the pre-heating time. GCU monitors the energy to glow plugs (the amount of pre-heating energy is always same). GCU monitors the battery voltage. If it is low, GCU extends the pre-heating time to get enough energy.

  • Page 292: Power Control

    10-9 1413-00 (3) Power control GCU estimates the temperature of glow plug for pre-heating. To avoid the power loss and overheat, GCU supplies the lowest power for getting target temperature when turning ON the ignition from OFF. (4) Operation GCU PWM control Frequency: 20~33Hz PWM control duty ratio - 1st step: 100%...
  • Page 293 10-10 (5) Pre-glow and Post-glow This shows the pre-glow and post-glow step as a chart.

  • Page 294: Specification

    11-3 1461-01 1. SPECIFICATION Description Specification Capacity 12V 2.3kW Engagement Meshed type Rotating direction Clockwise Pinion gear manufacturing Cooled forging Solenoid operating voltage Max. 8 V Weight 2.5 kg Bracket manufacturing Aluminum die casting...

  • Page 295: Troubleshooting

    11-4 2. TROUBLESHOOTING Problem Possible Cause Action Low battery voltage Charge or replace Loose, corroded or damaged battery cable Repair or replace Engine will not crank Faulty starter or open circuit Repair or replace Faulty ignition switch or blown fuse Poor engine ground Repair Low battery voltage...

  • Page 296: System Description

    11-5 1461-01 1. SYSTEM DESCRIPTION The starter (start motor) starts the engine with rotational power by converting the electric energy to the mechanical energy. When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the pinion gear clutch overruns to protect the pinion gear.
  • Page 297 11-6 2) Circuit Diagram...
  • Page 298 12-3 8510-23 1. SYSTEM DESCRIPTION 1) Overview AUTO CRUISE The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 299 12-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Improper use of the cruise control could be dangerous.
  • Page 300 12-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 301 12-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...

  • Page 302: Setting A Desired Speed

    12-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 303 12-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the leve (2) When the cruise control system is not running To increase the speed with the cruise control system while the system is not running, follow the...
  • Page 304 12-9 8511-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 305 12-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention.
  • Page 306 12-11 8511-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 307 12-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.

  • Page 308: Specification

    13-3 1793-00 1. SPECIFICATION Item Specification E-EGR valve Motor EGR response time 50 ms Driven by DC motor Valve EGR gas flow rate 120 Kg/h Position sensor Sensing type Hole sensor 5V ± 10% Supplied voltage Maximum signal 5% ~ 95% range ＜15mA Maximum power...
  • Page 309 13-4 1. SYSTEM DESCRIPTION 1) Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. To meet Euro-V regulation, the capacity and response rate of E-EGR valve in D20DTR engine have been greatly improved.
  • Page 310 13-5 1793-00 2) Location and Components HFM sensor E-EGR cooler and bypass valve EGR bypass EGR cooler Used as a main map value to control the EGR. See the section "Engine control" for E-EGR The coolant temperature, engine rpm, engine valve control logic.

  • Page 311: Operating Process

    13-6 2. OPERATING PROCESS 1) Schematic Diagram...

  • Page 312: Control Logic

    13-7 1793-00 2) Input/Output Devices 3) Control Logic The EGR system controls the EGR amount based on the map values shown below: ※ Main map value: Intake air volume ※ Auxiliary map value: Compensation by the coolant temperature Compensation by the atmospheric pressure: Altitude compensation Compensation by the boost pressure deviation (the difference between the requested value and the measured value of boost pressure) Compensation by the engine load: During sudden acceleration...
  • Page 313 14-3 2412-02 1. CAUTIONS ▶ Standard pattern of soot accumulation (1) Abnormal Soot Accumulation (2) Normal Soot Combustion ▶ Cautions to protect the catalyst filter Use the designated fuel only. Observe the recommended service intervals of engine oil. Check the engine oil level frequently and add if necessary. Do not idle the vehicle unnecessarily.
  • Page 314 14-4 (3) Warning Lamp Related to CDPF ▶ CDPF regeneration process (warning lamp NOT illuminated) The CDPF system enters the regeneration mode when the driving distance becomes approx. 600 to 1,200 km (may differ by the driving condition and driving style). Then, the engine ECU performs the CDPF regeneration operation.
  • Page 315 14-5 2412-02 1. OVERVIEW The DOC (Diesel Oxidation Catalyst) generates CO2 and H2O which are harmless through the oxidation process of CO and HC. And the DPF (Diesel Particulate Filter) collects PM (Particle Matter) and is regenerated to reduce the quantity of particulates, HC and CO. But there is a limitation in reducing the emission of exhaust gas for each system, so the CDPF which combines these two system is applied.
  • Page 316 14-6 2. COMPONENTS CDPF Front EGT Sensor Electric Throttle Body (DOC+DPF) Measures the combustion Regulates the air intake temperature. rate. Rear EGT Sensor Engine ECU (D20DTR) Differential Pressure Sensor Calculates the amount of PM collected by reading the pressure Measures the CDPF difference between pre-CDPF and temperature.
  • Page 317 14-7 2412-02 3. INPUT/OUTPUT DEVICES Front temperature sensor: This sensor is installed at the inlet of DOC and detects whether the DOC can burn (oxidize) the post-injected fuel or not. Rear temperature sensor: This sensor is installed at the inlet of DPF and monitors that the temperature of the exhaust gas is kept at 600℃.
  • Page 318 14-8 4. POST-INJECTION AND AIR MASS CONTROL A DPS (Differential Pressure Sensor) measures the pressure difference between before and after the CDPF and detects whether the soot is collected in the CDPF or not. If PM is collected in the CDPF (In this case the pressure difference between before and after the CDPF exceeds the specified value.
  • Page 319 14-9 2412-02 Front temperature sensor HFM sensor Rear temperature sensor Intake air mass Engine ECU (D20DTR) Measures the temperature of exhaust gas. Measure the outlet temperature of DOC. This sensor is located at the rear side of exhaust manifold and This sensor is located at monitors the temperature of the rear side of DOC and...
  • Page 320 14-10 5. OPERATING PROCESS [Configuration and principle of operation] Collecting PM Oxidation (DOC) → Regeneration The exhaust gas passed through the When the exhaust gas enters The engine ECU detects the exhaust manifold into the CDPF assembly, its amount of PM collected by enters into the CDPF CO, HC and PM are reduced the information from the...
  • Page 321 14-11 2412-02 1) Oxidation of DOC The DOC oxidizes HC and CO of the exhaust gas in the two-way catalytic converter at 180℃ or more, and performs best at the temperature between 400 and 500℃. The front EGT sensor detects whether the DOC can burn (oxidize) the post-injected fuel or not, and sends the signal to the ECU to maintain the DOC operating temperature between 300 and 500℃.
  • Page 322 14-12 2) Collecting PM of DPF There is a filter installed in the DPF and the PM filtered by this filter is burned (regeneration) when the temperature of exhaust gas is increased due to post-injection. The filter has a honeycomb- like structure to capture the particulate matter and the inlet and outlet of each channel are closed alternatively.
  • Page 323 14-13 2412-02 3) PM Regeneration of DPF The differential pressure sensor installed in the DPF measures the pressure values of inlet and outlet of CDPF. And the amount of the PM collected in the filter is calculated based on the exhaust temperature, intake air mass flow, booster pressure, etc.
  • Page 324 14-14 4) Fuel Injection During CDPF Regeneration The injection method in D20DTR engine has three steps; Pilot injection, Main injection, Post injection ▶ Post injection The post injection is the injection process after main injection and consists of ‘After injection”, “Post 1 injection”...

  • Page 325: Circuit Diagram

    14-15 2412-02 6. CIRCUIT DIAGRAM...
  • Page 326 14-16 7. CAUTIONS 1) Designated Engine Oil for CDPF (Low Ash Oil) Need to use the designated engine oil for CDPF The smoke from the vehicle may generate the particle material in the ambient air. CDPF is the device to reduce the smoke by collecting and recycling it. To ensure the performance of CDPF, the designated engine oil should be used.

  • Page 327: White Smoke

    14-17 2412-02 2) Do Not Use the Fuel Containing High Sulfur Producing white smoke during recycling The sulfur in exhaust gas is changed to sulfate gas during exhaust process. This sulfate gas is shown as white smoke. Producing odor during recycling The sulfur after oxidation may produce the odor.
  • Page 328 15-3 0000-00 1. ENGINE DATA LIST Data Unit Value ℃ 130℃~-40℃ Coolant temperature -40 to 130℃ (varies by ambient air ℃ Intake air temperature temperature or engine mode) 700 ± 50 (P/N), 600 ± (D) Idle speed Engine load 18~25% Mass air flow kg/h 16 to 25 kg/h...
  • Page 329 15-4 1. MAJOR COMPONENTS Oxygen Sensor Injector (C3I) E-VGT Actuator Glow Plug (Air mass/Temperature)
  • Page 330 15-5 0000-00 EGR Valve EGR Bypass Valve Water Sensor Variable Swirl Valve Actuator Electric Throttle Body (Glow Plug Control Unit)
  • Page 331 15-6 Front EGT Sensor Fuel Rail Pressure Sensor Rear EGT Sensor Differential Pressure Sensor Camshaft Position Sensor...
  • Page 332 15-7 0000-00 Fuel Temperature Coolant Temperature Sensor Sensor T-MAP Sensor Knock Sensor (2) D20DTR ECU...
  • Page 333 15-8 2. SYSTEM OPERATION 1) Input/Output of ECU (1) ECU Block diagram...
  • Page 334 15-9 0000-00 (2) Components for ECU Input - Auto cruise switch - Refrigerant pressure sensor - Blower switch signal - Brake pedal signal Crankshaft Accelerator pedal Throttle Knock sensor position sensor position sensor sensor EGT sensor HFM sensor T-MAP sensor Oxygen sensor Differential E-EGR valve...
  • Page 335 15-10 (3) Components for ECU Output E-EGR valve Injector Throttle position compressor sensor E-EGR cooler Variable swirl E-VGT actuator IMV valve bypass valve valve PTC heater Cooling fan - ABS & ESP unit - TCU - GCU - Self diagnosis - Indicator/Warning Lamp, Meter Cluster...

  • Page 336: Control Function

    15-11 0000-00 2) ECU Control (1) Function a. ECU Function ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels and analyzes to control respective actuators. ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft angle based on input data and stored specific map to control the engine power and emission gas.

  • Page 337: Fuel Injection Control

    15-12 (2) Fuel injection control a. Multi injection Fuel injection process consists of 3 steps: Main Injection, Pilot Injection, Post Injection Injection Function Main Produces engine power Pilot 1 Reduces PM by injecting before After PM control main injection. Reduces NOx and noise by Reduces PM by enabling fuel Pilot 2 Post 1...

  • Page 338: Pilot Injection

    15-13 0000-00 b. Pilot Injection Injection before main injection. Consists of 1st and 2nd pilot injection, and Pre-injection Inject a small amount of fuel before main injection to make the combustion smooth. Also, called as preliminary injection or ignition injection. This helps to reduce Nox, engine noise and vibration, and to stabilize the idling.
  • Page 339 15-14 c. Main Injection The power of the vehicle is determined by the main fuel injection volume. Main injection calculates the fuel volume based on pilot injection. The calculation uses the value for accelerator pedal position, engine rpm, coolant temperature, intake air temperature, boost pressure, boost temperature and atmospheric pressure etc.

  • Page 340: Fuel Pressure Control

    15-15 0000-00 (3) Fuel Pressure Control ▶ Fuel Pressure Fuel pressure is controlled by IMV opening according to the calculated value by ECU. ▶ Pressure in the fuel rail is determined according to engine speed and load on the engine. When engine speed and load are high The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize combustion.
  • Page 341 15-16 (4) Injection Timing Control ▶ Injection timing is determined by the conditions below. Coolant temperature Hot engine - Retarded to reduce Nox Cold engine - Advanced to optimize the combustion Atmospheric pressure Advanced according to the altitude Warming up Advanced during warming up in cold engine Rail pressure Retarded to prevent knocking when the rail pressure is high...

  • Page 342: Fuel Control

    15-17 0000-00 A fourth correction is made according to the pressure error. This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the pressure demand. A fifth correction is made according to the rate of EGR. This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation.

  • Page 343: Flow Limitation

    15-18 C. Idle Speed Controller The idle speed controller consists of 2 principal modules: The first module determines the required idle speed according to: * The operating conditions of the engine (coolant temperature, gear engaged) * Any activation of the electrical consumers (power steering, air conditioning, others) * The battery voltage * The presence of any faults liable to interface with the rail pressure control or the injection control.
  • Page 344 15-19 0000-00 F. Pilot Flow Control The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined according to the engine speed and the total flow. A first correction is made according to the air and water temperature. This correction allows the pilot flow to be adapted to the operating temperature of the engine.
  • Page 345 15-20 (6) MDP Learning Control MDP (Minimum Drive Pulse ) refers to the minimum power supply pulse for injection which the injector can perform. It is possible to control the fuel volume for each injector accurately through correct learning for the MDP value. The basic process of MDP learning is that the pulse slightly higher than MDP is supplied and then (b) the vibration generated from the cylinder is...
  • Page 346 15-21 0000-00 C. Learning Conditions Idle MDP learning Drive MDP learning over 60℃ over 60℃ Coolant temperature Vehicle speed Idling over 50km/h (over 5 seconds) 2,000 to 2,500 rpm Engine rpm 0 < Fuel temperature < 80℃ Fuel temperature 2 times for each cylinder (every 5 2 times for each cylinder Learning seconds)
  • Page 347 15-22 (7) Knocking Control A. Resetting the pilot injection The knocking control is used to reset the pilot injection flow in closed loop for each injector. This method allows the correction of any injector deviations over a period of time. The principle of use of the knocking control is based on the detection of the combustion noises.
  • Page 348 15-23 0000-00 This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse value replaces the value obtained during the previous resetting. The first MDP value is provided by the C3I. Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
  • Page 349 15-24 (8) Swirl control A. Overview ▶ Variable swirl valve The strong swirl caused by intake air is important element for anti-locking function in diesel engine. The swirl control valve partially closes the intake port to generate the swirl according to the engine conditions. When the engine load is in low or medium range, the swirl could not be generated because the air flow is slow.
  • Page 350 15-25 0000-00 B. Input/Output for variable swirl valve...
  • Page 351 15-26 C. Types of swirl Swirl: One cylinder has two intake air ports, one is set horizontally and the other one is set vertically. Swirl is the horizontal air flows in cylinder due to the horizontal intake air ports. Tumble: Tumble is the vertical air flows in cylinder due to the vertical intake air port Squish is the air flow at end of compression process according to the design of piston head.
  • Page 352 15-27 0000-00 Swirl Amount of Load Engine speed Remarks valve swirl Low speed, Increased EGR ratio, better air-fuel below 3,000 rpm Closed Heavy Low load mixture (reduce exhaust gas)) High speed, Increase charge efficiency, higher over 3,000 rpm Open Light High load engine power The variable swirl valve actuator operates when...
  • Page 353 15-28 (9) EGR control A. Overview The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating some of the exhaust gas to the intake system. To meet Euro-V regulation, the capacity and response rate of E-EGR valve in D20DTR engine have been greatly improved.
  • Page 354 15-29 0000-00 C. Input/Output of E-EGR system...
  • Page 355 15-30 D. Bypass control for EGR cooler ▶ Cooler temperature When the coolant temperature is below 70℃, the exhaust gas is bypassed the EGR cooler. ▶ Exhaust gas temperature When the exhaust gas temperature is below 300℃, the exhaust gas is bypassed the EGR cooler. Otherwise, PM could be increased due to too low exhaust gas temperature.
  • Page 356 15-31 0000-00 F. Features As EGR ratio goes up, smoke volume will be As EGR temperature goes up, the higher. But, this lowers the combustion concentration of NOx will be higher. Thus, it is chamber temperature and accordingly the necessary to cool down the exhaust gas. concentration of NOx is decreased.
  • Page 357 15-32 (10) E-VGT control A. Overview E-VGT (Electric-Variable Geometry Turbine) turbocharger system in D20DTF engine uses the venturi effect that controls the flow rate of exhaust gas by adjusting the passage in turbine housing. The newly adopted DC motor actuator (E-actuator) controls the E-VGT system more precisely and faster. To get the high operating power from turbine, the ECU reduces the exhaust gas passage In low speed range and increases it in high speed range.
  • Page 358 15-33 0000-00 C. Input/Output for E-VGT system...
  • Page 359 15-34 D. E-VGT system control Turbocharger system operates the E-VGT actuator according to the signals for engine epm, accelerator pedal position, atmospheric pressure, T-MAP, coolant temperature and intake air temperature. Turbocharger actuator is performed PWM control by ECU. In general, the boost pressure feedbacks the turbocharger operation and the boost temperature is used for calculating the precise density.
  • Page 360 15-35 0000-00 (11) Wide band oxygen sensor control A. Overview For diesel engine, combustion is not performed at the optimum (theoretically correct) air-fuel ratio and the oxygen concentration is thin in most cases. So the wide-band oxygen sensor is used for this kind of engine, and this sensor is a little different from the one that used for gasoline engine.
  • Page 361 15-36 C. Input/Output for oxygen sensor...
  • Page 362 15-37 0000-00 D. Oxygen sensor control The wide band oxygen sensor uses ZnO2. It produces the voltage by movement of oxygen ions when there is oxygen concentration difference between exhaust gas and atmosphere. If a certain voltage is applied to the sensor, the movement of oxygen ions occurs regardless of the oxygen density.

  • Page 363: Cooling Fan Control

    15-38 (12) Cooling fan control A. Overview of cooling fan and A/C compressor The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. The water pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head.
  • Page 364 15-39 0000-00 C. Input/Output for cooling fan and A/C compressor...
  • Page 365 15-40 D. Cooling fan and A/C compressor control ▶ Conditions for cooling fan control The PWM cooling fan is set by coolant temperature and A/C refrigerant pressure. And, the setting value in A/T equipped vehicle may vary according to the internal oil temperature. The The engine ECU controls the PWM cooling fan unit based on various signals to get the optimized temperature during engine running.
  • Page 366 15-41 0000-00 ▶ A/C compressor OFF conditions Coolant temperature: below -20℃ or over 115℃ Engine rpm: over 4500 rpm Engine rpm: below 600 rpm When abrupt acceleration Very high load during idling Refrigerant pressure: over 32 bar or below 2 Failure in refrigerant sensor, coolant temperature sensor, and cooling fan...
  • Page 367 15-42 (13) PTC heater control A. Overview The supplementary electrical heater is installed in DI engine equipped vehicle as a basic equipment. The PTC system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor. This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment.
  • Page 368 15-43 0000-00 C. PTC operation process The PTC operating condition (ON) is controlled in two steps. Basically, the engine ECU controls the relay to supply the power to PTC according to the coolant temperature sensor and ambient temperature sensor. ▶ 1st step (initial operation of PTC) Coolant temperature <...
  • Page 369 15-44 (14) Immobilizer control A. Overview The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized persons. The transponder integrated in the key and the engine control unit have the same code. When the ignition key with the integrated transponder is turned to the ON position, the ECU (Engine Control Unit) checks the crypto code of the key and, if correct, allows the vehicle to start the engine.
  • Page 370 15-45 0000-00 C. Key approval process When turning the ignition switch to ON position, the power is supplied to BCM and ECU. ECU communicate with the immobilizer key to check if it is valid crypto code. If it is valid, ECU start to control the engine when turning the ignition switch to START position.
  • Page 371 15-46 (15) CDPF control A. Overview As the solution for environmental regulations and PM Particle Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxidation Catalyst) is reduced.
  • Page 372 15-47 0000-00 C. Input/Output for CDPF control...

  • Page 373: Operation Process

    15-48 D. Operation process When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF, the sensor sends signal indicating the soot is accumulated and the post injection is performed to raise the temperature of exhaust gas. The amount of fuel injected is determined according to the temperature of exhaust gas detected by the rear temperature sensor.
  • Page 374 15-49 0000-00 E. Cautions Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. ▶ Use only specified engine oil (Low Ash Oil) The vehicle equipped with CDPF should use specific engine oil to improve the engine performance and fuel economy, and ensure the service life of CDPF.
  • Page 375 15-50 3) Input/Output for CAN communication...

  • Page 376: Component Locator

    01-4 1. COMPONENT LOCATOR 1) Front View...
  • Page 377 01-5 0000-00 ▶ Front View FUNCTION FUNCTION HFM sensor Intake manifold Intake air duct Connecting rod Resonance flap Exhaust manifold Cylinder head cover Crankshaft Exhaust camshaft Engine mounting Intake camshaft Starter Cylinder head Crankcase Spark plug connector Oil pump sprocket Valve tappet Oil strainer Injector...

  • Page 378: Side View

    01-6 2) Side View FUNCTION FUNCTION Camshaft adjuster Oil pump drive chain Cooling fan and viscous clutch Oil return pipe Piston Timing chain Flywheel of drive plate...

  • Page 379: Description And Operation

    01-7 0000-00 2. DESCRIPTION AND OPERATION 1) Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation.

  • Page 380: Specifications

    02-3 1113-01 1. SPECIFICATIONS 1) Engine Specifications...

  • Page 381: Performance Curve

    02-4 2) Performance Curve...

  • Page 382: Special Tools And Equipment

    02-5 1113-01 2. SPECIAL TOOLS AND EQUIPMENT...
  • Page 383 02-6...
  • Page 384 02-7 1113-01 Name and Part Number A9917 0012B (DW110-120)Holding Pin...

  • Page 385: Fastener Tightening Specifications

    02-8 3. FASTENER TIGHTENING SPECIFICATIONS...
  • Page 386 02-9 1113-01 1) Fastener Tightening Specifications (Cont'd)

  • Page 387: Fuel System Specification

    03-3 2211-22 1. FUEL SYSTEM SPECIFICATION ▶ Use Only Unleaded Fuel Rated at 89 Octane or Higher Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of theengine. Fuel with too low an octane number can cause engine knock. ▶...
  • Page 388 03-4 ▶ Temperature vs resistance...
  • Page 389 NO DATA...
  • Page 390 05-3 2420-01 1. OVERVIEW OF EXHAUST SYSTEM When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials.
  • Page 391 05-4 4. FASTENER TIGHTENING SPECIFICATIONS...

  • Page 392: Oil Circulation

    06-3 9210-01 1. OIL CIRCULATION...
  • Page 393 06-4 ▶ OIL CIRCULATION FUNCTION FUNCTION Oil pump Oil supply (to exhaust camshaft) Oil gallery (to oil filter) Oil supply (to intake camshaft) Oil supply Oil filter (to exhaust camshaft bearing) Oil supply Oil pressure switch (to intake camshaft bearing) Oil gallery Main oil gallery (oil supply to exhaust valve tappet)

  • Page 394: General Specifications

    07-3 2110-01 1. GENERAL SPECIFICATIONS...
  • Page 395 07-4 2. SPECIAL TOOLS AND EQUIPMENT...
  • Page 396 07-5 2110-01 3. FASTENER TIGHTENING SPECIFICATIONS...

  • Page 397: General Description

    07-6 1. GENERAL DESCRIPTION The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly. The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat and housing, a water pump, and a water pump drive belt.
  • Page 398 07-7 2110-01 2. COMPONENT LOCATOR...
  • Page 399 07-8 Radiator Inlet hose Electric fan Outlet hose Shroud 3 way hose Deaeration tube Deaeration hose (reserver tank) Clamp Clamp Deaeration hose (radiator) Clamp Electric fan mounting bracket Make up hose holder Bolt (M6, 8 pieces) Reserver tank Bolt (M6, 4 pieces) Bolt (M6, 2 piece) Bolt (M6, 4 pieces) Cooling fan...
  • Page 400 08-3 1452-01 1. GENERAL SPECIFICATIONS...
  • Page 401 08-4 2. FASTENER TIGHTENING SPECIFICATIONS...

  • Page 402: Charging System Operation

    08-5 1452-01 1. CHARGING SYSTEM OPERATION Alternators use a new type of regulator that incorpo-rates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier alternators. A conventional pulley and fan are used. There is no test hole. 1) Charging Time Required The time required to charge a battery will vary depending upon the following factors: ▶...

  • Page 403: Ignition System Operation

    08-6 3. IGNITION SYSTEM OPERATION This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition system ignition coil.
  • Page 404 08-7 1452-01 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT...

  • Page 405: Engine Data Display Table

    09-3 1522-16 1. ENGINE DATA DISPLAY TABLE...
  • Page 406 09-4 1) Temperature vs Resistance 2. FASTENER TIGHTENING SPECIFICATIONS...

  • Page 407: System Description

    10-3 8510-23 1. SYSTEM DESCRIPTION 1) System Description The cruise control is an automatic speed control system that maintains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially useful for motorway driving.
  • Page 408 10-4 2) Traffic Conditions for Using Cruise Control Use the cruise control system only when the traffic is not jammed, driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc.
  • Page 409 10-5 8510-23 2. CONFIGURATION 1) Circuit Diagram The engine ECU detects the operating conditions of cruise control system, and monitors the braking performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise switch signals (decelerating, accelerating, cruising).
  • Page 410 10-6 2) Configuration ▶ Test voltage(VCC 5V) FUNCTION KEY VOLUE REMARK MAIN 0.15 ~ 0.55V DECEL 0.7 ~ 1.1V ACCEL 1.6 ~ 2.0V RESUME 2.52 ~ 2.92V...

  • Page 411: Operation

    10-7 8510-23 3. OPERATION 1) Setting a Desired Speed To operate the cruise control, accelerate to the desired speed, which must be more than 36 km/h and less than 150 km/h. When the desired speed is reached, push up the ACCEL switch of the cruise control lever or push down the DECEL switch for 1 second per one switching and then release the accelerator pedal slowly.
  • Page 412 10-8 2) Accelerating with the Cruise Control System (1) While the cruise control system is running Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached without an accelerator pedal intervention. When the desired speed is reached, release the lever.
  • Page 413 10-9 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at less than 34 km/h.
  • Page 414 10-10 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by pulling up the cruise control lever when the current vehicle speed is over 36 km/h without an acceleration intervention.
  • Page 415 10-11 8510-23 5) Normal Cancellation of the Cruise Control The cruise control system will be canceled when one or more items of the following conditions are applied; When the brake pedal is depressed or When ESP is activated. When the cruising speed is downed less than 34 km/h When applying the parking brake during driving.
  • Page 416 10-12 (1) Abnormal Cancellation of the Cruise Control When the rapid deceleration is applied without braking. When the rapid acceleration is applied without acceleration pedal intervention. When the cruise control lever is faulty. When the brake switch and the brake light switch input signal are implausible. When the cruise control function is cancelled abnormally or intermittent problems occur, stop the vehicle and turn off the ignition switch and remove the key to reset the system.
  • Page 417 01-3 8410-02 1. CAUTIONS WHEN WORKING ON ELECTRICAL UNITS Disconnect the negative cable from the battery in advance when working on electrical units. Make sure to turn "OFF" the ignition switch and other lamp switches before disconnecting or connecting the negative battery cable.
  • Page 418 01-4 Make sure a connector is connected securely. Loose connection results in malfunction. When disconnecting a connector equipped with a lock, press it down to the direction in the below figure. When checking voltage or continuity of the connector terminal with a circuit tester, connect the tester probe to the terminal at the harness side.
  • Page 419 01-5 8410-02 2. CHECKING CABLES AND WIRES Check for loose connection or rust. Check terminals and wires for corrosion due to electrolyte leakage. Check terminals and wires for open circuit. Check the wire insulation and coat for damage, cracks or deterioration. Check if the conductive parts of the terminals do not contact with vehicle body or other metal parts.
  • Page 420 01-6 1. OVERVIEW The fuse and relay boxes consist of four boxes: Fuse & relay box, in engine room and Fuse and relay box in left side of instrument panel. 2. LOCATION ▶Engine Room Fuse and Relay Box PTC Box Assembly ▶Interior Fuse and Relay Box...
  • Page 421 01-7 8410-02 3. CIRCUIT DIAGRAM 1) Engine Room Fuse and Relay Box ▶SB1~SB4, C/FAN (HI,LO) REALY, F/HEATER RELAY, C/FAN (SUB) RELAY...
  • Page 422 01-8 ▶SB5~SB8, Ef5, Ef6, 2ND A/PUMP RELAY, ENG MAIN RELAY, START RELAY...
  • Page 423 01-9 8410-02 ▶SB9~SB11, Ef10, Ef23, RR BLOWER RELAY, DEFOGGER RELAY...
  • Page 424 01-10 ▶Ef2~Ef4, Ef19, Ef20, B/HORN RELAY, H/LAMP (LO,HI) RELAY, COMP RELAY...
  • Page 425 01-11 8410-02 ▶Ef7~Ef9, Ef21, FRT FOG LAMP RELAY, TAIL LAMP RELAY...
  • Page 426 01-12 ▶Ef11~Ef16, POWER WINDOW RELAY...
  • Page 427 01-13 8410-02 ▶Ef17, Ef18, Ef22, Ef24~Ef26, FUEL PUMP RELAY...
  • Page 428 01-14 2) Interior Fuse and Relay Box ▶F1 ~ F5...
  • Page 429 01-15 8410-02 ▶F6 ~ F12...
  • Page 430 01-16 ▶F13 ~ F16...
  • Page 431 01-17 8410-02 ▶F17 ~ F24...
  • Page 432 01-18 ▶F25 ~ F31...
  • Page 433 01-19 8410-02 ▶F32 ~ F36...

  • Page 434: Electrical Performance

    02-3 8710-01 1. SPECIFICATIONS OF RK - STICS 1) Electrical Performance Item Requirement Remark Rated voltage DC 12V Operating voltage DC 9 ~ 16V Should operate normally within this range. -30℃ ~ +80℃ Operating temperature -40℃ ~ +85℃ Reserved temperature Max.
  • Page 435 02-4 4) Input Signals Of Rk Stics...
  • Page 436 02-5 8710-01 The remote engine control function has been deleted in this model. 1. COMPONENTS Air bag ECU Sends the vehicle collision signals to STICS. SCAN-tool STICS / ICM module RK STICS SIW is used for REKES key coding and trouble diagnosis.

  • Page 437: Wiper Control

    02-6 2. FUNCTIONS OF RK STICS 1) Wiper Control (1) Wiper MIST and Washer Coupled Wiper The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch for 0.2 ~ 0.59 seconds (T2) with the ignition key “ON”, and it is turned off when the parking terminal is turned off.
  • Page 438 02-7 8710-01 If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation returns back to intermittent or AUTO mode with the stored operating interval.
  • Page 439 02-8 (2) Rain Sensor Coupled Wiper ▶ System layout This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
  • Page 440 02-9 8710-01 ▶ Rain sensing operation point The wiper relay is turned on and the wiper motor runs one cycle when the ignition key is turned to “ON” position (while the wiper switch is in “AUTO” position). The wiper relay (LO) is turned on and the wiper motor runs one cycle when changing the wiper switch to “AUTO”...
  • Page 441 02-10 ▶ Rain sensing sensitivity control The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to 1) (while the ignition key is in “ON” position, the wiper switch is in “AUTO”...
  • Page 442 02-11 8710-01 ▶ Wiper operation when the wiper parking terminal is grounded The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is grounded (while the ignition key is in “ON” position and the wiper switch is in “AUTO”...
  • Page 443 02-12 ▶ Defective rain sensor The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal (1) from the rain sensor. However, the wiper motor can be operated only when the rain sensor detects the "Rain Detected"...
  • Page 444 02-13 8710-01 The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in “ON” position and the wiper switch is in “AUTO” position). The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the malfunction signal (3) from the rain sensor (while the ignition key is in “ON”...
  • Page 445 02-14 ▶ Speed Sensitive INT (Intermittent) Wiper For STICS without rain sensor, perform the following operation: 1. Controls the wiper intermittent operation by the values from vehicle speed and volume. Calculates and converts the Intermittent interval automatically by using the vehicle speed and INT VOLUME when the ignition switch is in “ON”...
  • Page 446 02-15 8710-01 (1) Wiper MIST and washer coupled wiper When turning on the washer switch while the wiper relay is operating. If the wiper relay “ON” request time is shorter than the remained “ON” time, it is disregarded. (2) Speed sensitive INT (intermittent) wiper The wiper relay continues to output for remaining “ON”...
  • Page 447 02-16 ▶INT Switch Auto Position Reminder (Power-Up Reminder Wiper) When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of communication with rain sensor. When turning the INT-AUTO switch from the "OFF" to "ON" position with the ignition switch in the "ON"...

  • Page 448: Ignition Key Reminder

    02-17 8710-01 2) Ignition Key Reminder ▶Key Reminder Warning The chime buzzer output in the ICM box continues when opening the driver’s door while the ignition key is inserted into ignition switch. When removing the ignition key or closing the driver’s door during chime buzzer output, the output turns off.
  • Page 449 02-18 ▶Key Reminder This function does not work if the vehicle speed is over 3 km/h. The system outputs “UNLOCK” for 5 seconds (T2) from 0.5 seconds after the driver’s door is opened and the door lock switch is changed to “LOCK” (while the ignition key is in ignition switch).
  • Page 450 02-19 8710-01 ▶All Door Lock Prevention Function when a Door is Opened When a door is opened, all doors should be unlocked for 5 seconds if inputs LOCK signal. The LOCK signal means the central door locking (REKES, central door lock switch, knob switch) except LOCK input by rear door knob.
  • Page 451 02-20 3) Mark Lamp Left on Warning The chime buzzer in the ICM box sounds with the interval of 0.8 second when opening the driver’s door while the tail lamp is turned on and the ignition key is removed. The buzzer output stops when turning off the tail lamp and closing the driver’s door. The system outputs “UNLOCK”...

  • Page 452: Door Ajar Warning

    02-21 8710-01 4) Door Ajar Warning The warning light in indicator display comes on when opening any of driver’s door, passenger’s door, rear door or tailgate while the vehicle speed is below 6 km/h (V1). The warning light goes off when closing the door under step 1. The warning light blinks when the vehicle speed is over 10 km/h (V1) for more than 2 seconds while the warning light is turned on.

  • Page 453: Seat Belt Warning

    02-22 5) Seat Belt Warning 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”. If the seat belt is fastened before turning the ignition key to “ON”...
  • Page 454 02-23 8710-01 6) Parking Brake Warning The parking brake warning light comes on for approx. 4 seconds (T4) when turning the ignition key from “OFF” to “ON” position regardless of the vehicle speed and parking brake switch position. The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km/h (V1).
  • Page 455 02-24 7) Room Lamp Control ▶ Front Room Lamp The front room lamp comes on when opening the driver’s door or passenger’s door while the front room lamp switch is at door coupled position and the key reminder switch is turned off. The room lamp stays on for 2 seconds (T1) and then decays through 3 seconds (T2) when closing the driver’s door or passenger’s door.
  • Page 456 02-25 8710-01 ▶Rear Room Lamp The rear room lamp comes on when opening the rear door while the door coupled rear room lamp switch is pressed (except for luggage room lamp). The rear room lamp extends its lighting period by 5 seconds when closing the rear door.
  • Page 457 02-26 8) Ignition Key Hole Illumination (Except For Immobilizer) The ignition key hole illumination comes on when opening the driver’s door or passenger’s door while the ignition key is removed. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1. The output stops when the ignition key is turned to “ON”...
  • Page 458 02-27 8710-01 9) Battery Saver (Tail Lamp Auto Cut) The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door after removing the ignition key without turning off the tail lamp.

  • Page 459: Defogger Timer

    02-28 10) Defogger Timer The system outputs the tailgate, windshield and outside rearview mirror heated glass “ON” signal when turning on the defogger switch (while the engine is running). The output stops when turning on the defogger switch again during its operation. The output is “ON”...
  • Page 460 02-29 8710-01 This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine compartment fuse box. Windshield, rear rear glass and outside rearview mirror heated glass switch...
  • Page 461 02-30 11) Door LOCK/UNLOCK Control ▶Door Lock/Unlock by Door Lock Switch The door lock system outputs “LOCK” for 0.5 seconds (T1) when positioning the driver’s or passenger’s door lock switch to lock position (while the driver’s and passenger’s door lock switch is in “UNLOCK”...
  • Page 462 02-31 8710-01 ▶Door Lock/Unlock by Central Door Lock Switch The door lock system outputs “LOCK” for 0.5 seconds (T1) when pressing “LOCK” button on the central door lock switch. The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when pressing “UNLOCK” button on the central door lock switch.
  • Page 463 02-32 ▶Door LOCK/UNLOCK by Remote Control Key The door lock system outputs “LOCK” for 0.5 seconds (T2) when receiving “LOCK” signal from the remote control key. The door lock system outputs “UNLOCK” signal for 0.5 seconds (T3) when receiving “UNLOCK” signal from the remote control key.
  • Page 464 02-33 8710-01...
  • Page 465 02-34 ▶Auto Door Lock The door lock system outputs "LOCK" when the vehicle speed maintains over 50 km/h. However, it doesn't output "LOCK" when all doors are locked or failed. If any of doors is unlocked after outputting "LOCK" in step 1, outputs "LOCK" up to 5 times (except step (1)) at the interval of one second.
  • Page 466 02-35 8710-01 ▶Auto Door Unlock (Crash Unlock) The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to "ON" position. After this period, the door lock system outputs "UNLOCK" for all doors for 5 seconds from 40 ms after receiving the air bag collision signal.

  • Page 467: Time Lag Power Window Control

    02-36 12) Time Lag Power Window Control The power window is turned off when turning the ignition key to “ON” position. The power window relay is turned “ON” for 90 seconds (T1) when turning the ignition key to “OFF” position. However, the power window relay stays on for 90 seconds (T2) when the ignition key is turned to “OFF”...

  • Page 468: Theft Deterrent

    02-37 8710-01 13) Theft Deterrent (1) Description of Burglar Alarm Function ▶Theft deterrent mode ON conditions The “LOCK” output is “ON” when receiving the “LOCK” signal from transmitter while the ignition key is removed and all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output: once, hazard relay output: twice).
  • Page 469 02-38 ▶Armed mode cancellation requirements Unlocking by remote control key or engine starting. ▶Warning operation requirements When opening the door in armed mode When unlocking the door lock switch in armed mode When closing and then opening the door after completion of warning (27 seconds) ▶Warning operation The theft deterrent horn and hazard warning flasher output is “ON”...
  • Page 470 02-39 8710-01 (2) PANIC Warning The PANIC warning output is “ON” (theft deterrent horn) when receiving the PANIC signal from the remote control key (pressing PANIC button for less than 0.5 ~ 1.0 second). The PANIC warning output is “OFF” when receiving any signal from the remote control key during PANIC warning.
  • Page 471 02-40 (3) Auto Light Function The lights automatically come on and off according to the ambient brightness when the multifunction light switch is in “AUTO” position while the ignition key is in “ON” position. (4) Auto Door Lock The doors are locked and the theft deterrent mode is activated again if any of doors is not opened after unlocking them with a REKES key.

  • Page 472: Circuit Diagram

    02-41 8710-01 3. CIRCUIT DIAGRAM ▶ Tail lamp, key reminder SW, chime bell...
  • Page 473 02-42 ▶ Power window, warning lamp(brake, s/belt)
  • Page 474 02-43 8710-01 ▶ Wiper, door SW, lamp(door courtesy, g/handle), door open...
  • Page 475 02-44 ▶ Door lock, defogger...

  • Page 476: System Layout

    03-3 7010-06 1. SYSTEM LAYOUT 1) Location Immobilizer Warning Lamp Immobilizer Unit Diagnostic Connector REKES Key...

  • Page 477: System Diagram

    03-4 2) System Diagram The certification for the immobilizer is performed when turning the ignition switch to the "ON" position after the CAN communication between the ECU and immobilizer is established.
  • Page 478 03-5 7010-06 2. OVERVIEW The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized persons. The transponder integrated in the key and the engine control unit have the same code. When the ignition key with the integrated transponder is turned to the ON position, the ECU (Engine Control Unit) checks the crypto code of the key and, if correct, allows the vehicle to start the engine.
  • Page 479 03-6 3. VERIFICATION OF KEY 1) Verification The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
  • Page 480 03-7 7010-06 ▶ Immobilizer Indicator and Warning Lamp This indicator comes on when the ignition Immobilizer Indicator and Warning Lamp key is communicating with the engine control unit (during engine starting) and goes out after starting the engine. Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: immobilize...
  • Page 481 03-8 2) Circuit Diagram...

  • Page 482: Specifications

    04-3 8010-01 1. SPECIFICATIONS 1) Power, Voltage, Current Description Specification Rated voltage DC 12V Operating voltage DC 9V ~ 16V Inspection voltage DC 13.5V -30˚C ~ +75˚C (while driving) Operating temperature -40˚C ~ +85˚C Storage temperature Performance guarantee voltage DC 10V ~ 15V below 3mA (12V, 25°C), Stabilized conditions (standby Dark current mode) around 180 seconds after IGN OFF...
  • Page 483 04-4 1. OVERVIEW The instrument cluster for this vehicle consists of the Meter cluster and the Warning lamp/Indicator cluster. For 2012 Model, some warning lamps and indicators have been deleted, added, and changed according to the changes of engineering design. Deleted: Warning lamps and indicators for EAS, EPB, and TPMS Changed: EBD warning lamps Added: Indicators for Part-time transfer case...
  • Page 484 05-3 8310-01 1. LAYOUT 1) Exterior Lamps...

  • Page 485: Front Lamps

    05-4 (1) Front Lamps Headlamp Headlamp Side repeater (12V-5W) Right fog lamp Left fog lamp (12V-5W) (12V-5W) Tail lamp (12V-5W) Low beam (12V-55W) Turn signal lamp High beam (12V-55W) (12V-28W) Connector Tail lamp Tail lamp/Turn signal lamp connector Headlamp Headlamp Turn signal lamp (High beam) (Low beam)

  • Page 486: Rear Lamps

    05-5 8310-01 (2) Rear Lamps High mounted stop lamp (12V-6W) Tail lamp assembly License plate lamp (12V-5W, 2) Rear lamp Stop lamp (12V-8W) Rear turn signal lamp (12V-27W) Tail lamp (12V-8W) Stop lamp Tail lamp assembly Rear turn signal lamp or connector rear fog lamp (LH only) Tail lamp...

  • Page 487: Interior Lamps

    05-6 2) Interior Lamps...

  • Page 488: Multifunction Switch

    06-3 8510-00 1. SPECIFICATIONS 1) Multifunction Switch Description Description Multifunction Rated voltage DC 12V switch -30℃~+80℃ Operating temperature Rated load Light switch ON: 1A (Relay load) Dimmer and passing switch High beam/low beam/passing: 0.3A (Relay load) 6.6±0.5A (Lamp load) Turn signal switch Wiper switch Low: 5A, High: 7A (Motor load) Auto: 0.22±0.05A (Relay load)
  • Page 489 06-4 1. LAYOUT Remote Control Switches on Steering Wheel Manual gear shift Manual gear shift up switch down switch Mode button Volume button Mute button Power button Bluetooth switch Seek button Outside Rearview Mirror Adjusting/Folding Switches Window switch 4WD Switch, Headlamp Leveling Switch, Rear Wipe Switch...
  • Page 490 06-5 8510-00 Driver’s seat warmer Room Lamp and Sunroof Switch (w/ ESP OFF Front fog switch multimeter) switch lamp switch Sunroof switch Door coupled room lamp switch Hazard warning flasher switch Multimeter Rear fog lamp Passenger’s seat Defogger switch switch warmer switch Front room lamp switch Passenger’s Window Switch...
  • Page 491 07-3 7810-01 1. SPECIFICATIONS OF WIPER...
  • Page 492 07-4 2. CAUTIONS ON RAIN SENSOR When the wiper switch is in the AUTO position, the wiper will operate for 1 cycle if the initial engine start is made. This may cause the wiper blades to wear prematurely. Therefore, other than rainy days, set the switch to the OFF position.

  • Page 493: System Layout

    07-5 7810-01 1. SYSTEM LAYOUT ▶Components...

  • Page 494: Circuit Diagram

    07-6 2. CIRCUIT DIAGRAM...

  • Page 495: System Layout And Overview

    08-3 8610-11 1. SYSTEM LAYOUT AND OVERVIEW The rain sensing wiper unit in this vehicle doesn’t control the wiper directly. The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. Multifunction wiper switch: Rain sensing unit AUTO and sensitivity control...
  • Page 496 08-4 STICS The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. At this moment, STICS determines the wiper operation mode (washer, MIST, AUTO), then sends the information to the rain sensor.

  • Page 497: Rain Sensor Operation

    08-5 8610-11 2. RAIN SENSOR OPERATION The rain sensor is installed on the specific heat treated windshield that has minimum 13% of transmittance rate with specified intensity of radiation. It is installed on the glass with a adhesive of Sorepa. It communicates with STICS and makes the wipers to operate automatically under the rain sensing mode (multifunction switch wiper: AUTO mode).
  • Page 498 08-6 1) Rain Sensor Coupled Wiper ▶ System layout This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
  • Page 499 08-7 8610-11 ▶ Rain sensing operation point The wiper relay is turned on and the wiper motor runs one cycle when the ignition key is turned to “ON” position (while the wiper switch is in “AUTO” position). The wiper relay (LO) is turned on and the wiper motor runs one cycle when changing the wiper switch to “AUTO”...
  • Page 500 08-8 ▶ Rain sensing sensitivity control The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to 1) (while the ignition key is in “ON” position, the wiper switch is in “AUTO”...
  • Page 501 08-9 8610-11 ▶ Wiper operation when the wiper parking terminal is grounded The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is grounded (while the ignition key is in “ON” position and the wiper switch is in “AUTO”...
  • Page 502 08-10 ▶ Defective rain sensor The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal (1) from the rain sensor. However, the wiper motor can be operated only when the rain sensor detects the "Rain Detected"...
  • Page 503 08-11 8610-11 The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in “ON” position and the wiper switch is in “AUTO” position). The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the malfunction signal (3) from the rain sensor (while the ignition key is in “ON”...

  • Page 504: Operation Mode Of Rain Sensing Wiper System

    08-12 3. OPERATION MODE OF RAIN SENSING WIPER SYSTEM...
  • Page 505 08-13 8610-11 4. FUNCTIONS OF RAIN SENSOR The followings are the detailed description of the functions and operations of the rain sensing wiper control. 1) Windshield Glass and Coupler Attachment Check the outer windshield surface of sensing area for wear, damage and scratch. The sensor is able to compensate the wear up to a specific level.

  • Page 506: Self Diagnosis

    08-14 4) Washer Coupled Wiper Function Check the washer coupled wiper operation by pressing the washer switch. 5) Irregular Operations (Abrupt Operations) Check the sensor for coming off. Check the rain sensor cover installation. Check that the customer is familiar to how to control the wiper sensitivity. Check that the customer can select the sensitivity by selecting the variable resistance value (stage 1 to stage 5), that is, the wiper sensitivity control value.

  • Page 507: Diagnosis Procedures

    08-15 8610-11 5. DIAGNOSIS PROCEDURES...

  • Page 508: Rain Sensor Related Circuit

    08-16 6. RAIN SENSOR RELATED CIRCUIT The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram. However, in this vehicle, the terminal No. 1 and No. 2 are for communications between STICS and the rain sensor;...

  • Page 509: Rain Sensing Wiper

    08-17 8610-11 7. RAIN SENSING WIPER...

  • Page 510: Specifications

    09-3 8790-01 1. SPECIFICATIONS Description Specification Rated voltage DC 12V Operating voltage DC 9V ~ 16V Current consumption Unit below 100 mA Sensor below 20 mA (for each sensor) over 5 MΩ Sensor insulating resistance -30˚C ~ +80˚C Operating temperature -40˚C ~ +85˚C Storage temperature Relative humidity...
  • Page 511 09-4 2) Parking Aid Sensor Type: Piezo ceramic element Frequency: 40 kHz ± 2 kHz Detecting range (13.5 V) * Horizontal: Min. 20° at 110 ± 5 cm, Min. 100° at 50 ± 5 cm * Vertical: Min. 20° at 110 ± 5 cm, Min. 60° at 50 ± 5 cm...
  • Page 512 09-5 8790-01 2. CAUTIONS · Note that the display does not show everything in the rear area. Always check nobody, especially animals and children, is behind the vehicle when parking or reversing. · If you can not properly check the vehicle behind, get out of the vehicle and then visually check it.
  • Page 513 09-6 1. OVERVIEW When the gear shift lever is shifted into “R” position, theparking aid system is activated and the sensors in rearbumper detect the distance to obstacle. Driver can figure outthe distance from obstacle to vehicle with the alarming soundand the display in multimeter. 2.
  • Page 514 09-7 8790-01 Rear PAS Sensor Location Center sensor PAS Unit LH sensor RH sensor - 3 sensors on rear bumper - Operates only in “R” position - Controls the PAS sensors and sends the sensing data to multimeter and ICM box.
  • Page 515 09-8 ▶ Multimeter Display The multimeter displays the distance to obstacles by bar symbos. RH Sensor Center Sensor LH Sensor Distance to obstacle Alarm interval Multimeter display over 1.2 m No alarm 81 ~ 120cm Long beeps 51 ~ 80cm Short beeps 25 ~ 50cm Alarm stays on...
  • Page 516 09-9 8790-01 3) Circuit Diagram...

  • Page 517: Specification

    10-3 8910-05 1. SPECIFICATION Unit Description Specification Audio Voltage DC 14.4V Operating voltage DC 10.8V~16.0V 45W/ch (Speaker 4Ω) Output 4Ω Speaker Impedance Current consumption below 5A, max. 10A Dark current below 3mA 주파수EU Radio Frequency FM : 87.5 ~ 108MHz FM: 87.5~108MHz MW: 522 ~ 1620 KHz AM: 531~1602KHz...

  • Page 518: Major Changes

    10-4 2. MAJOR CHANGES Audio Assembly - Changed the audio assembly (added Bluetooth hands-free function)
  • Page 519 10-6 1. LAYOUT Bluetooth microphone Tweeter speaker Audio head unit Audio remote control switches Bluetooth Microphone Front Speaker...
  • Page 520 10-7 8910-05 Radio Antenna Amplifier Rear Speaker...
  • Page 521 10-8 1) Switches Name Power/Mute/Pause/Enter/Volume button Station memory button (1~6) and Audio function button Bluetooth hands-free CALL button Bluetooth hands-free END button Previous (≪) and Next (≫) button SCAN/INFO button BAND/AS button SETTING button Display window (LCD) RDS setup Disc Play button Disc Eject button Disc slot...
  • Page 522 01-3 3650-01 1. SPECIFICATIONS Item W5A580(2WD) / W5A400(4WD) Input torque 450Nm Diameter( Torque converter) 270mm Lockup function Gear ratios 3.595 2.186 1.405 1.000 0.831 Reverse: 3.167/1.926 S mode / W mode Driving type 2WD(4WD) Fluid specification Shell ATF 134 approx. 8ℓ Fluid capacity Selected lever P.R.N.D...
  • Page 523 01-4 항목 Item W5A330(300) W5A580(2WD)/W5A400(4WD) W5A580(400) 5.0 ± 0.2Ω M/P, S/P solenoid Resistance valve(23℃) Operating distance 0.6mm Operating current 0 ~ 1A 2.5 ± 0.2Ω Lockup solenoid Resistance valve(25℃) Operating distance 0.2mm Operating current 1.5 ~ 2.0A Operating range 3rd to 5th gears Speed sensor Resistance HALL type...
  • Page 524 01-5 3650-01 2. SPECIAL SERVICE TOLLS Part Name/Part Number Description W126 589 62 00 Install and remove the torque converter Handle W116 589 06 59 00 Support the transmission Support W140 589 12 15 00 Install the seal ring Drift W001 589 50 33 00 Install and remove the transmission housing ball bearing Puller...
  • Page 525 01-6 Part Name/Part Number Description W140 589 34 63 00 Support the transmission Mounting plate W140 589 06 34 00 Install and remove the transmission housing ball bearing Collet W140 589 13 43 00 Install and remove the B1, B2, B3 pistons Piston puller/installer Piston collar nut Install and remove the output shaft collar nut...
  • Page 526 01-7 3650-01 Part Name/Part Number Description 129 589 04 31 00 Measure the distance between ball bearing shaft and Straight edge parking lock gear shaft Compressor Compress the clutch/brake discs...

  • Page 527: Tightening Torque

    01-8 3. TIGHTENING TORQUE Description Tightening Torque (Nm) Remark Oil drain plug (oil pan) Hexagon, 5 mm Oil filler pipe (upper) 8 ~ 10 Oil filler pipe (lower) 8 ~ 10 Oil cooler pipe 30 ~ 38 Oil pan T 30 Torque converter housing/oil pump Transmission rear mounting bracket 36 ~ 44...
  • Page 528 01-9 3650-01 4. MJOR CHANGES Torque Converter The capacity of torque converter has been increased to optimize the output from D20DTR engine. Introduced Torsion Damper in Torque Converter Torsional damper The torsional damped has been newly installed in the torque converter. The torsional damper absorbs the shock, vibration and noise when delivering the engine driving force.
  • Page 529 01-10 1. OVERVIEW DC A/T Assembly Number DC A/T Assembly Number (With T/Converter) (With T/Converter) A/T Serial Number Base model AT type DC A/T Variant Number A/T Serial Number ▶DC 5-Speed Automatic Transmission DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the torque converter.
  • Page 530 01-11 3650-01 ▶Characteristics...

  • Page 531: Power Flow

    01-12 2. POWER FLOW 1) Power Flow ▶Sectional View B1 C1 C2 B3 C3 B2 ▶Shifting elements 1)Selector program switch: "S" mode 2) Selector program switch: "W" mode 3) Overrun...
  • Page 532 01-13 3650-01 ▶1st Gear (3.932) Torque converter lockup clutch 3rd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set 2nd gear ratio Input shaft: Clockwise rotation Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed Rear ring gear: Counterclockwise rotation...
  • Page 533 01-14 ▶2nd Gear (2.408) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set Input shaft: Clockwise rotation Sun gear and planetary gear carrier: Clockwise rotation by C1 activation Rear ring gear: Clockwise rotation Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed...
  • Page 534 01-15 3650-01 ▶3rd Gear (1.486) Torque converter lockup clutch Mounting elements Impeller Engine speed Rear planetary gear set Turbine wheel Transmission, input shaft Stator Front planetary gear set 1st gear ratio Center planetary gear set Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Center ring gear: Clockwise rotation by clutch 2 activation (direct connection) Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed...
  • Page 535 01-16 ▶4th Gear (1.000) Torque converter lockup clutch Stator Turbine wheel Engine speed Center planetary gear set Front planetary gear Planetary gear set Impeller Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Center ring gear and rear planetary gear carrier: Clockwise rotation Front sun gear and planetary gear carrier: Clockwise rotation (direct connection) Rear ring gear: Clockwise rotation Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
  • Page 536 01-17 3650-01 ▶5th Gear (0.830) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed 3rd gear ratio Impeller Transmission, input shaft Mounting elements Turbine wheel 1st gear ratio Rear planetary gear set Front planetary gear set Stator Input shaft: Clockwise rotation Front sun gear: Locked, Planetary gear carrier: Rotation with reduced speed...
  • Page 537 01-18 ▶Reverse 1st Gear (3.167) Torque converter lockup clutch Mounting elements Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set 2nd gear ratio Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Front sun gear: Locked by one-way clutch F1...
  • Page 538 01-19 3650-01 ▶Reverse 2nd Gear (1.926) Torque converter lockup clutch 2nd gear ratio Center planetary gear set Engine speed Mounting elements Impeller Transmission, input shaft Rear planetary gear set Turbine wheel 1st gear ratio Stator Front planetary gear set Input shaft: Clockwise rotation Front ring gear: Clockwise rotation Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection) Rear ring gear: Clockwise rotation...

  • Page 539: Circuit Diagram

    01-20 3. CIRCUIT DIAGRAM ▶Start Motor, Selector Lever, CAN Communication...
  • Page 540 01-21 3650-01 ▶Solenoid, Oil temperature sensor, Speed sensor (N2, N3)

  • Page 541: Specification

    02-3 3170-01 1. SPECIFICATION Description Specification Basic structure 2-shaft, 6-speed (directly connected 4 gears) Gear ratio 4.489 : 1 2.337 : 1 1.350 : 1 1.000 : 1 0.784 : 1 0.679 : 1 Reverse 4.253 : 1 Synchronizer T: Triple-cone ring type T: Triple-cone T: Triple-cone...

  • Page 542: Major Changes

    02-4 2. MAJOR CHANGES New Transmission (6-speed M/T) Old (5-speed M/T) New (6-speed M/T) To maximize the performance of D20DTR engine, new 6-speed manual transmission has been introduced for 2012 Model. Rear Mounting Insulator 2WD 6M/T 2WD A/T 4WD A/T P/N : 3190021M20 P/N : 3190021A20 P/N : 3190021A40...

  • Page 543: Special Service Tools

    02-5 3170-01 3. SPECIAL SERVICE TOOLS Part No. & Name Appearance Description Install the main shaft 1st gear sleeve Part No.: SSM00203-005 Install the drive pinion assembly front ball bearing Name: Install the main shaft double angular ball Main shaft 1st bearing sleeve installer Part No.:...
  • Page 544 02-6 Part No. & Name Appearance Description Install the counter shaft front roller bearing Part No.: SSM00203- Name: Counter shaft bearing installer Support the counter shaft when removing the Part No.: roller bearing with a puller T88310011A-9 Name: Bearing support...

  • Page 545: Tightening Torque

    02-7 3170-01 4. TIGHTENING TORQUE Tightening torque Part name Numbers Adhesive (Nm) 1. Seal bolt (rolling plunger and guide spring) 53.9~67.6 Loctite 2. Guide bolt 14.7~21.5 Loctite 3. Pocket ball bearing bolt 29.4~41.1 Loctite 4. Reverse shift fork retainer bolt 53.9~67.6 Loctite 5.
  • Page 546 02-8 ▶ 3163161-00 Housing Case - Transmission Breather - Air Retainer - Bearing Pulg - Seal (53.9 ~ 67.6 Nm) Bolt - Seal (19.6 ~ 24.5 Nm) Cylinder assembly - Concentric slave Seal - Oil Plunger - Rolling Bushing Boot Spacer Guide - Oil Gasket...
  • Page 547 02-9 3170-01 ▶ 3162-00 Main shaft...
  • Page 548 02-10 Ring - Snap Ring assembly - Triple cone Ring - Snap Gear assembly - 1st speed Bearing - Ball Sleeve - 1st gear Pinion assembly - Main drive Bearing - Double angular ball Bearing - Needle roller Ring - Snap Ring - Synchronizer Gear - Main shaft 5th Ring - Snap...
  • Page 549 02-11 3170-01 ▶ 33163-00 Counter shaft Ring - Snap Hub - Synchronizer Bearing - Roller Sleeeve - Synchronizer Gear - Counter shaft Ring - Synchronizer Gear - Counter shaft cluster Sleeve - Speed gear Bearing - Roller Bearing - Needle roller Sleeve ?- Speed gear Gear assembly - 6th speed Bearing - Needle roller...
  • Page 550 02-12 ▶ 3164-00 Adapter assembly Plate - Intermediate Bolt - Seal (19.6 ~ 26.4 Nm) Guide - Oil Shaft - Reverse idler gear Bolt (7.8 ~ 9.8 Nm) Bearing - Needle roller Pin - Dowel Gear - Reverse idler Retainer - Bearing Spacer - Reverse Magnet...
  • Page 551 02-13 3170-01 ▶ 3165-00 Rail and shift fork Shaft assembly - Control Lug _ Reverse shaft Ring - Retainer Fork - Reverse shaft Bearing - Retainer ball Rail - Shaft 5th & 6th Pin - Spring Fork - Shaft 5th & 6th Rail sub assembly - Shaft 1st &...
  • Page 552 02-14 ▶ 3166-00 Extension housing Lever assembly - Semi remote Bolt - Flange (42.1 ~ 53.9 Nm) Lever - Shift Seal - Oil Boot - Rubber Seal - Oil Ring - Retainer Pin - Dowel O-ring Switch - Neutral (29.4 ~ 34.3 Nm) Bearing Gasket Shim...
  • Page 553 02-15 3170-01 1. OVERVIEW 6-speed M/T Front view Sectional view 1) Characteristics of Transmission Forward and Reverse gears are helical gear. The clutch is operated by concentric slave cylinder (CSC). To prevent the improper gear shift, semi-remote control system has been introduced. To prevent the gears from engaging improperly, the synchronizer mechanisms and independent interlock systems are installed on 1/2 gears, 3/4 gears, 5/6 gears and reverse gear.

  • Page 554: Sectional Diagram

    02-16 2) Sectional Diagram Transmission housing Intermediate plate Extension housing Main drive gear Counter shaft Main shaft 3) Gear Ratio Teeth Gear Final gear ratio Input Output 4.489 2.337 1.350 1.000 0.784 0.679 4.253 IDLE : 25...

  • Page 555: Power Flow

    02-17 3170-01 2. POWER FLOW 1st speed 2nd speed...
  • Page 556 02-18 3rd speed 4th speed...
  • Page 557 02-19 3170-01 5th speed 6th speed...
  • Page 558 02-20 Reverse gear...

  • Page 559: Shifting Mechanism

    02-21 3170-01 3. SHIFTING MECHANISM High-Force mechanism for reverse gear shift Control shaft Neutral switch Backup lamp switch Lug arrangement Control finger 1st/2nd 3rd/4th 5th/6th...

  • Page 560: Specification

    03-3 3010-00 1. SPECIFICATION Description Specification Operating type Hydraulic type Clutch pedal Type Suspended type 150 ± 3mm Max. operating travel 95.2 ± 3mm Pedal height Pedal free play 5~15 mm Clutch disc Type Dry type single diaphragm Outer: Ø250 mm Diameter of facing Inner: Ø160 mm Numbers of disc...

  • Page 561: Troubleshooting

    03-4 2. TROUBLESHOOTING...
  • Page 562 03-5 3010-00 3. INSPECTION ▶ Pedal stroke and height Pedal stroke (A) Stop the engine. Measure the current pedal position. Depress the clutch pedal all the way and measure the pedal stroke (A). 150 ± 3mm Stroke (A) Pedal height (B) Stop the engine.
  • Page 563 03-6 ▶ Pedal free play Pedal free play (A) Stop the engine. Measure the current pedal position. Lightly depress the clutch pedal until you feel the resistancefrom the pedal and measure the distance. 5~15 mm Free play (A) Adjustment Release the lock nut (B) from the master cylinder.
  • Page 564 03-7 3010-00 1. OVERVIEW The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric slave cylinder fitted to the clutch housing as a hydraulic pressure. (The hydraulic pressure is transmitted in the following order: Clutch pedal - Clutch master cylinder - Clutch pipe - Clutch damper - Clutch pipe and hose - Concentric slave cylinder - Pressure plate - Flywheel.) If a driver depress the clutch pedal, the hydraulic pressure is generated in the master cylinder.

  • Page 565: System Description

    03-8 2. SATIC (SELF ADJUSTING TECHNOLOGY WITH INTEGRATED CASSETTE) 1) System Description ▶ Function On the conventional clutch, the pedal force tends to increase in proportion to the degree of disc run-out. However, the SATIC clutch has the adjusting function which activates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out.
  • Page 566 03-9 3010-00 2) Overview ▶ Driving elements The driving elements consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel and the other is the clutch pressure plate. The clutch pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel.
  • Page 567 03-10 3) Layout Clutch disc Clutch cover assembly T/M Input shaft Dual mass flywheel (DMF) Concentric slave cylinder...
  • Page 568 03-11 3010-00 3. DUAL MASS FLYWHEEL (DMF) The dual mass flywheel (DMF) is of having a mass divided into two halves. While one mass is connected to the engine crankshaft, which is affected by the mass moment of inertia of the engine, the other mass is affected by one of the transmission. The divided dual masses are connected to the coil spring and damping system internally.

  • Page 569: Specifications

    04-3 4120-01 1. SPECIFICATIONS ▶ Front Axle Description Specification Drive shaft type CV joint Axle housing type Build up Type Conventional type Differential Gear type Hypoid Gear Engine + M/T 3.54 Final gear reduction ratio Engine + A/T 4.55 Capacity 1.2L Specification SAE 80W / 90...
  • Page 570 05-3 3240-01 1. SPECIFICATIONS Description Specifications Total length 343mm Weight 32.4 kg (including oil) Oil capacity 1.4L Oil type ATF DEXRON II or III Location Transfer case Major element Housing Part-time Bolt 11EA, M8 x 1.25 Input shaft A/T: outer spline...

  • Page 571: Major Changes

    05-4 2. MAJOR CHANGES Adopted New Part-Time Transfer Case Side View Rear View - New Part-Time transfer case has been introduced in 2012 Model. Component Changes according to New Transfer Case Hub assembly Knuckle Front axle shaft Hub actuator - Some components in front axle have been changed according to new transfer case.
  • Page 572 05-5 3240-01 1. OVERVIEW By using the planetary gear sets, two-gears shift type part time transfer case achieves direct connection when selecting 4WD "HIGH" and 2.48 of reduction gear ratio when selecting 4WD "LOW". The silent chain in transfer case transfers the output power to front wheels. The simple operation of switches on instrument panel allows to shift between "2H"...
  • Page 573 05-6 ▶ Operation Description Mode Conditions Driving mode 2 Wheel drive Rear-wheel drive mode. This is used under (rear wheel) normal or high-speed driving conditions on public roads or highways. 4 Wheel drive This is used under sandy, muddy or snow- (high speed) covered road conditions 4 Wheel drive...
  • Page 574 05-7 3240-01 2. LAYOUT Front axle Front locking hub Front propeller shaft Part-time transfer case Rear propeller shaft Rear axle...

  • Page 575: System Layout

    05-8 3. SYSTEM LAYOUT...
  • Page 576 05-9 3240-01 4. IWE LOCKING HUB SYSTEM 1) Overview The vacuum locking hub uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator. It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Booster Operating Process...
  • Page 577 05-10 (2) Vacuum System Related to 4WD Check valve This valve allows the vacuum pressure to flow through it in only one direction. This prevent the vacuum from abruptly releasing due to faulty vacuum pump. Vacuum solenoid valve Hub actuator (RH) In 4WD mode, the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying...
  • Page 578 05-11 3240-01 5. POWER FLOW Switching 2H, 4H → 4L TCCU Vacuum solenoid Locking hub operation (Released internal vacuum) Transfer case Front propeller shaft Rear propeller shaft Rear axle Front axle Front wheel Rear wheel...
  • Page 579 05-12 1) 2H Mode (2 Wheel Drive) ▶ Power Flow Output shaft of Rear wheel transmission Input shaft of transfer case Rear propeller shaft Rear axle ↓ Output shaft of transfer case Rear wheel The driving force is directly engaged (1:1) to rear axle and is transferred only to the rear wheels.
  • Page 580 05-13 3240-01 2) 4H Mode (4 Wheel Drive - High Speed) ▶ Power Flow The driving force is pass through 4WD High magnetic clutch in transfer case and is distributed on front wheels and rear wheels (50;50).
  • Page 581 05-14 3) 4L Mode (4 Wheel Drive - Low Speed) ▶ Power Flow The gear ratio is reduced to 2.48;1 while passing through 4WD Low range and planetary gear set in transfer case and the driving force is distributed on front wheels and rear wheels (50;50).
  • Page 582 06-3 3310-01 1. SPECIFICATIONS Description Specification Universal joint with yoke arm and spider and CV Structure joint Front propeller shaft (4WD) One universal joint and one CV joint Rear propeller shaft Two universal joint and one CV joint Run-out below 0.4 mm Max.

  • Page 583: Special Service Tool

    06-4 2. SPECIAL SERVICE TOOL Part Number/Part Name Description 116 589 09 43 00 (P 99 48 003 To install the center bearing 0A) Installer 129 589 00 34 00 (P 99 33 002 To remove the center bearing 0B) Pulling arm...
  • Page 584 06-5 3310-01 1. OVERVIEW The propeller shaft transfers the power through the transmission and transfer case to the front/rear axle differential carrier (final reduction gear). It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending. Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length.
  • Page 585 06-6 Front propeller shaft A. Flange Components B. CV joint C. Universal joint Rear propeller shaft A. Universal joint B. Spline Components C. Center bearing D. CV joint E. Universal joint...

  • Page 586: Wheel Alignment

    07-3 4411-01 1. SPECIFICATIONS Specification Description Front Suspension Rear Suspension Suspension type Double wishbone Multi-link type Coil spring Coil spring Spring type Shock absorber type Reciprocating cylindrical type Reciprocating cylindrical type (gas type) (gas type) Stabilizer bar type Torsion bar type Torsion bar type 2.
  • Page 587 07-4 3. MAJOR CHANGES Front Sub Frame The engine mounting insulators (A) have been changed according to newly equipped engine (D20DTR). It improves the durability and NVH. Front Knuckle Assembly Locking hub Hub bearing actuator The front knuckle assembly has been changed according to new 4WD system (Part-time T/C).
  • Page 588 07-5 4411-01 Front Stabilizer Bar Assembly To reduce the rolling effect of vehicle, the front stabilizer assembly has been changed. Front Shock Absorber Assembly To enhance the riding comfort, the coil spring rate and damping force have been changed.
  • Page 589 07-6 4. DIMENSIONS OF FRONT SUSPENSION (1) Shock Absorber and Coil Spring...
  • Page 590 07-7 4411-01 ▶ Coil Spring Description 10.01 ± 5% 10.01 ± 5% Spring rate (kg/mm) 16.7 16.7 Coil diameter (mm) 58.3 58.3 Inner diameter (mm) 88.3 88.3 Spring identification None + Red or Blue Yellow + Red or Blue 8.49 8.49 Number of windings Number of active windings...
  • Page 591 07-8 ▶ Shock Absorber Fully extended length 547.0 ± 0.3 (mm) Fully compressed 462.0 + 0.3 (mm) length 85.0 (mm) Operating distance...

  • Page 592: Shock Absorber

    07-9 4411-01 5. DIMENSIONS OF REAR SUSPENSION (1) Shock Absorber Keep the suitable distance when compressed and extended. Minimum length should be 10 mm longer than the fully compressed length. ▶ Dimension Maximum operating length Minimum operating length Operating distance 487.0 ±...

  • Page 593: Coil Spring

    07-10 (2) Coil Spring High tensile steel used. Minimum length should be 20 mm longer than the fully compressed length. Spring seat used. ▶ Dimension Description 45110-21000 45110-21000 Part number 12.0 ±5% 12.0 ±5% Spring rate (kg/mm) 15.9 15.9 Coil diameter (mm) 69.1 69.1 Inner diameter (mm)
  • Page 594 08-3 4850-03 1. SPECIFICATIONS Description Specification Front brake Type Ventilated disc Rear brake Type Ventilated disc Master cylinder Type Step feed bore tandem, double cylinder Brake booster Type Tandem type(integrated level sensor) Operating type Foot operated type Brake oil Grade DOT 4 Service interval Replace every 2 years...
  • Page 595 08-4 2. SPECIAL SERVICE TOOL Piston Puller Caliper Piston Compressor...

  • Page 596: Troubleshooting

    08-5 4850-03 3. TROUBLESHOOTING Problem Possible Cause Action Noise or vehicle Incorrectly mounted back plate or caliper Repair vibration when Loosened bolt of back plate or caliper Retighten applied Uneven wear of brake disc Replace Brake pad contamination Clean or replace Sticking brake pad on contact surface Replace Wear or hardening of brake pad...
  • Page 597 08-6 Problem Possible Cause Action Increased pedal Air in brake line Bleed air stroke Oil leak Repair Worn brake pad Replace Excessive clearance between push rod and master Adjust cylinder Worn or damaged piston seal Replace Brake dragging Parking brake is not fully released Replace Incorrect adjustment of parking brake Adjust...
  • Page 598 08-7 0000-00 Problem Cause Action Burning smell Too frequent braking in high driving speed Reduce the use of around tire foot brake/use sed only foot brake during downhill driving engine brake properly Driving with foot on brake pedal Get off the foot from pedal Foreign materials such as dirt or sand in brake system Replace: caliper,...

  • Page 599: Front Brake System

    08-8 4. INSPECTION 1) Front Brake System Clean the dissembled components and visually check the followings: -Wear, rust and damage on the cylinder and piston - Damage, crack and wear on cylinder body and guide pin - Uneven wear and oil contamination on pad - Damage and tear on boot - Scratch and bending on disc plate ▶Pad Thickness...
  • Page 600 08-9 4850-03 ▶ Disc Run-Out Install the dial gauge on the side of brake disc and measure the run-out while rotating the brake disc. If the measured value exceeds the limit, replace the brake disc with new one. Otherwise, it may cause the pedal vibration and shimmy when braking.

  • Page 601: Rear Brake System

    08-10 2) Rear Brake System Clean the dissembled components and visually check the followings: - Wear, rust and damage on the cylinder and piston - Damage, crack and wear on cylinder body and guide pin - Uneven wear and oil contamination on pad - Damage and tear on boot - Scratch and bending on disc plate ▶...

  • Page 602: Brake Booster

    08-11 4850-03 3) Brake Booster Let the engine run for 1 to 2 minutes and stop it. If the brake pedal stroke is shortened as pumping the brake pedal, the system is normal. If not, the system is defective. Depress the brake pedal several times with engine off.

  • Page 603: Stop Lamp Switch

    08-12 4) Stop Lamp Switch Connect the multimeter to stop lamp switch connector (N.O.) and check if the continuity exists when pushing in the plunger. If the continuity doesn't exist, the stop lamp switch is normal. Connect the multimeter to stop lamp switch connector (N.C.) and check if the continuity exists when pushing in the plunger.
  • Page 604 08-13 4850-03 1. COMPONENTS...
  • Page 605 08-14...

  • Page 606: Front Brake

    08-15 4850-03 1) Front Brake The front brake system uses the ventilated disc and double piston caliper. Brake hose Caliper assembly Brake disc Brake pad Caliper carrier Pad spring Brake pad Bolt-caliper Piston Brake disc Caliper...

  • Page 607: Rear Brake

    08-16 2) Rear Brake ▶ Brake Disc Brake disc Caliper Lock nut Brake hose Backing plate Adjusting bolt Lock nut Parking brake Brake shoe operating lever...
  • Page 608 08-17 4850-03 ▶Caliper Assembly Brake pad Caliper carrier Piston Pad spring Bolt-caliper Caliper Caliper assembly Brake pad...

  • Page 609: Parking Brake

    08-18 4) Parking Brake ▶Parking Brake Controls Pedal assembly Equalizer assembly Return spring - upper Adjusting bolt Shoe holding spring Return spring - lower Operating lever...
  • Page 610 08-19 4850-03 Release lever Release cable Parking brake switch Brake damper Pedal assembly Pedal Equalizer assembly Equalizer bolt Tension spring Rear brake cable - LH Rear brake cable - RH...

  • Page 611: Specifications

    09-3 4891-01 1. SPECIFICATIONS Description Unit Location HECU CPU:MCU60 (32bit) CPU:MCU60 (32bit) (Hydraulic & Clock Frequency: 28MHz Clock Frequency: 28MHz Under the front Electronic Control Memory: 128~256 KB Memory:256~512 KB washer reservoir Unit) On each wheel Front air gap: Active type wheel speed Active type wheel speed Wheel Speed 0.335~0.945mm,...

  • Page 612: Sensor Cluster

    09-4 2) Sensor Cluster Description Specification Supplying voltage approx. 5V (4.75~5.25V) Output voltage while in stationary approx. 2.5V (Ignition ON) Output range 0.2~4.8V 4˚/s Operating start speed 3) Steering Wheel Angle Sensor Description Specification 9~16V Operating voltage 10mA Maximum output current 1500˚/s Maximum detection angle speed -30~75℃...
  • Page 613 09-5 4891-01 1. ESP (Electronic Stability Program) ESP system contains the ABS (Anti-Lock Brake System), ABD (Automatic Braking Differential), ASR (Acceleration Slip Regulation), Cornering Control and HBA (Hydraulic Brake Assist System) functions. ▶Cornering Control (Understeer and Overersteer) Function This function controls the vehicle stability by applying the braking pressure on each wheel according to the yaw rate, lateral sensing value and driver’s steering wheel control.
  • Page 614 09-6 2. LAYOUT Pressure Sensor Installed Removed HECU(Hydraulic & Electronic Control Unit) Name Location HECU Under the battery Pressure Sensor Under the master cylinder Wheel Speed Sensor On wheels Sensor Cluster Under the audio assembly Steering Wheel Angle Sensor Under the steering wheel...
  • Page 615 09-7 4891-01 2. Steering Wheel Angle 1. ESP Indicator Sensor 3. ESP OFF Switch 4. Sensor Cluster Front Wheel Speed Sensor Rear Wheel Speed Sensor...
  • Page 616 09-8 3. OPERATING PROCESS 1) Block Diagram of Input and Output...
  • Page 617 09-9 4891-01 2) Operation of ESP System (1) Under steering ▶ What is understeering? Understeer is a term for a condition in which the steering wheel is steered to a certain angle during driving and the front tires slip toward the reverse direction of the desired direction. Generally, vehicles are designed to have understeer.
  • Page 618 09-10 (2) Over steering ▶ What is oversteering? Oversteer is a term of a condition in which the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction. Compared to understeering vehicles, it is hard to control the vehicle during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases.

  • Page 619: Esp Control

    09-11 4891-01 (3) ESP Control The ESP (Electronic Stability Program) has been developed to help a driver avoid danger of losing control of the vehicle stability due to understeer or oversteer during cornering. The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the vehicle conditions when the inner or outer wheels are spinning during oversteer, understeer or cornering.
  • Page 620 09-12 (4) Vehicle Control During Cornering The figure below shows the vehicle controls by the ESP system under various situations such as when the brake pedal is depressed or not depressed during cornering, when the ABS is operating and when braking without the ABS. It also includes the vehicle conditions when the TCS, a part of the ESP system, is operating.
  • Page 621 09-13 4891-01 3) HBA (Hydraulic Brake Assist System) (1) Purpose HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster.
  • Page 622 09-14 (2) Operation The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emergency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves.

  • Page 623: Schematic Diagram

    09-15 4891-01 4. SCHEMATIC DIAGRAM 1) Hydraulic Circuit Diagram When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4- sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4- channel method.
  • Page 624 09-16 (1) Hydraulic Circuit Diagram When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes, the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet valve are closed.
  • Page 625 09-17 4891-01 (2) Hydraulic Circuit of HBA The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels.
  • Page 626 09-18 (3) Hydraulic Circuit Diagrams in Conditions ▶Idling and Normal Braking Condition In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel via the separation valve and inlet valve.
  • Page 627 09-19 4891-01 ▶DUMP (ESP is working) Mode The pressure decreases just before the wheel speed drops and the wheels are locked. The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
  • Page 628 09-20 ▶HOLD (ESP is working) Mode The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more.
  • Page 629 09-21 4891-01 ▶RISE (ESP is working) Mode The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is operated. When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the corresponding wheel gets locked.

  • Page 630: Electric Circuit Diagram

    09-22 2) Electric Circuit Diagram ▶ Wheel speed sensor, Stop lamp switch, Self diagnostic connector, Warning lamp (ABS/ESP)
  • Page 631 09-23 4891-01 ▶ Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch...

  • Page 632: System Overview

    10-3 4891-01 1. SYSTEM OVERVIEW When braking suddenly or braking on slippery roads, the vehicle keeps moving forward but the wheels are locking and not rotating. If these happen, the vehicle may lose stability or rotate resulting in an accident. ABS helps to maintain directional stability and control of the vehicle. ABS is designed to secure more safety and increase the control of steering wheel during emergency braking situation.
  • Page 633 10-4 2) Maximum Brake Force FBmax = wheel load FR x coefficient of friction (Mh) The braking process cannot be described sufficiently accurately with the brake forces calculated. The values calculated only apply if the wheel is not locked. In the case of a locking wheel, the static friction turns into lower sliding friction, with the result that the stopping distance is increased.

  • Page 634: Components And Layout

    10-5 4891-01 2. COMPONENTS AND LAYOUT The basic functions of ABS system are same with previous version. However, the wheel speed sensing type is different from previous version. Rear Active Wheel Front Active Wheel Speed Sensor Speed Sensor ABS HECU Warning Lamps EBD warning lamp ABS warning lamp...

  • Page 635: Abs System Operation

    10-6 3. ABS SYSTEM OPERATION 1) Block Diagram...

  • Page 636: Ebd (Electronic Brake Force Distribution) System

    10-7 4891-01 2) EBD (Electronic Brake Force Distribution) System ▶System description As an add-on logic to the ABS base algorithm, EBD works in a range in which the intervention thresholds for ABS control are not reached yet. EBD ensures that the rear wheels are sensitively monitored for slip with respect to the front axle. If slip is detected, the inlet valves for the rear wheels are switched to pressure hold to prevent a further increase in pressure at the rear-wheel breaks, thus electronically reproducing a pressure-reduction function at the rear-wheel brakes.

  • Page 637: Hydraulic Circuit Diagram

    10-8 4. HYDRAULIC CIRCUIT DIAGRAM 1) Hydraulic Circuit of ABS The vehicle equipped only with the ABS controls the wheel’s braking force using three 3-channel 4-sensor method. The front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves.
  • Page 638 10-9 4891-01 2) ABS Circuit Per ABS Operation Range ▶Hydraulic Pressure Circuit when ABS is Not Operating The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that hydraulic pressure is delivered reduces gradually.
  • Page 639 10-10 ▶Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases. This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels.
  • Page 640 10-11 4891-01 3) Circuit Diagram...

  • Page 641: Specifications

    11-3 4610-00 1. SPECIFICATIONS Description Specification Type 4-spoke type Steering wheel Outer diameter (mm) Type Rack and pinion type Steering gear box 36.4° Inner Steering angle 31.5° Outer Type Vane type 90±3 Maximum pressure (kgf/cm2) Steering oil pump Ø115 Pulley size (mm) -40℃...
  • Page 642 11-4 2. TIGHTENING TORQUE Kgf·m N·m Description Steering column mounting bolt 2.0 ~ 2.5 19.6 ~ 24.5 Steering wheel and steering column shaft 4.0 ~ 6.0 39.2 ~ 58.8 lock nut Steering column shaft Steering wheel and air bag module 0.7 ~ 1.1 6.8 ~ 10.8 mounting bolt...
  • Page 643 11-5 4610-00 3. TROUBLESHOOTING Problem Possible Cause Action Movements of steering Unregular wear or binding of steering ball joint Lubricate or replace feels heavy due to lack of lubrication or foreign material insertion Damaged or defective steering gear Replace the steering gear assembly Incorrect steering pinion preload Adjust...
  • Page 644 11-6 Problem Possible Cause Action Excessive vibration of Broken steering linkage Replace steering wheel (shimming) Looseness of steering gear box Retighten Broken or binding of steering ball joint Replace Worn or damaged front wheel bearing Replace Damaged wheel or tire Repair or replace Defective suspension Repair or replace...
  • Page 645 11-7 4610-00 ▶ Free Play Check Start the engine and place the wheels at straight ahead direction. Turn the steering wheel until the tires starts to move and measure the distance on the circumference of the steering wheel. 30mm Free play If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage.
  • Page 646 11-8 ▶ Oil Level Check Check the fluid level on a level ground with the engine turned off. The fluid level should be between the MIN and MAX marks on the reservoir cap gauge. Place the vehicle on a level ground and start the engine and let it run at idle speed.
  • Page 647 11-9 4610-00 ▶ Air Bleeding The air bleeding should be done after servicing the power steering system and when the difference between two measurements (cooled and normal temperature) is prominent. Lift up the vehicle very carefully. Turn the steering wheel to its both ends several times and add the oil up to MAX line in the steering oil reservoir.
  • Page 648 11-10 ▶ Oil Pump Pressure Check Check the oil pump pressure to locate any defect in oil pump. Before checking the pressure, check the oil level and belt tension. Prepare the empty container to collect the spilled oil during the service.
  • Page 649 11-11 4610-00 Measure the oil pressure with the gauge valve fully open. 3 ~ 5bar Pressure at no load If the pump pressure is in specified range, the pump is normal. If not, replace the power steering pump Turn the steering wheel righ or left until it stops with the engine idling ans valve fully open.
  • Page 650 11-12 1. SYSTEM LAYOUT...
  • Page 651 12-3 4170-01 1. SPECIFICATION Description Specification Tire 16 inch 225/65R16 Tire inflation pressure 35psi Wheel 16 inch 6.5J * 16 Inner: Clip-on type Balance weight Outer: Clip-on type Tightening torquse of wheel bolt 127.4~156.8 Nm 2. WHEEL DESIGNS 16 inch: 225/65R/16 16 inch: 225/65R/16 2WD (6.5J * 16) P/TIME (6.5J * 16)
  • Page 652 12-4 1. OVERVIEW A radial tire uses a cord angle of 90 degrees. That is, the cord material runs in a radial or direct line from one bead to the other across the tread. In addition, a radial tire has a belt overwrap under the tread surface to provide greater structural stability.
  • Page 653 12-5 4170-01 2) Tire Unit Indication Aspect ratio (%) = Nominal section height (H) / Nominal section width (W) X 100 3) Tire Inflation Pressure (35 psi) Proper inflation pressure Excessive inflation pressure Low inflation pressure Tread width Tread width Tread width The contact area between the The contact area between the...

  • Page 654: Standing Wave

    12-6 2. ABNORMAL TIRE SYMPTOM 1) Standing Wave 35psi Specified tire inflation pressure During driving, the rotating tire repeats deformation and restoring movement in is tread. This happens when the tire pressure is low in high speed driving. However, when the wheel rotating speed is fast, the tire is deformed even before it is restored to its original shape and the trembling wave appears on the tread portion.
  • Page 655 12-7 4170-01 2) Hydro Planing When the vehicle is driven on a road surface covered with water at high speed, tires do not contact with the road surface but rotate floating on a thin film of water. It causes brake failure, lower traction force and losing the steering performance. To prevent this, increase the tire inflation pressure, use tires with leaf shape tread which is not worn.

  • Page 656: Wheel Balance

    12-8 3. WHEEL BALANCE If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic.

  • Page 657: System Layout And Components

    01-2 1. SYSTEM LAYOUT AND COMPONENTS Type Air cindotioner controller Sun load sensor - instrument panel upper left FATC Manual air conditioner It change sun load coming through front windshield into current to input to FATC controller. Compressor - engine right AQS/Air source selection switch Front air conditioner module assembly - inside instrument panel...
  • Page 658 01-3 6810-30 Condenser Sub-condenser - right wheel Recevier driver-condenser front right Instslled in front of vehicle and Condenses high temperature and Absorbs moisture in the condenses vapor refrigerant into high pressure vapor refrigerant into refrigerant and reserves low temperature and high low-temperature-high-pressure refrigerant to supply pressure liquid refrigerant...

  • Page 659: Ventilation System

    01-4 1) Ventilation System (1) Location of Vents Front Ventilation Rear Ventilation A/C vents Heater vents...

  • Page 660: Ventilation Modes

    01-5 6810-30 (2) Ventilation Modes Vent mode Bi-level mode Floor mode Defrost and floor mode Defrost mode Rear air conditioning mode...
  • Page 661 01-6 2) AIR CONDITIONER MODULE WIRING AND LAYOUT (1) Front Air Conditioner Module Wiring layout Components Air conditioner Evaporator filter Blower motor Air source selection door actuator Blower high speed relay Heater core...
  • Page 662 01-7 6810-30 (2) Rear Air Conditioner Module Wiring layout Components Roof air conditioner duct Blower motor Air mixer door actuator Rear floor heater duct Mixer door Evaporator Heater & air conditioner Heater core pipes...

  • Page 663: System Block Diagram

    01-8 2. SYSTEM BLOCK DIAGRAM ▶ A/C compressor OFF conditions Coolant temperature: over 115℃ Engine speed: over 4,500 rpm for more than 2 seconds Engine speed: below 650 rpm Maximum output due to abrupt acceleration Excessive acceleration Increased load during engine idling (to prevent the engine from shutting off) Refrigerant pressure: over 32 bar or below 2 bar Defects in A/C related system (refrigerant pressure sensor, coolant temperature sensor, cooling fan)
  • Page 664 01-9 6810-30 3. CIRCUIT DIAGRAM 1) FATC (Full Auto Temperature Control) ▶ D20DTR, PWM Motor, Coolant Fan(SUB) relay...
  • Page 665 01-10 ▶ GSL 3.2, Condenssor Fan Relay...
  • Page 666 01-11 6810-30 ▶ Front Blower, Motor (Mode, Circulation), In-car Sensor, Ambient/AQS Sensor...
  • Page 667 01-12 ▶ Rear Air Conditioner (Blower, Mode Actuator)

  • Page 668: Manual Air Conditioner

    01-13 6810-30 2) Manual Air Conditioner ▶ D20DTR, Motor (Mode, Intake, Air Mix, PWM)
  • Page 669 01-14 ▶ GSL 3.2, Condenssor Fan, Motor...
  • Page 670 01-15 6810-30 ▶ Blower Motor (Front, Rear), Rear Mode Actuator...
  • Page 671 02-3 8810-03 1. SPECIFICATIONS 1) SDM Description Specification Operating voltage 9 ~ 16V -30 ~ 85℃ Operating temperature Accelerometer dynamic range -50 ~ 50G Impact record Diagnostic Trouble Code * Energy reservation for 150 ms even after shutting off the power. 2) Seat Belt ▶Front Seat Belt Description...
  • Page 672 02-4 ▶Rear 1st Row Seat Belt Description Specification Remark · 2-point seat belt (ELR): Swivel seat · 3-point seat belt LH/RH (ELR) · Center seat belt: Fool proof type · 2-point seat belt LH/RH (ELR) 11-seaters (w/ · Length of webbing: 3,200 mm (3-point), ·...

  • Page 673: Operation

    02-5 8810-03 2. OPERATION 1) Air Bag ▶Air bag inflates when: · In response to a severe frontal impact, the driver’s and front passenger’s air bags deploy at the same time to supplement the seat belts to prevent or reduce any personal injuries. ▶Air bag can inflate when: ·...
  • Page 674 When the engine starts, the air bag warning lamp comes on for a system check. It goes out after 3 to 7 seconds when the system is normal. If this warning lamp stays ON, then the system may be defective. Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation.

  • Page 675: Major Replacement Parts After Air Bag Deployment

    Wash it out with cold and clean water and consult the doctor if irritation continues. When any repairs are needed for the steering wheel, or when an accident occurred without the air bag deployment, have the air bag system checked by Ssangyong Dealer or Ssangyong Authorized Service Operation.
  • Page 676 02-8 1. LAYOUT 1) Components Front Seat Belt Height Adjuster Passenger's Air Bag Passenger’s Air Bag Unit Driver’s Front Seat Foxed Type Buckle Belt Type Buckle Driver's Air Bag...
  • Page 677 02-9 8810-03 Pre-tensioner (Driver's/ Passenger's) Retractor Seat Belt (2-point) for rear 1st row seat (swivelled) Rear 1st Rear 3rd Rear 2nd Row Seat Row Seat Row Seat Center Seat in Rear Center Seat in Rear Center Seat in Rear 1st Row Seat 2nd Row Seat 3rd Row Seat...
  • Page 678 02-10 2) Seat Belt Arrangement Front Seat (3-point) Rear 1st Row Seat (3-point + 2-point) Rear 2nd Row Seat (3-point + 2-point) Rear 3rd Row Seat (3-point + 2-point)

  • Page 679: Circuit Diagram

    02-11 8810-03 2. CIRCUIT DIAGRAM...

  • Page 680: Layout And Components

    03-2 1. LAYOUT AND COMPONENTS 1) Components of Seat Seat Control Switch (Driver's Seat) Sliding control Seat position control Seat height control Reclining control Sliding adjust lever Seat warmer switch Back supporter (Driver’s seat) Back flat adjust lever...
  • Page 681 03-3 7410-01 Back folding adjust lever Headrest Rear 3rd Row Seatback Folding Lever Seat sliding adjust lever Seat swivel control lever...
  • Page 682 03-4 2. COMPOSITIONS OF SEAT BELT 1) 11 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point + 2 point) ▶ Rear 2nd row (3 point + 2 point) ▶ Rear 3rd row (3 point + 2 point)
  • Page 683 03-5 7410-01 2) 9 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point) ▶ Rear 2nd row (3 point) ▶ Rear 3rd row (3 point + 2 point)
  • Page 684 03-6 3) 7 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point) ▶ Rear 2nd row (3 point + 2 point)
  • Page 685 03-7 7410-01 3. SEAT LAYOUT 1) Layout - 11 Passengers · Front seat : Move 36 mm from the far end to the front · Rear 1st seat : Movable · Rear 2nd seat: Movable · Rear 3rd seat : Fixed...
  • Page 686 03-8 2) Layout - 9 Passengers · Front seat : Move 36 mm from the far end to the front · Rear 1st seat : Movable · Rear 2nd seat: Movable · Rear 3rd seat : Fixed...
  • Page 687 03-9 7410-01 3) Layout - 7 Passengers...
  • Page 688 03-10 4) Various Seat Arrangement ▶ Front seat & rear 1st seat : Semi full flat · Front seat : Move to the far front Back semi full flat · Rear 1st seat : Move to the far end · Rear 2nd seat: Move to the far end ·...
  • Page 689 03-11 7410-01 ▶ Rear 1st seat (when swiveled) · Rear 1st seat : Move to the far end Center seat jumping Swiveled · Rear 2nd seat: Move to the far end · Rear 3rd seat : Fixed ▶ Rear 1st swiveled and rear 2nd seat back folding while driving ·...
  • Page 690 03-12 ▶ Rear 1st seat swiveled and rear 2nd seat back folding (while parking) · Front seat : Move to the far front · Rear 1st seat : Middle Center seat jumping Swiveled · Rear 2nd seat: Middle / Back folding ·...
  • Page 691 03-13 7410-01 ▶ 5 passengers with loading · Front seat : Move 36 mm from the far end to the front · Rear 1st seat : Move to the far end · Rear 2nd seat: Middle · Rear 3rd seat : Double folding ▶...
  • Page 692 03-14 5) Entry Way Rear 1st seat : Folding center seat Rear 2nd seat : Folding center seat Rear 3rd seat : Fixed...
  • Page 693 03-15 7410-01 6) Sliding of Rear 1st and 2nd Seat - 4 rail (1.610mm) for rear 1st and 2nd seat sliding - Rail mounting : Floor bolt type...
  • Page 694 03-16 7) Operation of Front Seat(Driver's Seat) (1) Components The descriptions in this chapter are based on the driver’s seat and rear 1st seat. Seat warmer connector Seat position Seat position (up/down (front up/down motor) rail) Seat position (up/down rail) Sliding rail Seat position (rear up/down...
  • Page 695 03-17 7410-01 (2) Operation of seat Sliding Seat moves from front to rear controllde by sliding control switch Seat cushion angle adjustment (front end) Front side of seat moves up/down controlled by seat position control switch Seat cushion angle adjustment (rear end) Rear side of seat moves up/down controlled by seat...
  • Page 696 03-18 Seat cushion height adjustment Seat moves up/down controlled by seat height control switch Seatback reclining Seat back reclining controlled by seat reclining control switch...
  • Page 697 03-19 7410-01 (3) Operation of center seat When seating When jumping Pull up the center seat when to jump Push down the center seat when to seat...
  • Page 698 03-20 (4) OPERATION OF REAR SEAT ▶ Rear 1st seat (swivel seat) Seat back folding cable Seat back flat cable Jumping mechanism Sliding cable Sliding lever Swivel lever...
  • Page 699 03-21 7410-01 (5) Operation of rear seat (Rear 1st and 2nd seat) ▶ Seat sliding Front Rear...
  • Page 700 03-22 (6) Seat back flat - When to recline or to flat fully. Rear 1st Rear 2nd (7) Seat back folding - Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table. Rear 1st/2nd seat...
  • Page 701 03-23 7410-01 (8) Seat swing (Rear 1st seat) - Turn around seat as the swing lever is pulled. (9) Rear 3rd seat Pull the lever behind back seat to fold the back seat. - As the seat is folded, disconnect hook and spread out the board...
  • Page 702 04-3 7340-01 1. SUNROOF LAYOUT...
  • Page 703 04-4 2. COMPONENTS OF SUNROOF...

  • Page 704: Components And Locations

    04-5 7340-01 3. COMPONENTS AND LOCATIONS Drain hose Control switch Sun shade & glass Control unit Sun roof motor...

  • Page 705: Sunroof Operation

    04-6 4. SUNROOF OPERATION 1) Tilting Push the front side of the button when the glass is closed then, mtor actuate the operating cable to lift up the glass. Push the rear side of the button to put down the glass.
  • Page 706 04-7 7340-01 2) Sliding push the rear side of the button to slide the door back. Motor actuates the operating cable Mechanical equipment slides the glass back and forth...
  • Page 707 04-8 5. CIRCUIT DIAGRAM...

  • Page 708: Body Interior

    05-3 7630-01 1. BODY INTERIOR 1) Storage Boxes Overhead console Glove box Front door map pocket CD carrier & Coin box Center console Seatback pocket...

  • Page 709: Convenient Devices

    05-4 2) Convenient Devices Ticket holder Front cup holder Front cigarette lighter Seatback table Power outlets Power outlet Rear cup holders Tea table...

  • Page 710: Assist Grips

    05-5 7630-01 3) Assist Grips (1) On passenger side ceiling (2) On B-pillar (3) On ceiling above rear seats Above rear 2nd seat Above rear 1st seat...

  • Page 711: Ovm Tools

    05-6 4) OVM Tools - The OVM tool box is located under the floor in luggage compartment. - OVM Tools...
  • Page 712 06-3 7870-01 1. LAYOUT AND COMPONENTS Hood Assembly Roof Rack Front Bumper Assembly Outside Rearview Mirror Front Door Rear Door...
  • Page 713 06-4 Rear Spoiler Tailgate Rear Bumper Assembly Sunroof Assembly...
  • Page 714 07-3 5110-01 1. MAJOR EXTERNAL DIMENSIONS Top View Side View Front View Rear View...
  • Page 715 07-4 2. JACK POINTS * Rear jack point * Front jack point Be sure to lift the vehicle only on the designated jack point otherwise, the vehicle could be body damaged.

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