Chassis PDF
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Damir MilisaChassis PDF
Uploaded by
Damir MilisaGENERAL INFORMATION
00
TABLE OF CONTENTS
DIMENSIONS ........................................................... 3
SPECIFICATIONS .................................................... 4
VEHICLE IDENTIFICATION ...................................... 6
MAINTENANCE SCHEDULE ................................... 9
RECOMMENDED FLUIDS AND LUBRICANTS ...... 11
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DIMENSIONS
GENERAL
Unit: mm
Top View
Side View
Front View Rear View
* ( ) : Optional
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SPECIFICATIONS
Descriptions D20DT D27DT
General Overall length (mm) 4,660 4,660
Overall width (mm) 1,880 1,880
Overall height (mm) 1,740 (1,755: with roof rack) 1,740 (1,755: with roof rack)
Gross vehicle weight (kg) A/T 2,530 2,530
M/T 2,530 2,530
Curb vehicle weight (kg) A/T 2WD: 1,920 / 4WD: 2,028 4WD: 2,071
M/T 2WD: 1,893 / 4WD: 2,001 4WD: 2,030
Fuel Diesel Diesel
Fuel tank capacity ( ) 75 75
Engine Engine name D20DT D27DT
Numbers of cylinders/Compression ratio 4 / 17.5:1 5 / 18:1
Total displacement (cc) 1,998 2,696
Camshaft arrangementMax. power DOHC DOHC
Max. power A/T 141 ps / 4,000 rpm 165 ps / 4,000 rpm
M/T 141 ps / 4,000 rpm 165 ps / 4,000 rpm
Max. torque A/T 310 Nm / 1,800 ~ 2,750 rpm 340 Nm / 1,800 ~ 3,250 rpm
M/T 310 Nm / 1,800 ~ 2,750 rpm 340 Nm / 1,800 ~ 3,250 rpm
Idle speed 750 ± 20 rpm 750 ± 20 rpm
Cooling system Water- cooled / forced circulation Water- cooled / forced circulation
Coolant capacity ( ) 11.5 11.5
Lubrication type Gear pump, forced circulation Gear pump, forced circulation
Max. oil capacity ( ) 8.2 9.2
Turbocharger and cooling type Turbocharger, air-cooled Turbocharger, air-cooled
Manual Operating type Semi- Remote control, Semi- Remote control,
Transmission floor change type floor change type
Gear ratio 1st 4.315 4.315
2nd 2.475 2.475
3rd 1.536 1.536
4th 1.000 1.000
5th 0.807 0.807
Reverse 3.919 3.919
Automatic Model Electronic, 5-speed Electronic, 5-speed
Transmission Operating type Floor change type Floor change type
* ( ) Optional
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GENERAL
Descriptions D20DT D27DT
Automatic Gear ratio 1st 3.951 3.595
Transmission 2nd 2.423 2.186
3rd 1.486 1.405
4th 1.000 1.000
5th 0.833 0.831
Reverse 1st 3.147 3.167
Reverse 2nd 1.930 1.926
Transfer Case Model Part-time Part-time
Type Planetary gear type Planetary gear type
Gear ratio High (4H) 1.000 : 1 1.000 : 1
Low (4L) 2.483 : 1 2.483 : 1
Clutch (M/T) Operating type Hydraulic type Hydraulic type
Disc type Dry single diaphragm type Dry single diaphragm type
Power Type Rack and pinion Rack and pinion
Steering Steering angle Inner 36.2° 36.2°
Outer 32.4° 32.4°
Front Axle Drive shaft type Ball joint type Ball joint type
Axle housing type Build-up type Build-up type
Gear ratio M/T 4.27 3.91
A/T 3.54 3.31
Rear Axle Drive shaft type 5-Link type Semi-floating type Semi-floating type
Independent type Independent type Independent type
Axle housing type Build-up type Build-up type
Gear ratio M/T 4.27 3.91
A/T 3.54 3.31
Brake Master cylinder type Tandem type Tandem type
Booster type Vacuum assisted booster type Vacuum assisted booster type
Brake type Front wheels Disc type Disc type
Rear wheels Drum (disc) Drum (disc)
Parking brake Cable type (internal expansion) Cable type (internal expansion)
Suspension Front suspension Wishbone + coil spring Wishbone + coil spring
Rear suspension Solid axle suspension 5-link + coil spring 5-link + coil spring
Air Conditioner Refrigerant (capacity) R-134a (650 ± 30g) R-134a (650 ± 30g)
Electrical Battery type / Capacity (V-AH) MF / 12 - 90 MF / 12 - 90
Starter capacity (V-kW) 12 - 2.2 12 - 2.2
Alternator capacity (V-A) With PTC: 12 - 140 With PTC: 12 - 140
(With FFH: 12 - 115) (With FFH: 12 - 115)
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VEHICLE IDENTIFICATION
Chassis Number Certification Label
The chassis number is stamped on the frame The certification label is located on the driver’s
behind the front right tire. door sill.
Engine Number (D20DT) Engine Number (D27DT)
The engine number is stamped on the lower
area of cylinder block in the intake manifold
side.
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GENERAL
1. Vehicle Identification Number
Vehicle identification number (VIN) is is on the right
front axle upper frame.
[KPTS0A1KS5P 122357]
K .. Nation (K: Korea)
P .. Maker Identification (P: Ssangyong Motor Company)
T .. Vehicle Type (T: Passenger car - 4WD)
S .. Line Models (S: Kyron)
0 .. Body Type (0: 5-door)
A .. Trim Level (A: Standard, B: Deluxe,
C: Super deluxe)
1 .. Restraint System (0: No seatbelts, 1: 3-point
seatbelts, 2: 2-point seatbelt)
K .. Engine Type (9: 3199cc, In-line 6 cylinders, Gasoline E32)
(K: 1998cc - common rail direct injection (D20DT),
F: 2696cc - common rail direct injection (D27DT))
S .. Check Digit (S: All area except North America)
5 .. Model Year (3: 2003, 4: 2004, 5: 2005)
P .. Plant Code (P: Pyungtaek plant)
122357 (Production serial number)
2. Certification Label
The certification label is affixed on the bottom of driver’s
side B-pillar.
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3. Engine Serial Number
The engine serial number is stamped on the lower area of cylinder block in intake manifold side.
D20DT D27DT
4. Manual Transmission Number
The transmission label is affixed on the upper area of
clutch housing.
5. Automatic Transmission Number
The transmisson label is affixed on the right area of trans-
mission housing.
6. Transfer Case Number
The transfer case label is affixed on the transfer case
housing.
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MAINTENANCE SCHEDULE
GENERAL
General
* Use only approved Ssangyong genuine parts.
Daily Weekly
Descriptions Check Check Service Interval
Engine Oil and Oil Filter Initial change: 5,000 km, change every 10,000 km or 12 months
–
(But, shorten the service interval under severe conditions)
Coolant Change every 60,000 km or 3 years. And, inspect and replen-
–
ish as necessary.
Additional Water Separator: Inspect 10,000 km, change every 150,000 km or 5 years
– –
A.W.S.
Brake / Clutch Fluid – Change every 2 years (Inspect frequently)
Brake Pipes and Hoses Initial check: 1,000 km, periodic check: every 20,000 km or 1
– –
year, replace as necessary.
Brake Pad, Shoe, and Disc Periodic check: every 10,000 km, adjust or replace as
– –
necessary.
Air Cleaner Element Initial clean: 5,000 km, clean every 10,000 km, replace every
– 30,000 km (But, shorten the service interval under severe
conditions)
Fuel Filter Replace every 25,000 km (Draining water from fuel filter:
– –
every 10,000 km)
Automatic Transmission Inspect every 10,000 km or 6 months (But change every
– –
Fluid 60,000 km under severe conditions)
Manual Transmission Fluid Inspect 10,000 km, change every 60,000 km (Frequent check
– –
of oil leak)
Transfer Case Fluid Inspect 10,000 km, change every 60,000 km (Frequent check
– –
of oil leak)
Axle Oil Front – – Inspect frequently, change every 30,000 km
Rear – – Inspect frequently, change every 30,000 km
Air Conditioner Filter Change every 10,000 km (But, shorten the service interval
– –
under severe conditions)
Severe Conditions in Engine Severe Conditions in Automatic Transmission and Axle
1. Frequent stop-and-go traffic, extended idling, short driv- 1. Towing a trailer or off-road driving
ing distance below 6 km, driving distance below 16 km 2. Taxi, patrol service or delivery service (extended idling
when the outside temperature remains below freezing and excessive driving with low speed)
2. Driving in hilly or mountainous terrain, sandy or dusty
area Severe Conditions in Air Conditioner Filter
3. High load driving such as trailer towing 1. Pollutant area or off-road driving, extended air condi-
tioner or heater operation
Sever Conditions in Air Cleaner Element
1. Pollutant area or off-road driving
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EU ONLY
* Use only approved Ssangyong genuine parts.
Daily Weekly
Descriptions Check Check Service Interval
Engine Oil and Oil Filter Change every 15,000 km or 12 months (But, shorten the
–
service interval under severe conditions)
Coolant Change every 60,000 km or 3 years. And, inspect and
– replenish as necessary.
Brake / Clutch Fluid – Change every 2 years (Inspect frequently)
Brake Pipes and Hoses Periodic check: every 15,000 km or 1 year, replace as
– –
necessary.
Brake Pad, Shoe, and Disc Periodic check: every 15,000 km, adjust or replace as
– –
necessary.
Air Cleaner Element Clean every 15,000 km, replace every 30,000 km
–
(But, shorten the service interval under severe conditions)
Fuel Filter Replace every 30,000 km (Draining water from fuel filter:
– –
every 10,000 km)
Automatic Transmission Inspect every 15,000 km or 12 months (But change every
– –
Fluid 60,000 km under severe conditions)
Manual Transmission Fluid Inspect 15,000 km, change every 60,000 km (Frequent check
– –
of oil leak)
Transfer Case Fluid Inspect 15,000 km, change every 60,000 km (Frequent check
– –
of oil leak)
Axle Oil Front – – Inspect frequently, change every 30,000 km
Rear – – Inspect frequently, change every 30,000 km
Air Conditioner Filter Change every 10,000 km (But, shorten the service interval
– –
under severe conditions)
Severe Conditions in Engine Severe Conditions in Air Conditioner Filter
1. Frequent stop-and-go traffic, extended idling, short driv- 1. Pollutant area or off-road driving, extended air condi-
ing distance below 6 km, driving distance below 16 km tioner or heater operation
when the outside temperature remains below freezing
2. Driving in a hilly or mountainous terrain, sandy, or dusty Sever Conditions in Air Cleaner Element
area 1. Pollutant area or off-road driving
3. High load driving such as trailer towing
* EU Countries
Severe Conditions in Automatic Transmission and Axle 1. Only countries that belong to EU. (It does not apply to
1. Towing a trailer or off-road driving all countries in EU.)
2. Taxi, patrol service or delivery service (extended idling
and excessive driving with low speed)
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RECOMMENDED FLUIDS AND LUBRICANTS
GENERAL
Capacity
Descriptions Specifications
D20DT D27DT
Engine Oil Ssangyong genuine engine oil
7.5 8.5
(Approved by MB Sheet 229.1 or 229.3)
Engine Coolant 11.5 11.5 Ssangyong genuine coolant
Automatic Transmission Fluid 8.0 8.0 Shell AFT 3353 or Fuchs AFT 3353
Manual Transmission Fluid 4WD: 3.6 4WD: 3.6 Ssangyong genuine oil (ATF DEXRON II)
2WD: 3.4
Transfer Case Fluid 1.3 1.3 Ssangyong genuine oil (ATF DEXRON III)
Axle Oil Front Automatic Ssangyong genuine oil
1.4 1.4 ~ 1.5
Transmission (API GL-5 or SAE 80W/90)
Manual 1.4 1.4
Transmission
Rear Solid Axle Ssangyong genuine oil
1.9 2.2
Suspension (API GL-5 or SAE 80W/90)
Brake/Clutch Fluid As required As required Ssangyong genuine oil (DOT4)
Power Steering Fluid 1.0 1.0 Ssangyong genuine oil (ATF DEXRON III)
NOTICE
• Use only Ssangyong recommended fluids and lubricants.
• Do not mix any different types or brands of oils or fluids. This may cause damages.
• Keep the specified levels when adding or replacing the fluids.
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AUTOMATIC TRANSMISSION
(DC 5-SPEED)
3650 / 3660 / 3110
TABLE OF CONTENTS
GENERAL INFORMATION ...................... 2 SPECIAL TOOLS AND EQUIPMENT .... 68
1. Overview .............................................................. 2
VALVE BODY .......................................... 72
AUTOMATIC TRANSMISSION
(DC 5-SPEED) .......................................... 4 HYDRAULIC CIRCUIT ........................... 80
1. Appearance ......................................................... 4 1. Hydraulic circuit diagram .................................. 80
2. Structure and specifications ............................... 5 2. Hydraulic circuit ................................................ 85
3. Power flow ......................................................... 11 3. Adapter plug ..................................................... 91
4. Valve body ......................................................... 93
FUNCTION AND DESCRIPTION ........... 19
1. Selector lever .................................................... 19 TCU (Transmission Control Unit) ........ 99
2. Torque converter ................................................ 24
3. Planetary gear set ............................................ 27 TROUBLE CODE AND DIAGNOSIS ... 104
4. Multiple-disc clutch .......................................... 28 1. Trouble diagnosis with SCAN-100 .................. 104
5. Freewheel ......................................................... 29 2. DTC (Diagnosis Trouble Code) of DC5AT ....... 105
6. Others ............................................................... 30 3. Removal and installation of TCU .................... 112
REMOVAL AND INSTALLATION ........... 33
1. Selector lever and link ...................................... 33
2. Front and rear propeller shaft ........................... 36
3. Transmission assembly .................................... 38
4. Replacing the o-ring on parking pawl guide
sleeve ................................................................ 42
5. Disassembly and reassembly
(DC 5-SPEED A/T) ............................................ 46
6. Valve body ......................................................... 65
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GENERAL INFORMATION
1. OVERVIEW
DC 5-speed Automatic Transmission Assembly T-Tronic DC 5-speed automatic transmission is an elec-
tronically controlled 5-speed transmission with a lockup
clutch in the torque converter. The ratios for the gears are
realized by three planetary gear sets. The 5th gear is de-
signed with a step-up ratio of 0.83 as an overdrive. The
selector lever is controlled by electronically and
mechanically. The gears are shifted by the corresponding
combination of three hydraulically actuated multiple-disc
brakes, three hydraulically actuated multiple-disc clutches
and two mechanical one-way clutches. This electronically
controlled automatic transmission adjusts the operat-
ing pressure to provide proper shifting in relation to engine
power. This function improves shifting quality significantly.
And, the driver can select “S” (Standard) mode or “W”
(Winter) mode according to the driving conditions.
Instrument Panel
TCU Assembly
TCCU
TCU
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A/T
M / T
Releasing Lock-up Solenoid Valve Standard Mode / Winter Mode
T/C
CLUTCH
AXLE
* When the gear selector lever cannot be moved
“S” mode is used in normal driving.
from “P” position to other positions, manually
release the lock-up function as shown in figure. When “W” mode is selected, the vehicle
SP
starts from 2nd gear (forward and
reverse) to achieve smooth starting on
the slippery road.
ST’NG
BRAKE
A / BAG
A / CON
Selector Lever
Downshift (Manual Mode) Upshift (Manual Mode)
1 ← 2 ← 3 ← 4 ←D 1 → 2 → 3 → 4 →D
The shiftable gear is down The shiftable gear is up by
by one step as the lever one step as the lever is
is moved to left (-) moved to right (+)
direction. direction.
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AUTOMATIC TRANSMISSION (DC 5-SPEED)
1. APPEARANCE
Left Side
With Torque Converter Without Torque Converter Rear View
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3650 5
2. STRUCTURE AND SPECIFICATIONS
A/T
Structure
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
This sectional drawing is based on DC 5-speed A/T 2WD model. 4WD model has also same structure.
1. Torque converter 7. Disc brake B3 13. Freewheel F2
2. Oil pump 8. Disc clutch C3 14. Center planetary gear set
3. Input shaft 9. Disc brake B2 15. Electric control unit (valve body)
4. Disc brake B1 10. Output shaft 16. Freewheel F1 (Front planetary gear set)
5. Disc clutch C1 11. Parking lock gear 17. Stator shaft
6. Disc clutch C2 12. Intermediate shaft 18. Converter lockup clutch
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Specifications
5-Speed Automatic Transmission
Item
D20DT D27DT
Input torque 2WD (580 Nm), 4WD (400 Nm)
Weight (including ATF) 76 kg (2WD), 78 kg (4WD)
Diameter (torque converter) 270 mm
Lockup function Yes
Gear ratios 1st 3.951 3.595
2nd 2.423 2.186
3rd 1.486 1.405
4th 1.000 1.000
5th 0.833 0.831
Rev. 1st: S / Rev. 2nd: W 3.147/1.93 3.167/1.926
Driving type 2WD/4WD
Fluid specification Fuchs ATF 3353 or Shell ATF 3353
Fluid capacity Approx. 8
Selector lever position P.R.N.D Mechanical
D+/D- Electrical
Parking lock system Brake switch
(signal) → TGS lever
Selected lever indication P.R.N.D Lever position
4, 3, 2, 1 CAN
Oil temperature sensor Resistance: R, D 0.5 ~ 2.5 kΩ
TCU EGS 52
Shift solenoid valve (25°C) Resistance 3.8 ± 0.2 Ω
Operating distance 0.2 mm
Operating current 1.5 ~ 2 A
M/P, S/P solenoid valve (23°C) Resistance 5.0 ± 0.2 Ω
Operating distance 0.6 mm
Operating current 0 ~ 1.2 A
Lockup solenoid valve (25°C) Resistance 2.5 ± 0.2 Ω
Operating distance 0.2 mm
Operating current 1.5 ~ 2.0 A
Operating range 3rd to 5th gears
Speed sensor Type HALL type
Operating voltage 6V
Start lockout switch Switch contact ON (D, R position)
Switch contact OFF (P, N position)
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A/T
Item 5-Speed Automatic Transmission
Mode switch W (Winter)
S (Standard)
M / T
One-way clutch F1, F2
Planetary gear set Number of planetary gear set
4, 4, 4
pinion (Front, Center, Rear)
T/C
Disc clutch C1 Single side friction plate
C2 Double side friction plate
CLUTCH
C3 Single side friction plate
Disc brake B1 Single side friction plate
B2 Double side friction plate
AXLE
B3 Double side friction plate
SP
ST’NG
BRAKE
A / BAG
A / CON
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Characteristics of Automatic Transmission
Performance Curve
D20DT
Standard Mode WINTER Mode (2WD)
Upshift: Lockup Mode (Open/Slipping)
Downshift:
Lockup (slipping):
Unlock (open):
FAST OFF:
Dynamic shift zone:
FAST OFF: When abruptly releasing the accelerator
pedal, the transmission remains at 4th gear other than
4 →5 shift (when slowly releasing the accelerator pedal,
the transmission is shifted to 5th gear).
Dynamic shift zone:
When operating the accelerator pedal ( ), the 4 → Low Mode (4WD)
3 shift is completed by kick-down signal after comple-
tion of 4 → 3 shift (100% of pedal position). When
promptly operating the accelerator pedal ( ), the 4 →
3 shift is done in shaded area (93% of pedal position).
4th gear: 1.000
5th gear: 0.833
Rev. 1st gear: 3.147
Rev. 2nd gear: 1.93
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A/T
D27DT
M / T
Standard Mode
Upshift:
T/C
Downshift:
Lockup (slipping):
Unlock (open):
CLUTCH
FAST OFF 4-5
FAST OFF:
Dynamic shift zone:
A
FAST OFF: When abruptly releasing the accelerator
AXLE
FAST OFF 3-4
pedal, the transmission remains at 4th gear other than
4 → 5 shift (when slowly releasing the accelerator
pedal, the transmission is shifted to 5th gear).
C 5-4
SP
FAST OFF 2-5
Dynamic shift zone:
B
4-5
When operating the accelerator pedal ( ), the 4 →
4-3
3 shift is completed by kick-down signal after comple-
ST’NG
3-4 tion of 4 → 3 shift (100% of pedal position). When
promptly operating the accelerator pedal ( ), the 4 →
3-2
2-3 3 shift is done in shaded area (93% of pedal position).
BRAKE
FAST OFF 1-2
2-1
1-2 4th gear: 1.000
5th gear: 0.831
A / BAG
0
20 40 60 80 100
Rev. 1st gear: 3.167
PEDAL VALUE (%) Rev. 2nd gear: 1.926
A / CON
Lockup Mode (Open/Slipping) WINTER Mode
5rd GEAR OPEN
5-4
4-5
5rd GEAR SLIPPING
4rd GEAR OPEN 4-3
3-4
2-3 3-2
4rd GEAR SLIPPING
3rd GEAR OPEN
3rd GEAR SLIPPING 0
20 40 60 80 100
PEDAL VALUE (%)
0
20 40 60 80 100
PEDAL VALUE (%)
CHANGED BY AUTO TRANSMISSION
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General Characteristics
Characteristic Function and Effect
Slope recognition Slope is recognized based on engine RPM and accelerator pedal position.
(down hill, up hill) → Delays up shift
Engine torque reduction Ignition timing is delayed to reduce torque at all shifting moments.
→ Improves shift quality
Engine rpm limitation Engine rpm is limited until the gears are fully engaged when shifting from “N” to “D”.
→ Prevents shift shock
ESP Operation When the ESP is controlling the engine torque, shifting is not available and vehicle
starts off with 2nd gear.
→Cannot use kick-down function and shift at maximum rpm
ABS Operation Brake control is not affected.
Fast-off function It is not shifted up when accelerator pedal is abruptly released.
→To get engine brake effect during cornering
Altitude recognition As altitude increases (atmospheric pressure reduces), engine torque decreases. To
compensate this torque reduction, shift up occurs when depressing the accelerator
pedal more than usual operation (adjusting shift diagram).
→Improves driving performance and increases torque
Oil temperature If transmission fluid temperature is too low, the shifting point gets delayed in full throttle
and kick down.
→Improves driving performance
Hydraulic pressure is When starting the engine with cycling the ignition switch (“OFF” and “ON”) due to
produced in emergency transmission trouble, the selector lever should be placed in “P” position. If starting
driving mode the engine with selector lever “N” position, the lever should be moved into “P” position.
The selector valve changes the path of hydraulic pressure in selector lever “P” position.
→ The hydraulic pressure flows to direct operation mode via “R” and “D”
valve to operate “reverse 2nd” and “forward 2nd” gear.
Adaptation Function to optimize the shifting quality.
→Compensates the shifting quality according to play and wear
Torque
converter Flywheel
lockup clutch
Torque Automatic Final drive Output
Engine torque
converter transmission gear torque
Multiple disc Multiple disc
clutch brake
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3. POWER FLOW
A/T
Sectional View
Brake B1 Brake B3 Brake B2
M / T
(disk) assembly (disk) assembly (disk) assembly
T/C
CLUTCH
AXLE
SP
ST’NG
C1 (Disk clutch) C2 (Disk clutch) C3 (Disk clutch)
assembly assembly assembly
BRAKE
A / BAG
A / CON
Shifting Elements
Gear C1 C2 C3 B1 B2 B3 F1 F2
3) 3)
1
3)
2
3
4
3)
5
P/N 1)
P/N 2)
3)
R 1)
R 2)
1) Selector program switch: S mode 2) Selector program switch: W mode 3) Overrun
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 3650
1st Gear (D20DT: 3.951, D27DT: 3.595)
Input Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
A. Engine speed F. Locking elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
D. 2nd gear ratio
1. Input shaft: Clockwise rotation
2. Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed
3. Rear ring gear: Counterclockwise rotation
4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed
5. Center ring gear: Clockwise rotation
6. Center sun gear: Locked by B2, Rotation with reduced speed
7. Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2 Lockup clutch
3) 3)
1
3) Overrun
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 13
2nd Gear (D20DT: 2.423, D27DT: 2.186)
A/T
M / T
T/C
CLUTCH
A B C D E
AXLE
SP
Output
ST’NG
BRAKE
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Locking elements P. Impeller
A / BAG
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
A / CON
1. Input shaft: Clockwise rotation
2. Sun gear and planetary gear carrier: Clockwise rotation by C1 activation
3. Rear ring gear: Clockwise rotation
4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed
5. Center ring gear: Clockwise rotation
6. Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed
7. Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2
3)
2
3) Overrun
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 3650
3rd Gear (D20DT: 1.486, D27DT: 1.405)
Input Output
16. Torque converter lockup clutch D. Locking elements P. Impeller
A. Engine speed H. Rear planetary gear set T. Turbine wheel
B. Transmission, input shaft L. Stator V. Front planetary gear set
C. 1st gear ratio M. Center planetary gear set
1. Input shaft: Clockwise rotation
2. Front ring gear: Clockwise rotation
3. Center ring gear: Clockwise rotation by clutch 2 activation (direct connection)
4. Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed
5. Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2
3
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 15
4th Gear (1.000)
A/T
M / T
T/C
CLUTCH
AXLE
SP
Output
ST’NG
BRAKE
16. Torque converter lockup clutch L. Stator T. Turbine wheel
A. Engine speed M. Center planetary gear set V. Front planetary gear set
A / BAG
B. Planetary gear set P. Impeller
A / CON
1. Input shaft: Clockwise rotation
2. Front ring gear: Clockwise rotation
3. Center ring gear and rear planetary gear carrier: Clockwise rotation
4. Front sun gear and planetary gear carrier: Clockwise rotation (direct connection)
5. Rear ring gear: Clockwise rotation
6. Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
7. Center sun gear: Clockwise rotation by C3 activation
8. Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection)
9. Output shaft: Clockwise rotation
Gear C1 C2 C3 B1 B2 F1 F2
4
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 3650
5th Gear (D20DT: 0.833, D27DT: 0.831)
Output
16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set
A. Engine speed F. Locking elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
D. 2nd gear ratio
1. Input shaft: Clockwise rotation
2. Front sun gear: Locked by B1, Planetary gear carrier: Rotation with reduced speed
3. Rear planetary gear ring gear: Clockwise rotation with reduced speed
4. Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation
5. Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear
(increased speed)
6. Center sun gear: Clockwise rotation with increased speed by clutch C3 activation
7. Center planetary gear carrier: Clockwise rotation (increased speed)
8. Output shaft: Clockwise rotation (increased speed)
Gear C1 C2 C3 B1 B2 B3 F1 F2
3)
5
3) Overrun
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 17
Reverse 1st Gear (D20DT: 3.147, D27DT: 3.167) - Standard (S) Mode
A/T
M / T
T/C
CLUTCH
AXLE
Output
SP
Input
ST’NG
BRAKE
16. Torque converter lockup clutch E. Locking elements M. Center planetary gear set
A. Engine speed F. Locking elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
A / BAG
C. 1st gear ratio L. Stator V. Front planetary gear set
D. 2nd gear ratio
A / CON
1. Input shaft: Clockwise rotation
2. Front ring gear: Clockwise rotation
3. Front sun gear: Locked by one-way clutch F1
4. Front planetary gear carrier: Clockwise rotation (reduced speed)
5. Rear planetary gear ring gear: Clockwise rotation
6. Rear planetary gear carrier: Locked by B3
7. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
8. Center ring gear: Locked by B3
9. Center planetary gear carrier: Counterclockwise rotation (reduced speed)
10. Output shaft: Counterclockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2
3)
R (S)
3) Overrun
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 3650
Reverse 2nd Gear (D20DT: 1.93, D27DT: 1.926) - Winter (W) Mode Mode
Input Output
16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set
A. Engine speed E. Locking elements P. Impeller
B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel
C. 1st gear ratio L. Stator V. Front planetary gear set
1. Input shaft: Clockwise rotation
2. Front ring gear: Clockwise rotation
3. Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
4. Rear ring gear: Clockwise rotation
5. Rear planetary gear carrier and center ring gear: Locked by brake B3
6. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
7. Center planetary gear carrier: Counterclockwise rotation (reduced speed)
8. Output shaft: Counterclockwise rotation
Gear C1 C2 C3 B1 B2 B3 F1 F2
R (W)
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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68 3650
SPECIAL TOOLS AND EQUIPMENT
Name and Part Number Application
126 589 01 62 00 (W99360220B) Removal/installation of torque converter
Handle
116 589 06 59 00 (W99360180B) Fixing automatic transmission
Fixing plate
140 589 12 15 00 (P99360041C) Installation of sealing ring
Drift punch
001 589 50 33 00 (P99420041B) Removal and installation of transmission
Puller housing ball bearing
AUTO TRANSMISSION CHANGED BY
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3650 69
A/T
Name and Part Number Application
M / T
140 589 34 63 00 (A99360030B) Fixing automatic transmission
Mounting plate
T/C
CLUTCH
AXLE
140 589 06 34 00 (P99360031C) Removal and installation of transmission
Collet chuck housing ball bearing
SP
ST’NG
BRAKE
140 589 13 43 00 (P99360021C) Removal and installation of B1, B2 and
Piston puller B3 pistons
A / BAG
A / CON
126 589 02 09 00 Removal and installation of
Socket collar nut for output shaft
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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70 3650
Name and Part Number Application
128 589 04 31 00 (W99360242C) Measuring the clearance
Measuring bridge between ball bearing and
parking lock gear
Compressor Compressing clutch and disc
brake
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 71
A/T
* Tool for ATF checking only
Name and Part Number Name and Part Number
M / T
126 589 12 63 00 (W99360282A) 210 589 00 71 00 (P99360012C)
Funnel Hand pipe
T/C
CLUTCH
AXLE
140 589 15 21 00 140 589 49 63 00
Dipstick gauge Filling pipe
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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72 3650
VALVE BODY
Shift Pressure Control Solenoid Valve
8 9
7 7
A B C D
10
E F
1. Leaf spring 7. Leaf spring and socket bolt 9. Solenoid valve
2. Contact spring 8. Solenoid valve C. Shift pressure control solenoid valve
3. Conductor track A. 1-2, 4-5 shift solenoid valve D. Modulating pressure control solenoid valve
4. O-ring B. 3-4 shift solenoid valve 10. Solenoid valve
5. O-ring E. Lockup PWM solenoid valve
6. Shift plate F. 2-3 shift solenoid valve
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 73
A/T
Function
M / T
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. Speed sensor, start lock-out
switch and oil temperature sensors are integrated in EHU.
The 13-pin connector is connected to automatic transmission via PCB.
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
T/C
The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against
the valve body by the leaf springs.
CLUTCH
Characteristics of up/downshift solenoid valve
I
The solenoid valve remains energized and therefore open (Current)
AXLE
until the shift process is completed according to the engine
and transmission conditions. If a solenoid valve is energized,
it opens and transmits the shift valve pressure to the corre- 2.5A
sponding command valve.
SP
Working current 1.5 ~ 2.0 A
Operating distance 0.2 mm 1.5A
ST’NG
Resistance 3.91 ± 0.12 Ω (25°C)
60ms T (Time)
BRAKE
1 cycle time: approx 20 ms
Circuit Diagram
A / BAG
A / CON
B3 (38)
3-4 shift S/V 2-3 shift S/V 1-2, 4-5 shift S/V
B12 (14)
B10 (16)
B11 (15)
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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74 3650
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring 4. MP control solenoid valve
2. Shift plate 5. SP control solenoid valve
3. Strainer
Function
These valves control the modulating pressure and the shift pressure by applying appropriate current to solenoid
valves according to driving condition of engine and transmission. When the current value from TCU is high or low,
accordingly the regulated pressure decreases or increases.
Working current 0 ~ 1.2 A
Operating distance 0.6 mm
Resistance 5.0 ± 0.3 Ω (23°C)
Line pressure
Regulated
pressure
Regulated pressure
Drain line
Drain line Line pressure
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 75
Circuit Diagram
A/T
M / T
B3 (38)
T/C
CLUTCH
B4 (37)
B5 (36)
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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76 3650
Lockup Solenoid Valve
1. Leaf spring 3. Shift plate
2. O-ring
Function
This valve activates and releases the lockup clutch by ad- Working current 1.5 ~ 2.0 A
justing the current to solenoid valve according to engine
throttle opening value and output shaft speed. Operating distance 0.2 mm
The lockup clutch operates in 3rd, 4th and 5th gear step Resistance 2.5 ± 0.2 Ω (25°C)
by step in order to reduce shift shocks. Operating range 3, 4, 5
Circuit Diagram
B3 (38)
Lockup S/V
11
B9 (17)
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3650 77
Speed Sensor
A/T
M / T
T/C
CLUTCH
Speed Speed
sensor (n3) sensor (n2)
AXLE
1. Leaf spring 3. Pulse ring
2. Valve body
SP
Function
The speed sensors are fixed to the shell of the hydraulic
Gear N2 N3
control unit via the contact tabs. A leaf spring, which rests
ST’NG
against the valve body, presses the speed sensors against 1 •
the transmission housing. This ensures a precise distance 2 • •
between speed sensors and impulse rings. The speed sen- 3 • •
BRAKE
sor (n3) detects the speed of the front sun gear and the
speed sensor (n2) detects the speed of the front planetary 4 • •
carrier. 5 • -
If the speed sensor is defective, the transmission is oper- R (S mode) • -
A / BAG
ated in emergency driving mode. Below diagram shows the
detection of speed sensor.
R (W mode) • •
A / CON
Circuit Diagram
B6 (35)
B13 (13)
Speed Speed B14 (12)
sensor sensor
n3 n2
B8 (33)
CHANGED BY AUTO TRANSMISSION
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AFFECTED VIN
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78 3650
Oil Temperature Sensor
Oil temperature sensor
Function
The oil temperature sensor is installed in the hydraulic control unit and is connected in series with the starter lock-out
contact.
This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed.
The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil
temperature, shift operations can be optimized in all temperature ranges.
Circuit Diagram
Start lock out switch
B7 (34)
AD converter
B8 (33)
Oil temperature sensor
AUTO TRANSMISSION CHANGED BY
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3650 79
Starter Lock-out Switch
A/T
M / T
T/C
CLUTCH
AXLE
SP
1. Plunger 3. Reed contact
2. Permanent magnet
ST’NG
Function
The starter lock-out switch is installed beside the oil temperature sensor and is actuated by a cam rail, which is
BRAKE
located on the latching plate.
In the selector lever positions “P” and “N”, the permanent magnet is moved away from the reed contact. This opens
the reed contact and the transmission control module receives an electrical signal. The transmission control module
A / BAG
activates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions
“P” and “N” via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the
switch contact is closed and the starter cannot be operated.
A / CON
Circuit Diagram
B+
ST Start lock out switch
B7 (34)
AD converter
B8 (33)
30 86
Start Oil temperature sensor
Relay
87 85 A12 (7)
Start motor
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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3650 85
2. HYDRAULIC CIRCUIT
A/T
Selector Lever “N”
M / T
T/C
CLUTCH
3-4 shift
solenoid
valve
AXLE
SP
8
ST’NG
BRAKE
A / BAG
1. Selector valve B2a : B2 piston
5. 3-4 holding pressure shift valve B2b : Opposite face of B2 piston
6. 3-4 command valve m : Annular surface
A / CON
7. 3-4 shift pressure shift valve p-A : Operating pressure
8. 3-4 overlap control valve p-Mod : Modulating pressure
10. Ball valve p-RV : Control valve pressure
13. Ball valve p-S : Shift pressure
14. 1-2/4-5 command valve p-S/RMV : Shift pressure/control solenoid valve
19. Shift pressure control valve p-SV : Shift valve pressure
27. B2 shift valve
The operating pressure (p-A) is formed and travels via the 2-3 holding pressure shift valve, the 2-3 command valve
and ball valve (13) to clutch C3 and via the 3-4 command valve (6) to the end face of the 3-4 shift pressure shift valve
(7). At the same time, the 3-4 solenoid valve is energized. This allows shift valve pressure (p-SV) to enter the spring
chamber of the shift valve B2 (27) and to reach the end face of the 3-4 command valve (6).
The shift valve B2 (27) is held in the upper position and the 3-4 command valve (6) moves towards the right. At the end
face of the 3-4 shift pressure shift valve (7), the operating pressure (p-A) is replaced by shift valve pressure (p-SV).
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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86 3650
Hydraulic Circuit when Selector Lever is in “D” Position (Shift Phase)
3-4 shift
solenoid
valve
1. Selector valve B2a : B2 piston
5. 3-4 holding pressure shift valve B2b : Opposite face of B2 piston
6. 3-4 command valve m : Annular surface
7. 3-4 shift valve p-A : Operating pressure
8. 3-4 overlap control valve p-Mod : Modulating pressure
10. Ball valve p-RV : Control valve pressure
13. Ball valve p-S : Shift pressure
14. 1-2/4-5 command valve p-S/RMV : Shift pressure/control solenoid valve
19. Shift pressure control valve p-SV : Shift valve pressure
27. B2 shift valve
The selector valve (1) opens the shift pressure (p-S) feed connection from the ball valve (10) with the shift valve B2
(27). With the shift valve B2 (27) in the upper position, shift pressure (p-S) travels behind the piston B2 (B2a) and
simultaneously to the opposite face of the piston B2 (B2b). The brake B2 begins to activate.
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 87
Hydraulic Circuit when Selector Lever is in “D” Position (1st Gear)
A/T
M / T
T/C
3-4 shift
solenoid
CLUTCH
valve
AXLE
8
SP
ST’NG
BRAKE
1. Selector valve B2a : B2 piston
5. 3-4 holding pressure shift valve B2b : Opposite face of B2 piston
A / BAG
6. 3-4 command valve m : Annular surface
7. 3-4 shift valve p-A : Operating pressure
8. 3-4 overlap control valve p-Mod : Modulating pressure
A / CON
10. Ball valve p-RV : Control valve pressure
13. Ball valve p-S : Shift pressureShift pressure
14. 1-2/4-5 command valve p-S/RMV : Shift pressure/control solenoid valve
19. Shift pressure control valve p-SV : Shift valve pressure
27. B2 shift valve
32. Pressure holding valve
The pressure on the opposite face of the piston B2 (B2b) ensures a soft activation of the brake B2. The TCU monitors
the activation sequence via the speed of input shaft, which slows down as the frictional connection in the brake
increases. When the speed drops to the specified level, TCU shuts off the power to the 3-4 shift solenoid valve. The
spring chamber of the shift valve B2 (27) is depressurized and moves downwards. This connects the line to the
opposite face of the piston B2 (B2b) with the pressure holding valve (32). The pressure on the opposite face of the
piston B2 (B2b) drops to a residual pressure. The 3-4 command valve (6) moves to the left. The operating pressure
(p-A) travels via the holding pressure shift valve (5) and the 3-4 command valve (6) to the piston of brake B2 (B2a).
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
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88 3650
Hydraulic Circuit after Shifted to 1st Gear
1-2/4-5 shift solenoid valve
14. 1-2/4-5 command valve 0 : Return flow to oil sump
15. 1-2/4-5 holding pressure shift valve p-A : Operating pressure
16. 1-2 /4-5 shift valve p-MOD : Modulating pressure
18. 1-2/4-5 overlap control valve p-S : Shift pressure
p-SV : Shift valve pressure
The end face of 1-2/4-5 command valve (14) is kept unpressurized via the 1-2/4-5 solenoid valve. The operating
pressure is applied to the brake B1 via the holding pressure shift valve (15). The clutch C1 is unpressurized. The
operating pressure from brake B1 acts against the holding pressure shift valve (15) and the end face of 1-2/4-5 shift
pressure shift valve (16).
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3650 89
Hydraulic Circuit During Shift Phase (2nd Gear)
A/T
1-2/4-5 shift solenoid valve
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
14. 1-2/4-5 command valve o : Return flow to oil sump
15. 1-2/4-5 holding pressure shift valve p-A : Operating pressure
A / BAG
16. 1-2/4-5 shift valve p-MOD : Modulating pressure
18. 1-2/4-5 overlap control valve p-S : Shift pressure
p-SV : Shift valve pressure
A / CON
The shift valve pressure (p-SV) is directed onto the end face of the 1-2/4-5 command valve (14) via the 1-2/4-5 shift
solenoid valve. The command valve (14) moves up and the shift pressure (p-S) coming from the 1-2/4-5 shift pressure
shift valve (16) is routed via the command valve (14) to clutch C1. Overlap pressure is simultaneously applied to
brake (B1) from the pressure overlap control valve (18). The B1 pressure acting on the end face of shift pressure shift
valve (16) is replaced by operating pressure (p-A). The increasing shift pressure (p-S) on clutch C1 acts on the
annular surface of the pressure overlap control valve (18) and reduces the overlap pressure controlled by the pressure
overlap control valve (18). It will shift at a corresponding pressure on the holding pressure shift valve (15).
CHANGED BY AUTO TRANSMISSION
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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90 3650
Hydraulic Circuit after Completed Gear Change (2nd Gear)
1-2/4-5 shift solenoid valve
14. 1-2/4-5 command valve o : Return flow to oil sump
15. 1-2/4-5 holding pressure shift valve p-A : Operating pressure
16. 1-2/4-5 shift valve p-MOD : Modulating pressure
18. 1-2/4-5 overlap control valve p-S : Shift pressure
p-SV : Shift valve pressure
The 1-2/4-5 shift solenoid valve interrupts the pressure on the end face of the command valve (14) and it returns to its
base position. The operating pressure (p-A) is now applied to clutch C1 via the holding pressure shift valve (15) and
the command valve (14). The brake B1 is disengaged (unpressurized). The spring of the shift pressure shift valve (16)
moves it into base position.
AUTO TRANSMISSION CHANGED BY
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AFFECTED VIN
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3. ADAPTER PLUG
A/T
The adapter plug is an input and output terminal assembly for TCU to control the valve body. It is installed to the valve
body with 7 mm bolts. To prevent oil leakage, two O-rings are installed on the plug.
M / T
1. Remove the heat shield for adapter plug wire next to exhaust tube.
T/C
CLUTCH
AXLE
SP
ST’NG
2. Turn the adapter plug lock counterclockwise and disconnect the plug connector.
BRAKE
A / BAG
A / CON
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3. Unscrew the bolts (7 mm) and carefully remove the adapter plug.
NOTICE
• Keep the specified tightening torque (4 Nm ± 0.5 Nm). Otherwise, it may result in unnecessary replacement of
electric kit in assembly due to oil leakage.
• Do not apply an excessive force to remove the adapter plug. It may cause an internal damage to electrci kit.
4. Place an empty container under the adapter plug and remove the adapter plug.
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4. VALVE BODY
A/T
Valve body can be replaced from onboard and from removed transmission.
Valve Body Assembly
M / T
T/C
CLUTCH
AXLE
SP
Modulating 1-2/4-5 Shift pressure
3-4 shift solenoid
ST’NG
pressure solenoid valve
solenoid valve valve
Shift pressure
BRAKE
Valve body solenoid valve
A / BAG
A / CON
Electric kit
2-3 shift Lock-up PWM
solenoid valve solenoid valve
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Valve Body Replacement (Onboard)
1. Remove the oil pan drain plug and drain the oil completely.
2. Unscrew the six oil pan bolts (T30) and carefully lower the oil pan (6).
3. Carefully remove the oil filter.
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A/T
4. Unscrew the fixing bolts (T30).
M / T
T/C
CLUTCH
AXLE
5. Carefully remove the valve body from transmission housing.
SP
ST’NG
BRAKE
A / BAG
A / CON
Valve Body Assembly
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Valve Body Replacement (From Removed T/M)
Preceding Works: Install the transmission on the
workbench.
NOTE
• To eliminate unnecessary working time and process,
prepare general tools, special tools, and gaskets be-
fore starting the work.
• The automatic transmission is very precise
equipment. Keep the transmission clean and tighten
the bolts with specified tightening torque.
1. Unscrew the hexagon bolt (7 mm) and remove the guide
bush from transmission housing.
Installation Notice
Tightening torque 4 Nm
2. Unscrew the oil pan bolts and remove the oil pan.
Installation Notice
Tightening torque 8 Nm
3. Remove the oil filter.
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4. Unscrew the bolts and remove the valve body from
transmission housing.
A/T
Installation Notice
Tightening torque 8 Nm
M / T
T/C
CLUTCH
5. Disassemble the valve body assembly.
AXLE
SP
ST’NG
BRAKE
5-1. Unscrew the socket bolts on the solenoid valve and
remove the leaf springs.
Installation Notice
A / BAG
Tightening torque 8 Nm
NOTICE
A / CON
• The length of socket bolts vary. Be careful not to mix
up.
5-2. Remove the solenoid valves from the valve body.
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NOTICE
• Make sure to install the solenoid valves in place
• Check the O-rings, and replace if necessary.
5-3. Remove the electronic control module from the shift
plate.
NOTICE
• Correctly align the electronic control module onto the
shift plate by using two central pins when installing.
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TCU (Transmission Control Unit)
A/T
Function
M / T
TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and
switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit.
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
TCU
A / BAG
1. Shifting Method
A / CON
Basic shift operation includes up-shift and down-shift for all gear groups. The shift control unit determines driving
resistance, accelerator pedal position, vehicle speed and some parameters (road surface condition, up hill and down
hill gradients, trailer driving conditions, catalytic converter conditions, driving habits and automatic transmission oil
temperature) to select a shift gear.
2. Down Shift
When engine speed increases excessively, the down shift does not occur. To get an engine brake effect during
downhill driving, the current gear is maintained in speed control mode.
3. Engine RPM Adjustment
During shifting, the engine torque is reduced to optimize the shift operation by delaying the ignition time.
4. Lock-Up Clutch Control
The lockup clutch in torque converter is activated in 3rd, 4th and 5th gear and operates in sequence via PWM
solenoid valve.
5. Others
The transmission is automatically controlled to compensate durability and wear.
The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are
permanently saved and the diagnosis is partially available.
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TCU Block Diagram
Engine torque M/P S/V
Max. Engine torque S/P S/V
Engine power loss
Engine rpm Power supply (valves)
Engine
Sol.
control ACC pedal position 1-2/4-5 gears S/V
valve
Shift pattern changes 3-4 gears S/V
Engine control status D 2-3 gears S/V
Engine torque reduction Lockup clutch S/V
I
G
Wheel speed FR, FL
T
Sensor power supply
ABS/ C I
Wheel speed RR, RL Sensor
ESP Sensor ground
HECU Shift pattern changes T
Driving force control
A
Start signal Starter
A L
C relay
Trouble diagnosis
Pos. ID signal
Selector
connector
lever W/S mode signal
Position
unit N2 speed
T/M
N N3 speed
U
Back-up
lamp Diagnosis Diag.
Conn.
TCU(EGS) power
IGN1
W/S mode signal P/N starting recognition
Selector lever indication
I/P
Mileage TCU(EGS) ground Power
ground
* Refer to the circuit diagram for the detailed wiring connection and related pin number.
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Characteristics of TCU and Automatic Transmission (LHM: Limp-Home
A/T
Mode)
The emergency driving mode is to minimize the vehicle’s operation, which is a mode for maintaining minimum driving
condition if the automatic transmission is defective. In emergency driving mode, excessively long driving and unrea-
M / T
sonable driving should be avoided to prevent a critical fault occurence in advance.
Emergency driving mode can largely be divided in electrical defective and hydraulic pressure/mechanical defective.
T/C
Electrical defect
1. If an electrical defective occurs in transmission during driving, current shift gear position is held.
CLUTCH
1) Shut off of various solenoid valves
2) Internal pressure in transmission increases (shift shock gets bigger when changing selector lever due to
maximized MP and SP)
3) Lockup clutch is released
AXLE
2. If the shift operation cannot be activated, the driver must reset the system as follows:
1) Stop the vehicle and place the selector lever to “P” position.
SP
2) Wait for 10 seconds after stopping the engine (release hydraulic pressure)
3) Start the engine.
4) Place the selector lever to “D” or “R” position.
ST’NG
Mechanical/hydraulic pressure defect
BRAKE
1. Characteristics that appears in the vehicle are as below:
1) Holds at 3rd gear (It can be held at proper gear if the fault occurs at 3rd gear)
2) Electrical devices operate normally and the shift shock is acceptable during shift operation.
A / BAG
2. If the shift operation cannot be activated, the driver must reset the system as follows:
1) Stop the vehicle.
A / CON
2) Stop the engine.
3) In most cases, it is reset when the engine is started and the vehicle operate normally.
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CAN (Controller Area Network)
Function
CAN Input Signal CAN Output Signal
Accelerator pedal position Selected gear
Wheel speed (all wheels) Shifted status
Engine rpm, Engine torque Lock-up clutch status
Coolant temperature
Downshift Driving position
Speed control (constant) TCU Engine torque control
2nd gear start up control Dangerous status (changes to
Gear status in transfer case emergency mode when
overloading, dangerous conditions,
Selector lever position
and internal fault exists)
Odometer (I/P)
ATF Temperature
Kick-down status
Circuit Diagram
A18 (1)
Self diagnostic 11
B1 (41)
B2 (40)
5 4
Instrument panel Selector lever unit
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Connector Arrangement and Pin Functions
A/T
Connector 1 10 12 17
M / T
Connector A Connector B
T/C
CLUTCH
23 30 33 38 L H
TCU (Connector connection)
A18 A9 B14 B9
AXLE
SP
A8 A1 B8 B1
ST’NG
Connector A Connector B
Pin No.
BRAKE
Description Connected to
DC No. EWD No.
1 A18 Diagnostic Diagnostic connector pin No.11
7 A12 Initiating the starter relay Starter relay
A / BAG
12 B14 Speed sensor N2 13-pin plug No.3
13 B13 Speed sensor voltage supply 13-pin plug No.7
A / CON
14 B12 1-2, 4-5 solenoid valve 13-pin plug No.13
15 B11 3-4 solenoid valve 13-pin plug No.9
16 B10 2-3 solenoid valve 13-pin plug No.8
17 B9 Lockup clutch solenoid valve 13-pin plug No.11
29 A2 TCU voltage supply -
30 A1 Ground -
33 B8 Speed sensor ground 13-pin plug No.12
34 B7 ATF temperature, Starter lock-out contact 13-pin plug No.4
35 B6 Speed sensor N3 13-pin plug No.1
36 B5 Modulating pressure solenoid valve 13-pin plug No.2
37 B4 Shift pressure solenoid valve 13-pin plug No.10
38 B3 Each solenoid valve voltage 13-pin plug No.6
L B2 CAN LOW ECM, HECU, selector lever unit, instrument panel
H B1 CAN HIGH ECM, HECU, selector lever unit, instrument panel
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TROUBLE CODE AND DIAGNOSIS
1. TROUBLE DIAGNOSIS WITH SCAN-100
Diagnostic Connector
Scan-100 Diagnosis Procedure
1. Connect the Scan-100 harness connector to the diag-
nostic socket.
2. Turn the ignition switch to “ON” position.
3. Select [TROUBLE CODE] in [FUNCTION SELECTION]
screen and press [ENTER].
4. Select [KYRON] in [VEHICLE SELECTION] screen and
press and press [ENTER].
5. Select [TCU] in [CONTROL UNIT SELECTION] screen
and press [ENTER].
6. Select DC 5-speed transmission.
7. Select [SELF-DIAGNOSTICS] in [SELECT TEST ITEM]
screen.
8. Determine the DTC and locate the trouble cause.
NOTE
• Choose “data list” item to check sensors and other
informative data.
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2. DTC (DIAGNOSIS TROUBLE CODE) OF DC5AT
A/T
Trouble
Defectives Action
Code
P2000 Faulty TCU internal watchdog test - Self-diagnosis with IGN ON.
M / T
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P2001 Faulty TCU internal watchdog - Self-diagnosis.
T/C
function - Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P2002 Faulty TCU external watchdog test - Self-diagnosis with IGN ON.
CLUTCH
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P2003 Faulty TCU external watchdog func- - Self-diagnosis.
tion
AXLE
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P2004 Faulty TCU Clock - Self-diagnosis.
- Cycle the IGN switch from OFF to ON. Check and
SP
replace TCU if the trouble still exists.
P2005 Faulty TCU RAM - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and
ST’NG
replace TCU if the trouble still exists.
P2006 Faulty TCU RAM CAN-Controller 1 - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and
BRAKE
replace TCU if the trouble still exists.
P2007 Faulty TCU RAM CAN-Controller 2 - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
A / BAG
P2008 Faulty TCU ROM - Self-diagnosis with IGN ON.
- When the TCU internal checksum is different from
scanner checksum.
A / CON
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P200A Faulty TCU EEPROM - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and
replace TCU if the trouble still exists.
P200B Faulty TCU CPU (internal) - Self-diagnosis.
- Check harness contact.
P200C Faulty TCU program control - Self-diagnosis.
- Check harness contact.
P2010 No TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is not exist.
- Check again after TCU coding.
P2011 Faulty TCU variant coding - Self-diagnosis with IGN ON.
- When the TCU coding is faulty.
- Check again after TCU coding.
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Trouble
Defectives Action
Code
P2012 Faulty TCU checksum - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace
TCU if the trouble still exists.
P2013 Faulty TCU (internally) - Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace
TCU if the trouble still exists.
P2100 Defective 1-2, 4-5 shift solenoid valve - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve
(turn the IGN OFF, then and disconnect TCU connector).
• TCU connector terminals: B12 (14), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered emergency mode when the defective is
detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2101 1-2, 4-5 shift solenoid valve - short - When 1-2 or 4-5 shift solenoid valve is defective.
- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn
the IGN OFF, then disconnect TCU connector).
• TCU connector terminals: B12 (14), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2102 Defective 2-3 shift solenoid valve - When 2-3 shift solenoid valve is defective.
- Measure the resistance of 2-3 shift solenoid valve (turn the
IGN OFF, then disconnect TCU connector).
• TCU connector terminals: B12 (14), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2103 2-3 shift solenoid valve - short - When 2-3 shift solenoid valve is defective.
- Measure the resistance of 2-3 shift solenoid valve (turn the
IGN OFF, then disconnect TCU connector).
• TCU connector terminals: B12 (14), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered mechanical emergency mode when the defective is
detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
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Trouble
Defectives Action
A/T
Code
P2104 Defective 3-4 shift solenoid valve - When 3-4 shift solenoid valve is defective.
- Measure the resistance of 3-4 shift solenoid valve (turn the
IGN OFF, then disconnect TCU connector).
M / T
• TCU connector terminals: B11 (15), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered mechanical emergency mode when the defective is
T/C
detected.
• Fixed at 2nd gear in “D” range.
CLUTCH
- Check the related harness for open, short and contact.
P2105 3-4 shift solenoid valve - short - When 3-4 shift solenoid valve is defective.
- Measure the resistance of 3-4 shift solenoid valve (turn the
IGN OFF, then disconnect TCU connector).
AXLE
• TCU connector terminals: B11 (15), B3 (38)
• Specified value : 3.8 ± 0.2 Ω
- Triggered mechanical emergency mode when the defective is
detected.
SP
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
ST’NG
P2106 Defective lockup clutch solenoid valve - Measure the resistance of lockup clutch solenoid valve (turn
the IGN OFF, then disconnect TCU connector).
• TCU connector terminals: B9 (17), B3 (38)
• Specified value : 2.5 ± 0.2 Ω
BRAKE
- Triggered emergency mode when the defective is
detected.
• Fixed at 2nd gear in “D” range.
A / BAG
- Check the related harness for open, short and contact.
P2107 Defective modulator pressure solenoid - Measure the resistance of modulator pressure solenoid valve
valve (turn the IGN OFF, then disconnect TCU connector).
A / CON
• TCU connector terminals: B5 (36), B3 (38)
• Specified value : 5.0 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2108 Defective shift pressure solenoid valve - Measure the resistance of shift pressure solenoid valve (turn
the IGN OFF, then disconnect TCU connector).
• TCU connector terminals: B4 (37), B3 (38)
• Specified value : 5.0 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
• Electrical error : Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
CHANGED BY AUTO TRANSMISSION
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Trouble
Defectives Action
Code
P2200 Faulty speed sensor N2 signal - When the speed sensor N2 detects 0 rpm of front sun
gear speed.
- Check the related harness for open, short and contact.
• TCU connector terminal B14: rectangular wave signal
B8: signal ground
B13: 6V
P2203 Faulty speed sensor N3 signal - When the speed sensor N3 detects 0 rpm of planetary
gear carrier speed.
- Check the related harness for open, short and contact.
• TCU TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P220A Abnormal speed sensor output signal - When the rpm difference between speed sensor N2 and
(N2, N3) N3 is over 150 rpm.
- Check the related harness for open, short and contact.
P2220 T/M Oil temperature sensor - short - Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
- T/M Measure the resistance of oil temperature sensor.
• TCU connector terminals B7, B8
- Check the related harness for open, short and contact.
P2221 Abnormal T/M oil temperature sensor - Turn the IGN OFF, then disconnect TCU connector.
signal - Selector lever position: R or D
- Measure the resistance of T/M oil temperature sensor.
• TCU connector terminals: B7, B8
- Check the related harness for open, short and contact.
P2222 Abnormal T/M oil temperature sensor - Turn the IGN OFF, then disconnect TCU connector.
signal - Selector lever position : R or D
- Measure the resistance of T/M oil temperature sensor.
• TCU connector terminals: B7, B8
- Check the related harness for open, short and contact.
P2300 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector.
- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
• Specified value : approx. 120 Ω
- Turn the IGN OFF, then disconnect TCU connector.
P2301 Faulty CAN communication - Check the communication line for open, short and
contact.
- Measure the resistance of CAN line: B1, B2
• Specified value : approx. 120 Ω
P2310 CAN: Faulty brake system communica- - Check CAN communication line H and L.
tion - Check ABS/ESP unit.
- Check the related harness for open, short and contact.
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Trouble
Defectives Action
A/T
Code
P2311 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
M / T
- Check the related harness for open, short and contact.
P2312 CAN: Faulty ECU communication - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
T/C
P2313 CAN: Faulty selector lever control - Check CAN communication line H and L.
communication - Check selector lever.
CLUTCH
- Check the related harness for open, short and contact.
P2315 CAN: Faulty instrument panel commu- - Check CAN communication line H and L.
nication - Check instrument cluster.
AXLE
- Check the related harness for open, short and contact.
P2317 CAN: Faulty communication between - Check CAN communication line H and L.
TCCU/TOD and CAN - Check TCCU/TOD unit.
(For 4WD only)
- Check the related harness for open, short and contact.
SP
P2330 CAN: Faulty brake system signal - Check CAN communication line H and L.
- Check ABS/ESP unit.
- Check the related harness for open, short and contact.
ST’NG
P2331 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
BRAKE
P2332 CAN: Faulty ECU message - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
A / BAG
P2333 CAN: Faulty selector lever signal - Check CAN communication line H and L.
- Check selector lever. Check selector lever.
- Check the related harness for open, short and contact.
A / CON
P2335 CAN: Faulty instrument cluster signal - Check CAN communication line H and L.
- Check instrument cluster.
- Check the related harness for open, short and contact.
P2337 CAN: Faulty TCCU/TOD - Check CAN communication line H and L.
(For 4WD only) - Check TCCU/TOD unit.
- Check the related harness for open, short and contact.
P2400 CAN: Faulty rear RH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel
speed sensor. (Air gap: 0.309 ~ 0.958 mm)
• Check the numbers of tooth wheel: 48
- Check the related harness for open, short and contact.
CHANGED BY AUTO TRANSMISSION
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Trouble
Defectives Action
Code
P2401 CAN: Faulty rear LH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel
speed sensor. (Air gap: 0.309 ~ 0.958 mm)
• Check the numbers of tooth wheel: 48
- Check the related harness for open, short and contact.
P2402 CAN: Faulty front RH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel
speed sensor. (Air gap: 0.335 ~ 0.945 mm)
• Check the numbers of tooth wheel: 48
P2403 CAN: Faulty front LH wheel speed - Check CAN communication line H and L.
sensor signal - Check ABS/ESP unit.
• Check wheel speed sensor connector.
• Check the air gap between tooth wheel and wheel
speed sensor. (Air gap: 0.335 ~ 0.945 mm)
• Check the numbers of tooth wheel: 48
P2404 CAN: No brake signal - Check CAN communication line H and L.
- Check ABS/ESP unit.
- Check the related harness for open, short and contact.
P2405 CAN: No accelerator pedal signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
P2406 CAN: No engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
P2407 CAN: No ESP signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
P2408 CAN: No minimum engine torque - Check CAN communication line H and L.
signal - Check engine ECU.
- Check the related harness for open, short and contact.
P2409 CAN: No maximum engine torque - Check CAN communication line H and L.
signal - Check engine ECU.
- Check the related harness for open, short and contact.
P240A CAN: No engine rpm signal - Check CAN communication line H and L.
- Check engine ECU.
- Check the related harness for open, short and contact.
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Trouble
Defectives Action
A/T
Code
P240B CAN: No engine coolant temperature - Check CAN communication line H and L.
signal - Check engine ECU.
M / T
- Check the related harness for open, short and contact.
P240C CAN: No selector lever position signal - Check CAN communication line H and L.
- Check selector lever.
- Check the related harness for open, short and contact.
T/C
P240D CAN: No transfer case position signal - Check CAN communication line H and L.
(For 4WD only) - Check TCCU/TOD unit.
CLUTCH
- Check the related harness for open, short and contact.
P2500 Invalid transmission gear ratio - Cycle the IGN switch from OFF to ON. Check A/T system
again after a certain period of driving.
- If the trouble still exists, replace A/T assembly.
AXLE
- To protect transmission, any shift is not available.
P2501 Excessive engine rpm - Check CAN communication line H and L.
- Check engine ECU.
SP
- Check the related harness for open, short and contact.
P2503 Faulty recognition of currently selected - Check selector lever.
gear - Check the related harness for open, short and contact.
ST’NG
P220B Excessive N2, N3 rpm - Check speed sensor N2 and N3.
P2510 Torque converter lockup clutch stuck - Check the hydraulic lines for leaks (valve No.22 in valve
BRAKE
body).
- Check the resistance of lockup clutch solenoid valve
(Turn the IGN OFF, then disconnect TCU connector).
A / BAG
• TCU connector terminals B9 (17), B3 (18)
• Specified value : 2.5 ± 0.2 Ω
- Triggered emergency mode when the defective is detected.
A / CON
• Fixed at 2nd gear in “D” range.
- Check the related harness for open, short and contact.
P2511 Faulty torque converter lockup heat - Check the hydraulic lines for leaks.
control
P2520 Faulty recognition of torque reduction - Check ECU.
P2502 Poor gear mesh, transmission slip - Check the hydraulic lines for leaks.
- Check oil filter.
P2600 Too low TCU supply voltage - Check TCU supply voltage.
P2601 Too high TCU supply voltage - Check TCU supply voltage.
P2602 Abnormal solenoid valve supply - Check solenoid supply voltage.
voltage
P2603 Abnormal speed sensor supply - Check speed sensor supply voltage.
voltage • TCU connector terminals B13 (13) : 6V
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3. REMOVAL AND INSTALLATION OF TCU
1. Disconnect the negative battery cable.
2. Slide the drive’s seat and fold up the carpet.
3. Unscrew the two bolts (10 mm) on TCU.
Installation Notice
Tightening torque 10 Nm
4. Disconnect the TCU connect and remove the TCU.
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MANUAL TRANSMISSION
3170
TABLE OF CONTENTS
GENERAL INFORMATION ...................................... 3
1. Overview and characteristics of manual transmission ........... 3
2. Manual transmission system ................................................5
MANUAL TRANSMISSION ................................... 10
1. Location .............................................................................. 10
2. System components ........................................................... 11
3. Shifting mechanism ............................................................ 19
4. Diagnostic information and procedures ............................... 26
5. Removal and installation ..................................................... 30
6. Disassembly and reassembly ............................................. 36
7. Inspection/maintenance ...................................................... 67
8. Special tools and equipment ............................................... 70
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3170 3
GENERAL INFORMATION
A/T
1. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION
M / T
SYSTEM COMPONENTS
Inside
T/C
CLUTCH
AXLE
SP
ST’NG
Front View
BRAKE
A / BAG
A / CON
Features
1. All gears use the helical type and high strength 4. The synchronizing devices are installed in 1/2, 3/4,
materials. 5/R gears. To prevent the double engagement, the
independent interlock devices are installed.
NOTE
• The helical type gear prevents the axial gear miss- NOTE
ing and provides less noise. • TSM54/52 transmission uses the inertia lock type
key to make smooth gear engagement and to pro-
vide silent gear engagement.
2. The semi-remote control type gear shift mechanism
is used to prevent incorrect shifting.
5. The clutch release system is available to use CSC
3. To improve the shifting performance, 3-piece double
(Concentric Slave Cylinder) or Fork type according
cone is used for 1/2 shift.
to the vehicle model.
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Specifications
Description Specifications (D20DT, D27DT)
Length (mm) 628.3 mm
Distance between shafts (mm) 81 mm
Input torque (kg-m) 34.7 kg-m (340 Nm)
Transmission control type Semi-remote
Weight (kg) - not including transmission fluid 44 kgm
Gear ratio/Gear teeth 1st gear 4.315
(input gear: main gear) 2nd gear 2.475
3rd gear 1.536
4th gear 1.000
5th gear 0.807
Reverse gear 3.919
Transmission fluid Specification ATF DEXRON II
Capacity ( ) 3.6 / 3.4 (4WD / 2WD)
Change interval Inspect at every 10,000 km, replace at every 60,000 km
(add or replace if necessary)
Tightening Torque
Description Tightening Torque
1. Oil drain plug & filler plug 40 ~ 50 Nm
2. Backup lamp switch (24 mm) 30 ~ 40 Nm
3. Extension housing bolt (14 mm) 42 ~ 57 Nm
4. Extension housing spring plug (27 mm) 70 ~ 100 Nm
5. Neutral switch 30 ~ 40 Nm
6. Shift top cover bolt (12 mm) 17 ~ 26 Nm
7. Concentric slave cylinder adapter bolt 10 ~ 16 Nm
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2. MANUAL TRANSMISSION SYSTEM
A/T
Neutral Switch
M / T
T/C
CLUTCH
0.5 mm
AXLE
N (Neutral) Switch 0.5 mm
SP
Outside N Switch Inside N Switch
ST’NG
BRAKE
A / BAG
A / CON
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Function of N Switch
1. Aids a smooth start of the vehicle by raising the RPM during the gear shifting when the engine is cold.
When the vehicle is trying to start from the stopped state (vehicle speed below 3 km/h), the N switch determines the
shifting timing by using the clutch switch and the N switch. It raises the engine RPM (100 ~ 200 rpm). Operation
conditions are as follows.
1) The vehicle speed is at the stopped state (Vehicle speed below 3km/h detection).
2) While depressing the clutch (Clutch switch detection).
3) The gear lever is at a position other than neutral (N switch detection).
4) Start the vehicle while depressing the clutch pedal (Clutch switch detection).
5) The RPM increases in accordance with the temperature of the engine coolant (Engine coolant temperature
sensor detection).
: appx. 100 rpm increase
: appx. 100 ~ 170 rpm increase
: appx. 80°C (normal temperature of the engine coolant): around 200 rpm increase
6) When the gear has been smoothly shifted and the vehicle speed exceeds 3km/h, it returns to the previous
operation interval of the engine RPM.
In case of Kyron, the N switch signal is transmitted to the instrument panel, and then the instrument panel transmits
it to the engine ECU through the CAN communication.
Vehicle Made After 04.09.15 Kyron
E Instru- E
12
C ment C
Panel CAN
U U
commu-
nication
Terminal
Return spring
Spring
Body
Ball
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A/T
2. Detects the position of the shifting lever for the HDC operation among ABS/ESP functions.
M / T
It is used for the second item of the 6 operation conditions of the ABS/ESP’s HDC function. Please refer to the ABS/
ESP section for the specific information related to the HDC.
1) HDC Operation switch ON and
T/C
and
2) Forward/Reverse Shifting lever location
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in the neutral position).
CLUTCH
Automatic transmission: possibly operates except in the P (parking) or N (neutral) position.
NOTICE
AXLE
• The vehicle with the manual transmission does not have a separate device or switch that detects the 1st
gear. It only detects the forward/reverse direction of the vehicle through the back-up light switch and the
neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, though
the HDC also operates in the 2nd gear position, is because the engine may turn off during the HDC operation
process. You may face a very dangerous situation if the engine turns off at a steep hill.
SP
• The HDC aids the slowdown of the vehicle when driving down a steep hill and cannot sufficiently decelerate
only with the engine brake. Thus, a driver must operate the HDC only in the 1st gear when driving a vehicle
with the manual transmission.
ST’NG
3) When not depressing the accelerator pedal or brake pedal. and
BRAKE
4) The vehicle speed is above 7 km/h (based on the automatic transmission/4H drive mode). and
5) The ESP’s vehicle position control function and HBA function are not in operation. and
A / BAG
The HDC is added to aid drivers when driving down the hill, but when any basic function of the ESP is in
operation prior to the HDC system operation, the ESP takes priority over the HDC.
6) The inclination of the driving road exceeds 10%.
A / CON
When the inclination of the driving road exceeds 10%, the HDC operates until the vehicle reaches the speed
condition given in step 4).
When the Inclination is 10% ~ 20% During the HDC Operation
When depressing the accelerator pedal or brake pedal, it converts to the stand-by mode, and when depressing
the accelerator pedal again, the HDC operates again. Therefore, driver may maintain a desired speed by repeat-
ing this depressing and releasing process of the accelerator pedal.
When the Inclination Exceeds 20% During the HDC Operation
When depressing the accelerator pedal, it converts to the HDC operation stand-by mode. When depressing the
brake pedal, the HDC operation state is maintained and the braking power is enhanced.
In this case, the HECU emits an abnormal noise and the brake pedal may feel very rigid, but this is a normal
occurrence resulted from the HDC operation.
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Note: Overview of HDC Operation
HDC (Hill Descent Control) System
The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to
about 7 km/h with increment of 0.1G, on steep roads (inclination exceeding 10%) through a separately
installed switch operation. When the vehicle speed reaches below 7 km/h (refer to the information below), the
HDC automatically terminates the operation.
The HDC does not have a separate sensor for the input signal and detects
the inclination of hills by using the G sensor (acceleration sensor) in the
sensor cluster.
When you see a steep downhill ahead, press the HDC switch and the
green HDC indicator comes on. When the G sensor within the sensor
cluster detects a inclination exceeding 10%, the ESP’s HDC function
operates. When this occurs, the green HDC indicator goes off along with a
loud operation noise.
HDC Switch
Sensor Cluster HDC Indicator (Instrument panel)
The G Sensor within the sensor cluster detects When pressing the HDC switch, the green HDC
the inclination of driving roads. When the HDC indicator on the instrument panel comes on, and
switch is in operation, if the G sensor detects a when the HDC operates, the green HDC indictor
downhill inclination exceeding 10%, it transmits blinks with 0.5 seconds of interval.
the HDC operation signal to the ESP HECU.
HDC HDC
NOTICE
Red Letters Green Letters
• The G sensor within the sensor cluster
measures the actual road inclination.
However, it may recognize a sharp turn or
rough road as a downhill with a inclination * For the specific information, please refer to the ABS/
exceeding 10%, and the HDC may operate. ESP section.
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Variant Coding Related to N Switch
A/T
Kyron’s N Switch transmits information to the ECU through the CAN communication while New Rexton is connected
to the ECU through wires. Thus, if you set the variant coding in the engine ECU, you must do it differently, and you
must set the variant coding differently according to the vehicle category and specification as below.
M / T
Variant Coding Options
T/C
CLUTCH
Neutral Signal Input None / Wire / CAN
No Yes
Kyron model with manual transmission
AXLE
New Rexton model with manual transmission
Manufactured after 04.09.15
SP
BODY IN: after 154600
Automatic transmission
ST’NG
BRAKE
A / BAG
A / CON
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MANUAL TRANSMISSION
1. LOCATION
Transfer case
Oil filler plug
Center cross member &
transmission insulater mounting
Oil drain plug
Trasmission housing bolt
T/M assembly
(14 mm - 11)
T/M Assembly
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A/T
2. SYSTEM COMPONENTS
Gear Combinations
M / T
5/R shift fork 1/2 shift fork 3/4 shift fork
T/C
1st gear 2nd gear
CLUTCH
5th gear
AXLE
SP
Output shaft Input shaft
ST’NG
R Idle
Reverse Counter 3rd gear 4th gear
gear shaft
BRAKE
Shift Fork and Rail Combinations
A / BAG
Transmission Interlock
adapter plate
A / CON
3/4 rail 5/R rail
1/2 rail
Reverse Fork plate
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Sectional View
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A/T
1. Transmission front housing 37. Needle bearing (Reverse idler)
2. Input shaft oil seal 38. Reverse idler gear
3. Front cover (DWF) 39. Reverse idler spacer
M / T
4. Hexagon flange bolt (17 ~ 26 Nm) 40. Reverse idler bracket (Bolt: 30 ~ 40 Nm)
5. Oil drain plug (40 ~ 50 Nm) 41. Retainer ring (Reverse idler)
6. Sealing 42. Reverse lock nut (150 ~ 195 Nm)
7. Pin 43. Transmission adapter
T/C
8. Input shaft 44. Input shaft spacer (Bearing end play: 0 ~ 0.05 mm)
9. 4th clutch gear 45. Counter spacer (Bearing end play: 0 ~ 0.05 mm)
10. Taper roller bearing (main) 46. Reverse needle bearing
CLUTCH
11. Taper roller bearing 47. Reverse gear
12. Counter shaft 48. Reverse clutch gear
13. Taper roller bearing (counter) 49. Reverse counter gear
AXLE
14. Output shaft 50. Synchro hub (5th & R)
15. Inner race (reverse) 51. 5th counter gear
16. Inner race (1st) 52. 5th needle bearing
17. Needle bearing 53. 5th gear
SP
18. 1st gear 54. 5th clutch gear
19. 1st clutch gear 55. Thrust washer
20. Synchro outer ring (for 1st gear) 56. Shift ball
ST’NG
21. Synchro - middle cone 57. 5th outside retainer ring
22. Synchro inner ring 58. 5th retainer ring
23. Synchro spring 59. Counter shaft bushing
BRAKE
24. Synchro key 60. Counter roller bearing assembly
25. Synchro hub (1st & 2nd) 61. Counter lock nut
26. Double synchro sleeve 62. Extension housing
27. 2nd gear 63. Output shaft oil seal
A / BAG
28. 3rd gear 64. Offset plate
29. 3rd clutch gear 65. Counter screw (4~6 Nm)
30. Synchro hub (3 & 4th) 66. Top cover
A / CON
31. Synchro ring (4/5/R) 67. Counter oil seal
32. Single synchro sleeve (5th & R) 68. Shift shaft
33. Retainer ring (3 & 4th) 69. Shift lever
34. Adapter dowel pin 70. Semi-remote lever assembly
35. Reverse idler shaft 71. Pin spring
36. Dowel pin 72. Pin spring
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Front View and Rear View
Front View
Rear View
1. Reverse idler bracket (tightening torque: 30 ~ 40 Nm) 13. Shift fork (3 & 4th)
2. Shift lug (3 & 4th) 14. Input shaft
3. Spring pin (6 x 25) 15. Counter shaft
4. Shift lug (5 & reverse) 16. Reverse idler assembly
5. Shift rail (5 & reverse) 17. Spring pin (6 x 25)
6. Backup lamp switch (tightening torque: 30 ~ 40 Nm) 18. Spring pin (6 x 25)
7. Shift rail (3 & 4th) 19. Concentric slave cylinder adapter
8. Interlock bolt (tightening torque: 40 ~ 50 Nm) (tightening torque: 10 ~ 16 Nm)
9. Shift lever
10. Interlock plate (8) Bond-592 loctite
11. Shift rail (1 & 2nd) (6) Bond-592 loctite
12. Spring pin (6 x 25)
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Cross Sectional Diagram of Major Components
A/T
Shift Rail and 5/R Gear
M / T
1/2 shift rail
T/C
CLUTCH
5/R shift rail
3/4 shift rail
AXLE
Offset Lever
1. Reverse lock spring 9. TGS pin SP
ST’NG
BRAKE
A / BAG
A / CON
2. Reverse lock plate 10. Lock bolt (tightening torque: 17 ~ 26 Nm)
3. Reverse lock bolt (tightening torque: 8 ~ 12 Nm) 11. Offset lever
4. Stopper plate 12. Offset lever bushing
5. Air vent (tightening torque: 20 ~ 35 Nm) 13. Rolling plunger
6. Lock washer 14. Return spring
7. TGS bushing 15. Spring plug (tightening torque: 70 ~ 100 Nm)
8. Outer spring pin
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Power Flows
1st gear
Counter shaft
4th 3rd 2nd 1st Reverse 5th
gear gear gear gear gear gear
2nd
4th 3rd 2nd 1st Reverse 5th
gear gear gear gear gear gear
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Power Flows (Cont’d)
A/T
3rd
M / T
T/C
CLUTCH
AXLE
SP
4th 3rd 2nd 1st Reverse 5th
gear gear gear gear gear gear
ST’NG
BRAKE
4th
A / BAG
A / CON
4th 3rd 2nd 1st Reverse 5th
gear gear gear gear gear gear
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Power Flows (Cont’d)
5th
4th 3rd 2nd 1st Reverse 5th
gear gear gear gear gear gear
Reverse gear
Reverse
gear
4th 2nd 1st 5th
gear gear gear gear
3rd Reverse
gear idler gear
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3. SHIFTING MECHANISM
A/T
Interlock System
Interlock system prevents the gears from meshing over two sets.
M / T
Interlock bolt
T/C
Interlock plate Inner shift lever
CLUTCH
AXLE
SP
1/2 3/4 5/R
(3/4 & 5/R lock) (1/2 & 5/R lock) (1/2 & 3/4 lock)
ST’NG
Reverse Interlock System
BRAKE
Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
A / BAG
Neutral 5/R select 5/R shift 5th gear disengaged
A / CON
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Offset Lever and Rolling Plunger
To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear
selection gate after a gear has been selected.
1. Offset lever 3. Shift lever
2. Shift lever 4. Rolling plunger (rolling plunger return spring and ball)
1. Shift check device
It determines the shift fork position (N or each gear) and Detent pin
gives a detent movement to notice a shift lever seating when
operating the shift lever. Top cover
Also, it prevent the selected gear from getting out of its
meshed position.
Shift shaft
Set ball
2. Gear jump out locking device Hub spline Sleeve spline
It prevents the shift lever is beyond the correct shift position
while shifting.
Clutch gear
spline
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A/T
3. Guiding a control direction and preventing an over
stroke.
M / T
T/C
CLUTCH
Offset lever Offset plate
AXLE
SP
Backup Lamp Switch
It is normal open type switch. Its circuit is formed when the
reverse gear is selected.
ST’NG
NOTICE
Installation Notice
BRAKE
• Sealant: Bond-592-Loctite
• Tightening torque: 30 Nm ~ 40 Nm
A / BAG
A / CON
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Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each other).
1. 3/4 and 5/R shift: Single cone type
2. 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner
cone and middle cone)
Single Cone Type Double Cone Type
1/2 shift 3/4 shift 5/R shift 1/2 shift 3/4 shift 5/R shift
1. Synchronizer sleeve 5. Synchronizer key locking ring
2. Synchronizer hub 6. Synchronizer inner cone
3. Synchronizer ring 7. Synchronizer middle cone
4. Synchronizer key
NOTICE
• Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.
• The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).
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A/T
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed
to prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is
M / T
turning and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until
friction slows it down or stops it. Thus when the driver shifts into another gear, he/she is trying to mesh gears that
may be moving at different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced
and shifting effort is lowered.
T/C
[1st step]
CLUTCH
Sleeve Synchronizer ring
Gear spline area
Projected area
AXLE
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring
SP
[2nd step]
ST’NG
Sleeve Synchronizer ring
Gear spline area
BRAKE
Synchronizer key
A / BAG
Spline area of sleeve Spline area of synchronizer ring
[3rd step] Sleeve Synchronizer ring
A / CON
Gear spline area
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring
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Bearing
The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in
transmission housing.
Taper Roller Bearing Needle Bearings
1. Taper roller bearing (input shaft, counter shaft and 3. Needle bearing for reverse gear (with cut out area)
output shaft) 4. Needle bearing for 5th gear
2. Needle bearings for 1/2 and 3/4 shift
End Play of Taper Roller Bearing
1. Taper roller bearing for input shaft A. End play A: 0 ~ 0.05 mm
2. Taper roller bearing for counter shaft B. End play B: 0 ~ 0.05 mm
NOTICE
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft.
(Specified range of end play: 0 ~ 0.5 mm)
• For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 m)
• For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 m)
MANUAL TRANSMISSION CHANGED BY
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Thrust Ring (Washer)
A/T
When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly
receives the axial force and this force acts as a resistance to rotating gears.
Input Thrust Thrust
M / T
shaft ring 1 3/4 1/2 5/R washer
synchronizer synchronizer synchronizer Output
shaft
T/C
CLUTCH
Lock nut
Counter gear assembly
AXLE
SP
3rd Reverse
Head set gear 2nd gear 1st 5th
gear gear gear gear
ST’NG
Lubrication
BRAKE
Transmission oil: ATF DEXRON III Initial installation for taper roller bearing and needle roller bearing, lubrication for
shift rail: MoS2 Grease
A / BAG
A / CON
Oil level
Oil drain screw
NOTICE
• Sealant on oil drain screw during installation: Bond-592 Loctite
• Tightening torque: 40 ~ 50 Nm
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4. DIAGNOSTIC INFORMATION AND PROCEDURES
Trouble Diagnosis
Symptom Cause Action
Can not shift (control Control lever assembly broken or damaged. Replace control lever and housing assembly.
lever moves) Damaged offset lever, shift fork, selector Remove extension, adapter or case cover.
place or selector arm. Check or replace damaged parts.
Hard shift or control Clutch not releasing. Adjust or replace clutch.
lever will not move Improper or low transmission oil. Add or replace with specified oil.
into gear
Shift or shift rail binding. Remove extension, adapter or case cover.
Check or replace damaged parts.
Binding of sliding synchronizers or gears. Remove extension, adapter or case cover.
Check synchronizers and gears and replace
damaged parts.
If reverse only, faulty backup switch. Check or replace backup switch.
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Gears crash when Engine idle speed too high. Adjust idle speed to specified speed.
shifting Damaged or faulty clutch. Adjust or replace clutch.
Pilot bearing between input shaft and output Replace or check roller bearings.
shaft binding.
Damaged synchronizer. Check or replace synchronizer parts.
Bell housing misaligned. Align bell housing and bore.
Damaged gear(s). Check or replace gear(s).
Worn or damaged flywheel pilot bushing. Replace pilot bushing.
Transmission jumps Loosened transmission or flywheel housing Tighten bolts to specified value. Realign if
out bolts, improper alignment. necessary.
Synchronizer damaged or excessively worn. Check or replace synchronizer parts.
Blocking ring damaged, worn index slots or Check or replace blocking ring.
friction surfaces worn or damaged.
Excessive countershaft end play. Check worn or damaged parts. Adjust shim
thickness using roller bearings if necessary.
Worn or damaged fork due to loosened shaft, Check for wear or damaged. Replace worn
rail or shifting fork. or damaged parts.
Transmission Fork or offset lever loose on shaft or rail. Replace extension, adapter or case cover.
locked in one gear Check or replace loose parts on shaft or rail.
Replace roll pin(s).
Worn or damaged forks, offset lever, shaft Remove extension, adapter or case cover.
or rail. Check for wear or damaged. Replace dam-
aged parts.
Worn or damaged synchronizer. Check worn or damaged synchronizer
parts and replace if necessary.
Worn or damaged gears. Check worn or damaged gears and replace
if necessary.
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A/T
Trouble Diagnosis (Cont’d)
Symptom Cause Action
M / T
Transmission noise Improper or low transmission oil. Add or drain and replace with proper oil.
Loose bolts or other attaching parts. Tighten as specified.
Improper flywheel housing to engine Realign correctly.
T/C
crankshaft alignment.
Noisy transmission bearing. Check bearings, bearing rollers and parts
for wear or damage. Replace if necessary.
CLUTCH
Noisy gears. Check for worn or damaged gears (including
speedometer gear). Replace if necessary.
Transmission leak- Leakage from transmission. Clean all exposed surfaces, then check for
AXLE
age leaks.
Vent or breather clogged. Clean or replace vent or breather.
Too much oil. Check oil level.
Loose bolts at sealing faces. Tighten as specified.
SP
Improperly applied sealant. Clean leaking surfaces. Reapply sealant.
Worn or damaged oil seal. Replace oil seal.
ST’NG
BRAKE
A / BAG
A / CON
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Diagnosis Table
Application
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
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OIL CHECK/CHANGE
A/T
Place the vehicle on the flat and even ground and stop the engine. After 5 minutes, check the oil level.
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
1. Oil level check plug 2. Oil drain plug
A / BAG
A / CON
2. If needed, add the oil through the oil level plug hole
NOTICE (1).
• Do not check or change the oil Immediately after
3. Fully tighten the plug and check the oil leaks.
driving off. It may cause serious hurt.
4. If the oil level is up to the bottom line (5 ~ 7 mm) of
plug hole, it is OK.
Place the vehicle on the flat and even ground and stop
the engine. After 5 minutes, check the oil level. NOTICE
1. Remove the oil level plug (1) and check the oil level. • The oil in manual transmission is major element
for mechanical durability of transmission. Check
the oil level with a specific interval and replace if
NOTICE needed.
• The oil replacement should be done at the quali-
• If the oil level is up to the bottom line (5 ~ 7 mm)
fied and authorized service station.
of plug hole, it is OK.
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5. REMOVAL AND INSTALLATION
Transfer case
Oil filler plug
Cross member - Center
Mounting insulator
Oil drain plug
Transmission housing T/M assembly
mounting bolt
(14 mm - 11EA)
Removal and Installation
Preceding Work: Disconnect the battery negative
cable and remove the center console.
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A/T
1. Unscrew two bolts (12 mm) and remove the change
lever from shift lever.
Installation Notice Change lever
M / T
Tightening torque 12 ~ 23 Nm 1
T/C
2. Unscrew two bolts (12 mm) from semi-remote
controller.
Installation Notice
CLUTCH
2
Tightening torque 12 ~ 23 Nm
AXLE
3. If the oil should be changed, remove the oil drain
SP
plug (A) in transmission housing and fully drain the
oil. And, retighten the plug (A).
Installation Notice
ST’NG
Tightening torque 40 ~ 50 Nm
BRAKE
A / BAG
A / CON
4. Unscrew four bolts (17 mm) and separate the rear and front propeller shafts connected to transfer case output
shaft. Compress the propeller shaft and bind to torsion bar not to disturb the operation.
Tightening torque: Tightening torque:
81 ~ 89 Nm 81 ~ 89 Nm
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5. Disconnect the air bleeder hose, neutral switch connector, back up lamp switch connector and transfer case
connectors.
6. Support the underbody of transmission with a hydraulic jack not to deflect it and unscrew the bolts (14 mm - 4EA)
and cross nuts (14 mm - 2EA) and remove the cross member.
Tightening torque:
28 ~ 47 Nm
Tightening torque: Tightening torque:
85 ~ 95 Nm 85 ~ 95 Nm
7. Unscrew two bolts (14 mm) at both sides and remove the transmission mounting insulator. Unscrew the mount-
ing bolts (14 mm, 2) at both sides and remove the mounting insulator bracket.
Mounting Insulator Bracket
Tightening torque:
28 ~ 47 Nm
Tightening torque:
28 ~ 47 Nm
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8. Unscrew eleven bolts (14 mm) and remove the transfer case with a hydraulic jack.
A/T
M / T
Tightening torque:
38 ~ 52 Nm
T/C
CLUTCH
AXLE
NOTICE
• When installing the transfer case, make sure that
the bolts are facing correct direction.
SP
• From transmission side (upper: 8), From transfer
case side (lower: 3)
ST’NG
9. Disconnect the clutch oil hose from adapter.
BRAKE
A / BAG
A / CON
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10. Support the transmission housing with a hydraulic jack and unscrew eleven transmission bolts (17 mm).
(Tightening torque: 50 ~ 60 Nm)
11. Carefully lower the hydraulic jack with transmission assembly.
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Inspection before Installation
A/T
Install in the reverse order of removal. Check the compo-
nents for wear or damage before installation.
M / T
1. Check the concentric slave cylinder for abnormal wear
and replace if necessary.
2. Check the pressure spring plate for wear.
T/C
NOTICE
• The excessively worn components should be
replaced.
CLUTCH
3. Check the alignment conditions of clutch housing as
follows:
AXLE
1) Install the magnetic holder on pressure spring.
2) Alignment check for housing bore
• Install a dial gauge in the housing bore.
• Note the measurement while rotating the crank-
SP
shaft for one revolution.
ST’NG
BRAKE
3) Alignment check for clutch housing surface
• Install a dial gauge on the clutch housing surface.
• Note the measurement while rotating the crank-
shaft for one revolution.
A / BAG
NOTICE
• If the pointer indicates beyond 0.010 inch, align the
A / CON
clutch housing by inserting shims between housing
and clutch.
4. Check the following parts, if necessary
1) Pressure plate spring assembly
2) Disc
3) Flywheel
NOTICE
• The excessively worn components should be
replaced.
• SAT clutch cover can not be re-installed if
disassembled. SST is needed for re-vse.
• Refer to the P.11 at the of this book clutch section.
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6. DISASSEMBLY AND REASSEMBLY
MANUAL TRANSMISSION ASSEMBLY
Disassembly
1. Remove the transmission oil drain plug (hexagon, 14
mm) and completely drain the oil. Place the removed
transmission on the workbench.
2. Pull out the lock washer (1) and remove the TGS pin (2).
3. Push the semi remote lever rearward and unscrew the
mounting bolts (4) with a wrench (12 mm) to remove the
top cover.
NOTE
• Be careful not to lose the disassembled components.
4. Pull out the spring pin (6 x 25) and remove the offset
lever.
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5. Remove the bolts from the extension housing with a
wrench (14 mm).
A/T
M / T
T/C
CLUTCH
6. Remove the extension housing with a special tool.
NOTICE
AXLE
• Remove the offset lever and rolling plunger with the
extension housing. Be careful not to drop them.
SP
ST’NG
BRAKE
7. Remove the rear ball bearing with a puller and remove
the speedometer driven gear.
8. Remove the 5/R shift fork spring pin (6 x 28). A / BAG
A / CON
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1) Pull the counter gear (5th gear) retainer ring out from
the ring groove with a ring pliers.
NOTICE
• Be careful not to stiffen the retainer ring.
9. Spread the retainer ring and remove the 5th counter
gear with a puller.
10. Remove the counter reverse spacer.
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11. Remove the 5th gear retainer ring with a ring pliers.
A/T
M / T
T/C
CLUTCH
12. Remove the thrust washer from the shaft.
AXLE
SP
ST’NG
BRAKE
13. Remove the 5th gear and pull out the spring pin.
NOTICE
• Be careful not to lose or mix the spring pins.
14. Remove the 5th gear needle bearings (2). A / BAG
A / CON
NOTICE
• Be careful not to lose or mix the needle bearings.
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15. Remove the 5th gear synchronizer ring.
NOTICE
• Store at a safe place not to be mixed with other syn-
chronizer rings.
16. Remove 5/R gear retainer ring from the shaft with a
ring pliers.
NOTICE
• Store the ring with the relevant gear to prevent in-
correct installation.
17. Remove the 5/R synchronizer hub assembly, the re-
verse gear and the shift fork at a time.
18. Remove the counter reverse gear.
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19. Remove the counter reverse gear needle bearing.
A/T
NOTICE
• Store the needle bearing with the relevant gear.
M / T
T/C
CLUTCH
20. Remove the interlock bolt (17 mm).
AXLE
SP
ST’NG
BRAKE
21. Remove the transmission adapter from the surface.
NOTICE
• Be careful not to damage the adapter mating surface.
22. Remove the gear assembly from the housing. A / BAG
A / CON
NOTICE
• Do not forcefully remove the gear assembly. It may
damage the level grooves resulting in incorrect
installation. Carefully remove the gear assembly.
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23. Remove the main and counter gear assembly.
1) Pull out the pins from 5/R and 1/2 shift rails and
remove the shift rails
2) Pull out the locking pins from shift forks.
24. Remove the shift rail and shift fork. Place the output
shaft and counter gear on the special tool.
25. Place the output shaft assembly with the 1st gear fac-
ing down and remove the intermediate taper roller bear-
ing with a special tool.
NOTICE
• To prevent the bearing damage, securely seat the spe-
cial tool before removing the intermediate taper roller
bearing that is pressed in.
• Do not use general bearing puller.
26. Remove the 3/4 gear retainer ring.
NOTICE
• Be careful not to lose or mix the retainer ring.
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27. Remove the 3/4 gear synchronizer hub and single syn-
chronizer sleeve and 3rd gear with a special tool. Pull
A/T
out the needle bearing.
M / T
T/C
CLUTCH
28. Loose the 1/2 gear and hub and double synchronizer
sleeve with a press.
AXLE
SP
ST’NG
BRAKE
29. Remove the reverse gear inner race.
30. Remove the main taper roller bearing. A / BAG
A / CON
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31. Remove the inner race from 1st gear and 1st gear from
1st gear, and remove the needle bearing from the shaft.
NOTICE
• Store the disassembled gears by relevant
components.
32. Remove the synchronizer inner intermediate cone and
outer ring in 1st gear side.
Synchronizer Synchronizer Synchronizer
inner ring intermediate outer ring
cone
33. Remove the 1/2 gear synchronizer hub along with
double synchronizer sleeve.
34. Remove the synchronizer inner intermediate cone and
outer ring in 2nd gear side.
Synchronizer Synchronizer Synchronizer
outer ring intermediate inner ring
cone
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35. Remove the 2nd gear and needle bearing.
A/T
M / T
T/C
CLUTCH
36. Remove the oil seal from the extension housing.
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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Inspection Before Reassembly
1. Clean all the disassembled components with solvent and
dry them with compressed air.
Check the components for crack, wear and damage.
1) Case, extension housing, shift lever
2) Input bearing retainer
3) Counter shaft rear bearing retainer
2. Check the bearing and shaft supporting area for wear
and replace if needed.
3. Check the surface conditions on:
1) Input shaft
2) Main shaft and gears
3) Counter shaft and 5th drive gear
4. Reverse idler shaft and gears
NOTICE
• Replace the excessively worn components. Do not
grind the precisely machined components.
5. Check the following components for wear:
1) Selector arm
2) Interlock plate
3) 1/2 and 3/4 shift fork
4) Shift shaft
5) Detent/guide plate and offset lever
6) Each shift lever shift fork
MANUAL TRANSMISSION CHANGED BY
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7) Hub and sleeve
A/T
8) 1/2 shift fork, pads, synchronizer sleeve
M / T
T/C
CLUTCH
9) 3/4 shift fork, pads, synchronizer sleeve
10) 5th gear shift rail/fork, pads, synchronizer sleeve
AXLE
11) Reverse fork and reverse idler gear sleeve
SP
ST’NG
BRAKE
6. Check the following components for excessive wear:
1) Crankshaft pilot bushing in front of input shaft
2) Clutch release bearing
3) Main shaft pilot bearing roller
A / BAG
4) Main shaft thrust bearing mating surface
5) Main shaft speed gear roller bearing
6) Main shaft rear bearing
A / CON
7) Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface.
8. Check the gear sets for excessive wear, crack and
break and replace if needed.
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9. Check the conditions of each synchronizer sleeve
and hub.
1) Engagement of hub and sleeve
2) Wear on cone clutch surface in synchronizer ring
(brass) engaging the gears
10. Measure the clearance between blocking ring and
speed gear.
1) New 1/2 gear synchronizer ring: 0.87 ~ 1.4 mm
2) New 3/4 gear synchronizer ring: 0.88 ~ 1.5 mm
NOTICE
• If the clearance is excessive, replace it with new
one. Otherwise, it may cause the missing or break-
age of the gears.
11. Check the speed gear clutch and synchronizer
sleeve for damage in teeth surface.
12. Check the engagement of synchronizer sleeve and
speed gear clutch.
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Reassembly
A/T
1. Install the 2nd gear needle bearing.
NOTICE
M / T
• The 1st/2nd/3rd gear needle bearings have one bear-
ing row and the sizes of them are same. The reverse
needle bearing has two bearing rows. The 5th needle
bearing is smaller than others and consists of two
T/C
bearings.
CLUTCH
2. Install the 2nd gear and synchronizer outer ring, inter-
mediate cone and inner ring in turns.
3. Insert three keys into 1/2 synchronizer hub and double AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
synchronizer sleeve. Install the synchronizer spring in
offset so that it should not be missed out.
NOTICE Groove
• 1/2 gear double synchronizer sleeve doesn’t have a
step at edge, however, 3/4 and 5/R gears have it.
No step
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4. Install the 1/2 synchronizer hub and double synchro-
nizer sleeve into the output shaft by using a press.
NOTICE
• Make sure that the hub groove faces to 2nd gear.
Align the synchronizer key and the synchronizer ring
groove in 2nd gear.
5. Install the synchronizer outer ring, intermediate cone
and inner ring in turns.
6. Install the 1st gear.
7. Install the 1st gear needle bearing.
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8. Install the 1st gear inner race by using a press.
A/T
NOTICE
• The 1st inner race doesn’t have a step at edge.
M / T
T/C
CLUTCH
9. Install the main taper roller bearing by using a press.
AXLE
SP
ST’NG
BRAKE
10. Install the reverse gear inner race by using a press.
NOTICE
• The reverse gear inner race has a step at edge.
11. Place the output shaft assembly with the 1st gear A / BAG
A / CON
facing downward and install the 3rd gear needle
bearing.
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12. Install the 3rd gear.
13. Install the synchronizer ring on the 3rd gear.
14. Insert three keys into 3/4 synchronizer hub and syn-
chronizer sleeve. Install the synchronizer spring in off-
set so that it should not be missed out.
NOTICE
• 3/4 gear synchronizer sleeve have a step at edge.
Place the groove in hub to face the 3rd gear and align
the synchronizer key and the synchronizer ring
groove in 3rd gear.
MANUAL TRANSMISSION CHANGED BY
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15. Install the 3/4 gear retainer ring.
A/T
NOTICE
• Adjust the end play between retainer ring and hub to
a range of 0.0 to 0.5 mm by using a feeler gauge.
M / T
T/C
CLUTCH
16. Install the intermediate taper roller bearing by using a
press. Install the intermediate taper roller bearing by
using a press.
AXLE
NOTICE
• Apply the force on the inner race other than other
points.
SP
ST’NG
BRAKE
17. Install the input shaft along with the 4th synchronizer
ring. Place the input shaft to face downward on the
work bench.
A / BAG
A / CON
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18. To relieve the load and to provide a clearance to the
shaft bearing, insert a special tool.
19. Place the counter gear with input/output shaft on the
workbench.
20. Install the transmission adapter on the input shaft and
the counter gear.
21. Install the reverse gear needle bearing.
NOTICE
• The reverse gear needle bearing has two bearing
rows and the others consist of two bearings.
MANUAL TRANSMISSION CHANGED BY
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22. Install the reverse gear in the shaft.
A/T
M / T
T/C
CLUTCH
23. Install the synchronizer ring on the reverse gear.
AXLE
SP
ST’NG
BRAKE
24. Insert three keys into 5/R synchronizer hub and syn-
chronizer sleeve. Install the synchronizer spring in off-
set so that it should not be missed out.
A / BAG
NOTICE
• Place the groove in hub to face the 5th gear and align
the synchronizer key and the synchronizer ring
groove in reverse gear.
25. Install the 5/R gear retainer ring. A / CON
NOTICE
• Adjust the end play between retainer ring and hub to
a range of 0.0 to 0.5 mm by using a feeler gauge.
CHANGED BY MANUAL TRANSMISSION
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26. Install the counter reverse gear by using a press.
NOTICE
• Place the counter reverse gear with a longer protru-
sion facing to the adapter.
27. Install the counter reverse spacer.
28. Install the 5th synchronizer ring.
29. Install two 5th gear needle bearings in line.
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30. Install the 5th gear.
A/T
M / T
T/C
CLUTCH
31. Install the 5th counter gear by using a press. At this
time, place it with a longer protrusion area facing to
the adapter.
AXLE
SP
ST’NG
BRAKE
32. Install the counter 5th gear retainer ring.
33. Install the locking ball. A / BAG
A / CON
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34. Install the thrust washer (t= 5.0) while aligning the key
grooves.
35. Install the retainer ring.
NOTICE
• Adjust the end play between retainer ring and hub to
a range of 0.08 to 0.22 mm by using a feeler gauge.
36. Install the inner race of counter roller bearing by using
a press.
NOTICE
• Place it with a protrusion area facing to the 5th gear.
37. Place the gear assembly on a workbench in parallel.
MANUAL TRANSMISSION CHANGED BY
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38. Install the inner shift lever and interlock plate in the 3/
Interlock plate Inner shift lever
4 gear shift rail.
A/T
NOTICE
• The spring pin for locking the inner shift lever is small
M / T
(6 × 22) and its slot should face to the shaft.
T/C
CLUTCH
39. Install the 3/4 gear shift rail in the transmission adapter.
AXLE
NOTICE
• The part which is longer the distance between the
left hold of shift rail and the end of shift rail should
face to the input shaft.
SP
ST’NG
BRAKE
40. Install the 3/4 gear shift fork.
NOTICE
• The 1/2 and 5/R shift fork are compatible, but 3/4 shift
A / BAG
fork isn’t. Also, the 3/4 shift fork is chamfered, but 1/
2 and 5/R aren’t.
41. Install the 3/4 shift fork and shift rail while aligning the A / CON
grooves.
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42. Install the 1/2 gear shift rail in the transmission adapter.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the re-
verse lock spring, reverse lock plate and reverse lock
bolts.
NOTICE
• Align the 1/2 gear shift lug and interlock plate mating
surface.
45. Partially engage the 5/R gear shift fork to the shift rail.
MANUAL TRANSMISSION CHANGED BY
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46. Install the 5/R shift lug and 5/R shift fork on the shift
rail.
A/T
NOTICE
• Align the 5/R shift lug and the interlock plate surface.
M / T
T/C
CLUTCH
47. Install the spring pin into the 1/2 shift lug.
AXLE
NOTICE
• Place the spring pin with the pin slot facing to the
shaft.
SP
ST’NG
BRAKE
48. Install the spring pin into the 5/R shift lug.
NOTICE
• Place the spring pin with the pin slot facing to the
A / BAG
shaft.
49. Install the spring pin into the 1/2 shift fork. A / CON
NOTICE
• Place the spring pin with the pin slot facing to the
shaft.
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50. Install the spring pin into the 5/R shift fork.
NOTICE
• Place the spring pin with the pin slot facing to the
shaft.
51. Install the reverse lock plate and reverse lock spring
on the 1/2 shift rail.
52. Install the stopper plate on the 3/4 shift rail and insert the spring pin. (intermediate size: t= 6 x 25)
NOTICE
• Place the spring pin with the pin slot facing to the
shaft.
MANUAL TRANSMISSION CHANGED BY
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53. Apply the sealant to the transmission housing.
A/T
NOTICE
• Sealant: Silicon sealant - bulk #732
M / T
T/C
CLUTCH
54. Install the gear assembly and the adapter to the trans-
mission housing.
55. Install the speedometer driven gear on the output shaft
AXLE
and install the ball bearing by using a press.
SP
ST’NG
BRAKE
56. Apply the sealant to the extension housing.
Press down the extension housing against the adapter.
NOTICE
A / BAG
• Sealant: Silicon sealant -bulk #732
A / CON
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57. Tighten the extension housing bolts (14 mm-10EA).
Installation Notice
Tightening torque 42 ~ 57 Nm
58. Insert the offset lever into the 3/4 rail and install the
spring pin.
59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt (17 mm) and
insert it into the interlock plate hole and bolt hole.
NOTICE
• Make sure that the gear is at neutral position. If not,
the interlock bolt cannot be inserted into the inter-
lock plate hole.
Installation Notice
Sealant Bond 592 loctite
Tightening torque 40 ~ 50 Nm
MANUAL TRANSMISSION CHANGED BY
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61. Apply the grease to the top cover and install four bolts
(12 mm).
A/T
NOTICE
• Make sure that the gear is at neutral position.
M / T
Installation Notice
Sealant Silicon sealant -bulk #732
T/C
Tightening torque 17 ~ 26 Nm
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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TRANSMISSION ADAPTER
Disassembly and Assembly
1. Remove the reverse idler retainer ring.
2. Remove the components as follows and install in the
reverse order of removal.
1) Unscrew the reverse lock nut and idler bracket bolts
and remove the bracket and spacer.
2) Remove the reverse idler gear and the needle bearing.
3) Pull out the dowel pin and remove the reverse idler
shaft.
NOTICE
Tightening torque
Reverse idler bracket bolt 17 ~ 26 Nm
Reverse lock nut 70 ~ 100 Nm
BACKUP LAMP SWITCH
Remove the backup lamp switch with 24 mm wrench. Apply the sealant when installing.
NOTICE
Tightening torque
Sealant Bond-592 LOCTITE
Tightening torque 30 ~ 40 Nm
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7. INSPECTION/MAINTENANCE
A/T
SHIM ADJUSTMENT
1. Unscrew nine bolts (14 mm) and remove the front fork
cover.
M / T
NOTICE
• The shim adjustment is necessary when replacing
T/C
the housings, counter gear, input shaft and output
shaft.
CLUTCH
2. Separate the front fork cover from the housing.
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
3. Remove the input spacer.
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4. Remove the counter spacer.
5. Prepare the special tools and dial gauge.
6. Prepare the special tools and dial gauge. Place the trans-
mission with the output shaft facing downward and set
the special tool on the counter gear and input shaft.
Apply a proper force to the counter gear and input shaft
so that the end plays for bearings are maximized.
7. Tighten the adjusting bolt on the special tool to hold the
bearings.
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8. Set up the dial gauge on the transmission housing
surface and put the gauge needle to “0” point.
A/T
9. Put the probe end of the gauge on the taper roller
bearing outer race in counter gear and measure the
end play.
M / T
1) If the measured value is out of the specified range,
adjust it by using spacers.
End play 0 ~ 0.05 mm
T/C
CLUTCH
10. Put the probe end of the gauge on the main taper
roller bearing outer race and measure the end play.
1) If the measured value is out of the specified range,
AXLE
adjust it by using spacers.
End play 0 ~ 0.05 mm
SP
ST’NG
BRAKE
11. Apply the sealant to the front fork cover and tighten
the bolts (14 mm).
Measure the starting torque after installation.
A / BAG
Installation Notice
Starting torque 20 ~ 25 Nm
Sealant Silicon sealant -bulk#732
A / CON
Tightening torque 17 ~ 26 Nm
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8. SPECIAL TOOLS AND EQUIPMENT
Name and Part Number Application
661 589 04 62 00 (W 99 31 007 0B) Removal/installation of transmission
Transmission fixture
W 99 31 001 1B Removal of pressed in interme-
diate taper roller bearing
Bearing puller
W 99 31 002 1B Pressing of the bearing and gear
Pressure pipe
W 99 31 003 1B Providing a space to input
shaft bearing
Insert key
MANUAL TRANSMISSION CHANGED BY
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A/T
Name and Part Number Application
W 99 31 004 1B Assembly of gears and
M / T
bearings on the shafts
Die
T/C
CLUTCH
W 99 31 005 2B Measurement of taper roller
AXLE
bearing end play
Holder
SP
ST’NG
W 99 31 006 1B Measurement of taper roller
BRAKE
bearing end play
Dial gauge holder
A / BAG
A / CON
W 99 31 007 1B Removal of 5/R synchronizer
hub assembly, reverse gear
Drift
and shift fork at one time
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PART TIME TRANSFER CASE &
LOCKING HUB SYSTEM
3240 / 3410
TABLE OF CONTENTS
GENERAL ................................................. 2 REMOVAL AND INSTALLATION ........... 26
1. Overview .............................................................. 2 1. Components location ........................................ 26
2. Removal and installation of IWE (Integrated
PART TIME TRANSFER CASE ............... 3 Wheel End) ....................................................... 34
1. Structure ............................................................. 3
SPECIAL TOOLS AND EQUIPMENT .... 41
2. System layout and functions .............................. 5
3. Locking hub system ........................................... 6
TCCU (TRANSFER CASE CONTROL
4. Transfer case .................................................... 15
UNIT) ....................................................... 42
POWER FLOW ....................................... 20 1. Major changes in TCCU .................................... 42
1. Power flow ......................................................... 20
SYSTEM OPERATION ........................... 44
2. 2H mode (2WD) ................................................ 21
3. 4H mode (4WD - high speed) ........................... 22 1. TCCU (Transfer Case Control Unit) .................. 44
4. 4L mode (4WD - low speed) ............................. 23 2. Trouble diagnosis test ...................................... 47
3. Self-diagnosis test ............................................ 48
TROUBLE SHOOTING .......................... 24 4. Diagnostic trouble code .................................... 49
1. General diagnosis ............................................. 24
MAINTENANCE AND REPAIR .............. 25
1. Oil level check and change .............................. 25
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GENERAL
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” and “4H” easily while driving
(for 4L: stop vehicle first). The warning lamp warns the driver when the system is defective.
The 4WD system integrated in KYRON does not have big difference in comparison to the conven-
tional part time transfer case, but the changes in comparison to the conventional transfer case are
as follows:
1. No additional coding is required when replacing TCCU.
2. Delete the devices (tone wheel speed sensor, wiring etc.) related to the speed sensor in
the transfer case.
This system receives the speed signals from ABS/ESP HECU or instrument panel
(for non-ABS vehicle(Note 1)) through the CAN communication.
3. The new TCCU is available to install on the vehicle with the conventional DI engine part time
TCCU.
Note : In non-ABS vehicle, the vehicle speed sensor is installed on the rear drive
axle. The engine ECU sends the speed signal to the instrument panel, and
then the instrument panel provides the information to TCCU and other devices.
Specifications
Description Part Time T/C
Total length 343 mm
Mating surface of front flange 40 mm
Weight 33.9 Kg (without oil)
Oil capacity 1.4 L
Location Transfer case
Major elements Housing Part time
Tightening bolt 11EA, M8 x 1.25
Input shaft A/T: External spline
M/T: Internal spline
Ring gear Inserted into housing groove
Sun gear Separated input shaft and sun gear
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PART TIME TRANSFER CASE
A/T
1. STRUCTURE
M / T
T/C
Front axle
CLUTCH
Front locking hub
system (IWE)
AXLE
Front propeller shaft
Transmission
SP
ST’NG
Part time transfer case
BRAKE
A / BAG
A / CON
Rear propeller shaft
Rear axle (IRS type)
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Components Location
Magnet clutch power supply
connector (for 1 pin)
Transfer case main connector
Shift motor connector
Transfer case assembly
T/C motor
Rear propeller shaft
Oil drain plug
(Tightening torque: 19 ~ 30 Nm)
Damper
Front propeller shaft
Oil filler plug
(Tightening torque: 19 ~ 30 Nm)
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2. SYSTEM LAYOUT AND FUNCTIONS
A/T
System Layout
Indicators (T/C control indicator lamp)
M / T
T/C
HECU (Wheel speed signal)
CLUTCH
T/C control switch
AXLE
TCCU CAN Communication
SP
Output
ST’NG
BRAKE
Vacuum line
Solenoid valve
A / BAG
Atmo- Atmo-
sphere sphere
A / CON
Transfer case
FL Locking hub FR Locking hub
Magnetic
clutch
Motor
Front output
shaft
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3. LOCKING HUB SYSTEM
The transfer case and the TCCU differ from previous models only in the speed sensor related parts. However, the
vacuum locking hub operation system works oppositely from previous models and its components also have changed.
The vacuum locking hub that is applied to Kyron uses the IWE (Integrated Wheel End) system, and in this system,
the vacuum is generated only within the hub actuator.
It is structured to transmit power to the front section after the actuator hub is engaged following the release of
vacuum from the drive shaft end gear and the hub end gear.
Operating Process
Vacuum pump
Booster TCCU
Atmo- Electrical
sphere signal Atmo-
Vacuum modulator
sphere
(for engine)
Vacuum solenoid valve for IWE
Locking hub actuator Locking hub actuator
Vacuum generation process in front hub actuator:
TCCU T/C control switch
Vacuum pump Solenoid valve Air filter (Vacuum hose)
Hub actuator (FR) Hub actuator (FL)
Atmosphere Atmosphere
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A/T
Vacuum System
M / T
In 4WD mode, the TCCU blocks the
transferring of vacuum pressure from
vacuum pump to locking hub by
supplying the power to solenoid valve.
T/C
CLUTCH
Vacuum operation during 2WD
mode
During 2WD mode, the vacuum pres-
AXLE
sure from vacuum pump is continu-
ously transmitted to the locking hub
system. This vacuum pressure pulls in
the locking hub actuator so that it will
not be engaged with the front end hub
SP
gear.
Air filter
ST’NG
BRAKE
A / BAG
4WD (releasing vacuum pressure from
hub actuator)
A / CON
The vacuum pressure is released from the hub
actuator. At this time, the front hub end gear
is engaged.
Atmosphere
(in 4WD mode)
2WD (applying vacuum pressure to
hub actuator)
The vacuum pressure pulls in the locking
hub actuator so that it will not be engaged
with the front end hub gear.
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Components of IWE (Integrated Wheel End)
Front Hub Assembly
The front hub assembly is connected to the tire and it drives the wheel by receiving the rotation
force from the drive shaft during 4WD mode. When the hub actuator is moved to the gear (vacuum
pressure released), the 4WD mode is engaged. When the hub actuator is out of the gear (vacuum
pressure applied), the 4WD mode is concelled.
Rubber O-ring
Replace it with a new one when removing.
Function: preventing moisture and foreign
matter from entering into gears. Steel O-ring
Preventing the actuator hub from
pressing against the wheel end hub
Apply the grease to
the steel O-ring
before installation.
Gear
NOTICE
• Rubber O-ring: Replace it with
a new one when removing/in-
stalling the front hub.
Front Drive Shaft
The front drive shaft is the part that receives the power when the transfer case operates in 4WD
mode. During the 2WD mode, the hub actuator is positioned at the drive shaft end, and during the
4WD mode, the hub actuator is interlocked to the drive shaft end gear and the front hub end gear.
Drive shaft end gear
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A/T
Solenoid Valve
The vacuum solenoid valve is installed at bottom of the battery tray (theft warning horn side) and
M / T
serves the function that allows to connect and block the vacuum pressure from vacuum pump to
hub actuator.
During the 2WD mode, a vacuum line is established between vacuum pump and hub actuator.
T/C
During the 4WD mode, the TCCU applies 12V to the vacuum solenoid to block the vacuum pressure.
Vacuum pump
CLUTCH
TCCU
AXLE
Actuator
SP
ST’NG
Locking Hub Actuator
This device transfers or blocks the output from drive shaft to the front wheel end according to the
vacuum pressure. Unlike the conventional systems, the vacuum pressure to the front wheel end
BRAKE
operates only within the actuator.
Supplying vacuum
pressure
A / BAG
Atmosphere
A / CON
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2WD:
The locking hub actuator is out of the front wheel hub end gear when applying the vacuum pressure.
Locking hub actuator: pulled in when
applying vacuum pressure
Front wheel end Drive shaft
Front hub end gear is not
visible (4WD mode released)
4WD:
The locking hub actuator is engaged with the front wheel hub end gear when releasing the vacuum pressure.
Locking hub actuator: pulled out
when releasing vacuum pressure
Front wheel end Drive shaft
Front hub end gear is not
invisible (4WD mode engaged)
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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Front Wheel End in Vehicle with 4WD
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
Front Wheel End in Vehicle without 4WD
A / BAG
A / CON
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Vacuum Locking Hub Check
Compared to conventional locking hub systems, when the vehicle is in 2WD mode, the vacuum pressure from
vacuum pump is continuously applied to the locking hub actuator. If any vacuum line is leaking, the 4WD system
may not operate. Make sure that the vacuum lines are not leaking.
How to check the vacuum locking hub system:
1. Disconnect hub actuator vacuum line from vacuum solenoid valve.
2. Connect vacuum gauge to vacuum line of hub actuator.
Vacuum
gauge
Solenoid valve Connect vacuum gauge to
vacuum line of front hub
actuator.
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A/T
3. Check vacuum pressure with vacuum pressure gauge.
2WD: vacuum pressure applied
M / T
T/C
CLUTCH
AXLE
SP
During 2WD mode, the vacuum pressure
is applied to the locking hub actuator and
the drive shaft is separated from the front
ST’NG
wheel hub end gear. Thus, when apply-
ing the vacuum pressure with a vacuum
pressure gauge, only the wheel must rotate.
BRAKE
4WD: vacuum pressure released
A / BAG
A / CON
During 4WD mode, the vacuum pres-
sure is released from the locking hub
actuator and the drive shaft is engaged
with the front wheel hub end gear. Thus,
when releasing the vacuum pressure
(gauge indication: 0) with a vacuum
pressure gauge, the drive shaft should
be rotated along with the wheel.
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Hub Actuator Check
Disconnect the vacuum hose from the hub actuator and install the vacuum pressure gauge to the
hub actuator. Apply vacuum pressure to make sure the hub actuator maintains vacuum condition.
Normal Leakage
If the vacuum pressure is maintained, the If the vacuum pressure is not maintained,
actuator hub component condition is OK. replace the actuator with a new one.
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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4. TRANSFER CASE
A/T
Appearance
M / T
T/C
CLUTCH
AXLE
SP
Connect to Air bleeder
transmission
output shaft
Transfer case assembly
ST’NG
BRAKE
Connect to rear
A / BAG
propeller shaft
Rear flange
A / CON
Shift motor connector
Shift
motor
Connect to front
propeller shaft
Front flange
1 pin connector
(For magnetic clutch power supply)
* Delete power supply terminal and
ground for conventional speed
sensor.
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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Sectional Drawing
Planetary
gear set Oil pump
Magnetic
clutch
Input shaft
Connect to
rear propeller
shaft
2H-4H
Shift fork
4H-4L (Lockup fork)
Shift fork
(Reduction shift fork)
Shift motor
Connect to front
propeller shaft
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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Shift Motor Connector
A/T
When selecting a position in the 4WD switch (2H, 4H, 4L), TOD control unit exactly changes the motor position
to 2H, 4H and 4L by detecting the electric signals from position encoder that monitors motor position.
Pin Function
M / T
1 Position A
2 Position B 4 (Orange/
3 (Brown/
3 Position C White) White)
T/C
5 (Yellow/
4 Position D 2 (White)
White)
5 Position ground 6 (Yellow) 7 (Orange)
CLUTCH
6 Control (4L - 4H -2H)
7 Control (2H - 4H - 4L)
1 (Violet)
AXLE
Rear view of connector
Connector Shape and Function
Magnetic Clutch Coil Power Supply Connector
SP
The transfer case integrated in KYRON doesn’t have an internal speed sensor and receives the speed signal
from ABS/ESP HECU or the instrument panel (Non-ABS vehicle) via CAN communication. Therefore, there are
ST’NG
not extra terminals for speed sensor power supply and ground.
Transfer case side Supply side
Pin Function
BRAKE
A Magnetic clutch coil power supply
A / BAG
A / CON
Note (Old Version)
The rear speed sensor utilizes the hall effect. It gen-
erates 0V and 5V of square type digital wave accord-
ing to the rotation of the wheel with teeth of transfer
case rear output shaft. The speed signal from rear
propeller shaft is entered into control unit. When the
control unit determines that 4WD HIGH operation is A (Brown)
available, electric current flows into the clutch coil. The B (Green)
coil magnetized by this electric current pull in the lockup C (Blue)
hub to engage into output spline. Accordingly, the D (Gray/Red)
power is transferred to front wheels.
Pin Function
A Clutch coil
B Sensor power (5V)
C Sensor signal
D Sensor ground
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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Transfer Case Block Diagram
2 Shift motor output
13 15 (Motor LOW-HIGH)
Battery voltage
26
1 Shift motor output
Ignition switch (Motor HIGH-LOW)
23 14
ON/OFF
P
Electronic
Position 1 18 A 11
magnetic clutch coil
Position 2 5 R
Position 3
T
19
Position encoder
Position 4 17 20 ground
T (Return position)
I
M
2WD/4WD switch 4
E
T
HIGH/LOW switch 16 C
C
U
CAN HIGH 8 K-Line
21 (Self diagnosis)
CAN LOW 9
24 Hub solenoid
12
25
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Transfer Case Circuit Diagram
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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POWER FLOW
1. POWER FLOW
Switch Transfer
2H, 4H →4L
TCCU
Locking Hub Solenoid
Locking Hub Operation
(Internal vacuum released)
Transfer
Front Propeller Shaft
Rear Propeller Shaft
Front Axle Rear Axle
Front Wheel Rear Wheel
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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A/T
2. 2H MODE (2WD)
M / T
T/C
Rear Axle
CLUTCH
Transmission
(Rear Wheel)
AXLE
SP
Front Axle
ST’NG
(Front Wheel)
BRAKE
A / BAG
Power Flow
A / CON
Transmission
Rear Wheel
Output Shaft
Transfer Case
Input Shaft
Rear Propeller Shaft Rear Axle
↓
Output Shaft
Rear Wheel
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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3. 4H MODE (4WD - HIGH SPEED)
Transmission Rear Axle
(Rear Wheel)
Front Axle
(Front Wheel)
Power Flow
Motor Transmission
TCCU
Input Shaft
Shift
Cam, Rail, Fork
Magnetic
T/C Output Shaft
4WD-HI Clutch
Locking Hub Solenoid
Operation
Engagement of Front Drive
Shaft and Locking Hub
Rear Propeller
Front Wheel Drive
Shaft
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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4. 4L MODE (4WD - LOW SPEED)
A/T
M / T
Transmission Rear Axle
T/C
(Rear Wheel)
CLUTCH
AXLE
Front Axle
SP
(Front Wheel)
ST’NG
Power Flow
BRAKE
Motor Transmission
TCCU
A / BAG
Input Shaft
Shift
Planetary Gear
A / CON
Cam, Rail, Fork
4WD-LO
Locking Hub Solenoid
Magnetic clutch Output Shaft
Operation
Engagement of Front Drive Rear Propeller
Shaft and Locking Hub Shaft
Front Wheel Drive
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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TROUBLE SHOOTING
1. GENERAL DIAGNOSIS
Symptoms Check Action
Electric shift problems • Faulty or damaged TCCU, speed sensor, • Overhaul and check, replace if necessary
motor, clutch or internal wirings
• Damaged or worn shift cam, hub, • Overhaul and check for wear and damage.
fork and rail shift
• Binding shift fork, hub collar or gear • Check sliding parts, replace if necessary.
Cannot drive front wheel • Broken drive chain • Check internal parts and replace drive chain.
when shifting to 4H, 4L
Noise in 4WD operation • Improper or low oil • Drain and replace with specified oil.
• Loosened bolts or mounted parts • Retighten as specified.
• Noisy T/C bearing • Disassemble bearings and parts and check
for wear or damage. Replace if necessary.
• Gear abnormal noise • Check for wear and damage including speed-
ometer gear. Replace if necessary.
Noise in 4H or 4L • Worn or damaged sprockets or drive • Disassemble and check for wear and damage.
chain Replace if necessary.
• Incorrect tire pressure • Adjust tire pressure.
Transfer case oil • Cracked transfer case • Replace the case.
leakage
• Leakage from other parts • Clean case and parts and check for leakage.
• Breather clogging • Remove breather hose and clean. Replace if
necessary.
• Improper or too much oil • Use specified oil and adjust oil level.
• Loosened sealing bolts • Retighten.
• Improperly applied sealant • Use specified sealant and retighten.
• Worn or damaged oil seal • Replace oil seal.
TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the
trouble code is stored into TCCU memory.
If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition
switch is turned to “OFF” before shifting completes, TCCU continues monitoring for input and output required
for the shifting.
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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MAINTENANCE AND REPAIR
A/T
1. OIL LEVEL CHECK AND CHANGE
M / T
Oil Level Check
1. Clean the oil level plug (filler plug) and surroundings.
T/C
2. Remove the oil level plug an check whether oil is spilled Oil level plug
out.
3. Add oil if necessary. Tighten the oil level plug.
CLUTCH
Installation Notice
Tightening torque 19 ~ 30 Nm
AXLE
Drain plug
SP
Oil Change
ST’NG
1. Clean the oil level plug, drain plug and surroundings.
2. Place a proper container under the transfer case.
3. Remove the drain plug and then remove the oil level plug
BRAKE
(filler plug).
Drain plug
4. Drain the oil and tighten the drain plug.
5. Fill the oil through the oil level plug until oil begins to
A / BAG
drip out.
Installation Notice Oil level plug
Tightening torque 19 ~ 30 Nm
A / CON
Cautions for Oil Level Check and Plugs
1. Be careful of hot oil when draining.
2. Do not use an impact wrench to remove or tighten the
oil level plug or drain plug since this will damage the
threads in the plug.
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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REMOVAL AND INSTALLATION
1. COMPONENTS LOCATION
Magnetic clutch power supply
connector (for No.1 pin)
Transfer case main connector
Shift motor connector
Transfer case assembly
T/C motor
Rear propeller shaft
Drain plug
(Tightening torque: 19 ~ 30 Nm)
Damper
Front propeller shaft
Filler plug
(Tightening torque: 19 ~ 30 Nm)
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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Exploded View
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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1. Snap ring 34. Breather
2. Snap ring 35. Name plate
3. Snap ring 36. Output shaft
4. Bearing 37. Dust shield
5. Hub 38. Magnet
6. Input shaft assembly 39. Snap ring
7. Thrust plate 40. Lower sprocket
8. Sun gear 41. Spacer
9. Snap ring 42. Chain
10. Carrier assembly 43. Retaining ring
11. Reduction hub 44. Bearing
12. Main shaft 45. Bearing
13. Clamp 46. Cover
14. Hose 47. Clip
15. Filter assembly 48. Bolt
16. Driving sprocket 49. Clip
17. Lockup collar 50. Washer
18. Spring 51. Nut
19. Lockup hub 52. Companion flange
20. Armature 53. Oil seal
21. Snap ring 54. Spacer
22. Cam/coil housing assembly 55. Tone wheel
23. Electric coil assembly 56. Nut
24. Return spring 57. Clip
25. Shift rail 58. Screw
26. Shift fork 59. Clip
27. Shift fork assembly 60. Connector lock
28. Electric shift cam 61. Connector
29. Spring 62. Hexagon bolt
30. Spacer 63. Hexagon cap screw
31. Shift shaft 64. Electric motor assembly
32. Retaining ring 65. Oil seal
33. Transfer case assembly 66. Pipe plug
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Transfer Case
A/T
1. Disconnect the motor connector from the transfer case.
M / T
T/C
CLUTCH
AXLE
2. Remove the rear propeller shaft. And separate the front propeller shaft from transfer case.
Front Rear
SP
ST’NG
BRAKE
A / BAG
Installation Notice Installation Notice
A / CON
Tightening torque 81 ~ 89 Nm (T/C) Tightening torque 81 ~ 89 Nm (T/C )
70 ~ 80 Nm (Axle)
3. Disconnect the air hose from the transfer case.
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4. Place the safety jack under the transfer case and automatic transmission. Unscrew the transmission cross
member bolts (14 mm) and the center bolt (14 mm), and remove the transmission cross member.
Tightening torque:
(85 ~ 95 Nm)
Tightening torque:
(28 ~ 47 Nm)
Tightening torque:
(85 ~ 95 Nm)
5. Unscrew the bolts (14 mm) and remove the transfer case
mounting insulator and insulator bracket.
Tightening torque
Mounting insulator 28 ~ 47 Nm
Bracket bolt 28 ~ 47 Nm
6. Unscrew eleven bolts (12 mm) and carefully remove the
transfer case.
Installation Notice
Tightening torque 20 ~ 25 Nm
NOTICE
• When installing the transfer case, make sure that the
bolts are facing correct direction.
From transmission side (upper: 8), From transfer
case side (lower: 3)
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7. When installing, keep the tightening torque and install in reverse order of removal.
A/T
Side View Front View
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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Transfer Case Motor
Preceding Work: Disconnect the negative battery cable.
1. Disconnect the magnetic coil clutch connector and motor connector from the transfer case.
2. Unscrew the bolts and remove the transfer case motor with bracket.
Motor connector
Magnetic coil clutch connector
NOTICE
• Remove two nuts to separate the bracket and motor.
Bracket mounting nut
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A/T
3. Pull the shift motor assembly out while keeping the
level. Clean the mating surface of the transfer case
and shift motor.
M / T
NOTICE
• Do not disassemble the shift motor since it is re-
T/C
placed as an assembled unit.
CLUTCH
AXLE
4. Apply sealant on the mating surface when installing
new shift motor assembly.
5. Install in the reverse order of removal. Make sure that
SP
the mode switch selection is matched with the motor’s
driving position before installation.
ST’NG
NOTICE
• To do that, install a new shift motor on the same lo-
cation that the used shift motor was on.
BRAKE
A / BAG
A / CON
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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2. REMOVAL AND INSTALLATION OF IWE (INTEGRATED WHEEL END)
Wheel Speed Sensor
Preceding Work: Disconnect the negative battery cable and remove the tires.
Note: Wheel speed sensor location
Front side (2WD) Rear side (5-link type) Rear side (IRS type)
1. Unscrew the two bolts (19 mm) and set the removed brake caliper on the frame.
Tightening torque:
(85 ~ 105 Nm)
2. Unscrew the two screws and remove the brake disc.
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A/T
3. Remove the hub cap and unscrew the lock nut.
NOTICE
M / T
• Replace the hub cap with a new one when installing.
T/C
Tightening torque:
(28 ~ 30 Nm)
CLUTCH
AXLE
SP
4. Unscrew the three wheel end hub mounting bolts (10 mm).
ST’NG
Installation Notice
Tightening torque 100 ~ 130 Nm
BRAKE
A / BAG
A / CON
5. Slightly pull the wheel end hub until the wheel speed sensor is visible. Unscrew the mounting bolt (5 mm) and
remove the wheel speed sensor.
Tightening torque:
(6 ~ 8 Nm)
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6. Disconnect the wheel speed sensor and the cable.
Disconnect connector
Wheel speed sensor
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Locking Hub Actuator Assembly
A/T
Preceding Work: 1. Remove the tire and the brake disc.
2. Remove the wheel speed sensor.
M / T
1. Unscrew the two bolts (10 mm) and remove the brake
dust cover.
Installation Notice
T/C
Tightening torque 4 ~ 8 Nm
CLUTCH
AXLE
2. Pull out the upper arm lock pin and unscrew the mounting nut (19 mm).
SP
At this time, do not fully remove the nut.
ST’NG
BRAKE
A / BAG
Tightening torque:
(140 ~ 160 Nm)
A / CON
3. Pull out the steering gear linkage lock pin from the knuckle. Unscrew the mounting nut (19 mm) and remove
the tie rod end.
Lock pin
Tightening torque:
(110 ~ 130 Nm)
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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4. Unscrew the lower arm mounting nut (22 mm).
Tightening torque:
(140 ~ 160 Nm)
5. Remove the knuckle between upper arm and lower arm with special tool.
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Hub Actuator
A/T
1. Unscrew the three bolts (10 mm) on the disassembled locking hub actuator assembly and remove the hub actuator.
Tightening torque:
M / T
(8 ~ 12 Nm)
T/C
CLUTCH
AXLE
Structure of Hub Actuator
SP
Vacuum tube
Vent tube
ST’NG
BRAKE
A / BAG
A / CON
Detail
7Shift seal
1
Clutch ring
2
Shift fork
Housing
6
Piston Diaphragm Spring
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Inspection
1. Check the internal seal ring of hub actuator for damage.
2. Replace the O-ring of the locking hub end with a new
one.
Installation Notice
* Completely clean the parts and apply the grease them before installation.
Be careful not to damage the internal seal ring of the hub actuator.
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SPECIAL TOOLS AND EQUIPMENT
A/T
Name and Part Number Application
M / T
661 589 01 37 00 (W 99 31 001 1B) Removal/installation of carrier
Pliers assembly in transfer case
T/C
CLUTCH
AXLE
DW 220 - 080 (W 99 31 005 0B) Installation of oil seal to
Oil seal installer transmission case
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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TCCU (Transfer Case Control Unit)
1. MAJOR CHANGES IN TCCU
TCCU controls the 4WD system and is located under the driver’s seat.
The new TCCU makes some difference compared with TCCU for the conventional part time transfer case and the
differences are as follows:
1. No additional coding is required when replacing TCCU.
2. Delete the devices (tone wheel, wiring etc.) related to the speed sensor in the transfer case.
This system receives the speed signals from ABS/ESP HECU or instrument panel (for non-
ABS vehicle(Note 1)) through the CAN communication.
3. Delete the pin related to the speed sensor from TCCU pins.
4. Change the transfer case wiring connector from No.4 pin to No.1 pin (Power and ground
related to the speed sensor).
5. The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU.
Location
TCU
TCCU
Pin Arrangement
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TCCU Pin Numbers and Description
A/T
M / T
T/C
CLUTCH
T/C: Transfer Case
Pin No. Function Input/Output Description
AXLE
This is a terminal that outputs the input signal to the T/C motor during
1 Motor HI - LO Output
the 4WD switch operation. When switching the 2WD mode to 4WD
mode, the battery power is supplied to “Motor Hi-Lo” and the opposite
2 Motor LO - HI Output
side is earthed, and vice versa.
3 - - -
SP
4 4WD switch Input Switch position converting (2H-4H) recognition
5 Position 2 Input Detecting shift motor position 2 position.
6 - - -
ST’NG
7 - - -
These lines are sharing the information among the related units
8 CAN H through the CAN communication. The differences from the conven-
Both tional part time T/C models are that the speed sensing type tone
BRAKE
9 CAN L wheel in T/C has been eliminated and the speed signal comes from
the ABS/ESP HECU or the instrument panel.
10 - - -
A / BAG
11 EMC (Electronic Output Supplying the voltage to clutch coil for all shifting operations
magnetic clutch) • When supplying power: Battery voltage
• When no power supplied: Ground power
12 Ground Input Provide the ground to TCCU
A / CON
13 Battery Input Battery voltage supplying terminal to operate the system
14 Motor High-Low Output Same as No.1, 2 pin
15 Motor Low-High Output
16 High-Low switch Input Recognition converting switch between 4H and 4L
17 Position 4 Input Detecting shift motor position 4 position.
18 Position 1 Input Detecting shift motor position 1 position.
19 Position 3 Detecting shift motor position 3 position.
20 Position return Input Providing the ground related to shift motor sensor plate.
21 K-Line Both Connected to trouble diagnosis connector
22 - - -
23 Ignition power Input Power supply terminal when ignition switch is ON
24 Solenoid power Output Locking hub system applied to KYRON makes difference in related
supply to the conventional part time system and the vacuum supply in
operating process.
25 Ground
26 Battery
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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44 3240
SYSTEM OPERATION
1. TCCU (TRANSFER CASE CONTROL UNIT)
4WD Operation
TCCU is located under the driver’s seat and permits the
vehicle to shift from the two-wheel drive to the four-wheel
drive (and back shift) according to driver’s switch operation TCCU
during driving (for the shifting between 4WD HIGH and 4WD TCU
LOW, stop the vehicle).
1. 2H → 4H
1) Change the 4WD switch in instrument panel from
2H to 4H.
2) This shift is available during driving.
3) The “4WD HIGH” indicator in meter cluster comes on.
When the System is Defective
• The “4WD CHECK” warning lamp comes on
2. 4H → 2H
1) Change the 4WD switch in instrument panel from 4H
to 2H.
2H - 4H - 4L
2) This shift is available during driving.
3) The “4WD HIGH” indicator in meter cluster goes out.
3. 4H → 4L
1) This function is only available when the speed signal
from speed sensor is about to stop (below 2 km/h).
2) This function is only available when the clutch pedal
is depressed (manual transmission) or the selector
lever is selected to the “N” position (automatic
transmission). (TCCU must recognize the clutch
pedal signal or “N” signal.)
3) Change the 4WD switch in instrument panel from 4H to 4L.
4) The “4WD LOW” warning lamp in meter cluster flickers
during this process, then goes out when the shift is
completed.
5) The “4WD CHECK” warning lamp comes on when
the system is defective.
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM CHANGED BY
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A/T
Reading Position Encoder
M / T
The position encoder is the code that TCCU can determine the shift motor position.
Position Code
Motor Position Remark
1 2 3 4
T/C
0 0 0 0 Left Stop
1 0 1 0 2H
CLUTCH
0 0 1 0 Zone 1
0 1 1 0 Zone 2
Input voltage
0 0 1 0 Zone 3
1: above 4.5V (HIGH)
AXLE
0 0 1 1 4H
0: below 0.5V (LOW)
0 0 0 1 Zone 4
1 0 0 1 Zone 5
Zone 6
SP
1 0 0 0
1 1 0 0 4L
0 0 0 0 Right stop
ST’NG
1 1 1 1 Encoder Off State
BRAKE
Operation
A / BAG
TCCU initialization and operation
1. TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition
switch is turned to ON. At this time, the 4WD indicators (4WD LOW and 4WD HIGH) come on for 0.6 seconds.
A / CON
2. TCCU starts diagnosis by operating clutch and hub solenoid for 1.5 seconds.
3. The shift operation is controlled to move only toward selector switch position if the selector switch position is not
met with shift motor position code when the ignition switch is turned to ON.
Function of indicating lamp during shifting
1. As the operation of shift motor starts, the indicator flick- 0.3 seconds
ers in the interval of 0.3 seconds and stops after the
Shift
shifting operation is completed or cancelled. completed
1) Operation diagram of “4H” indicator when changing
the switch to 4H from 4L
2) Operation diagram of “4H” indicator when changing
the switch to 4L from 2H/4H
0.3 seconds
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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Drive Mode Change
The shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for
2 seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis.
Once the motor starts, the shift conditions are no longer checked.
Shift conditions are as follows:
1. Normal battery voltage and shift motor for all gears
2. 2H and 4H shifts has nothing to do with the vehicle speed, the “N” position in the automatic transmission or the
clutch signal.
3. The shift operation between 4H and 4L is only available when the vehicle speed is below 11 rpm or 2 kph.
Motor Controls
1. The shift steps have the sequence of 2H →4H →4L and 4L →4H →2H. TCCU operates the shift motor until it
reads the required position code. If it detects the faulty code, the system is operated with the compensation
mode.
2. Once the shift operation is started, it is completed regardless of the ignition power. If there are not operating
signals from the position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting
time between 2H and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the
shifting time exceeds the specified time, TCCU cannot properly supply the voltage to shift motor and is operated
in compensation mode.
3. Even though the system recognizes a fault before motor starts, it is considered as a fault.
4. Motor stops operation when it reaches target range.
Synchronization
Synchronization occurs during shifting from 2WD (2H) to 4WD (4H or 4L). The synchronizer clutch and the hub
solenoid are controlled during the synchronization as follows:
1. The clutch coil operates when the selector changes from 2H to 4H/4L.
2. The shift motor moves in 4H mode.
3. The hub solenoid starts its operation 4 seconds after shifted to 4H.
4. The clutch coil stops its operation 5 seconds after the hub solenoid is activated.
Compensation
The motor stops when the encoder related to troubles are detected during shift operation. It moves toward LOW-
HIGH direction for 5 seconds so that the motor is not left in unidentified position.
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2. TROUBLE DIAGNOSIS TEST
A/T
Shift Motor Test
1. Check short and open circuit before and during shifting.
M / T
2. When the system detects a fault in the shift motor for over 1 second, the “4WD CHECK” warning lamp comes on
and a trouble code is stored into memory.
3. The trouble code being detected in shift motor during its operation is defined as timeout.
T/C
4. The trouble code for the shift motor can be erased by using scanner.
CLUTCH
Transmission System Timeout Test
1. The shift timeout occurs when the position sensor of shift motor does not try to operate, which happens 1.5
seconds after completion of 2H-4H shift and 3 seconds after completion of 4H-4L shift.
AXLE
2. When the timeout occurs, TCCU cuts off the voltage to shift motor and operates the compensation mode.
SP
Position Encoder Test
1. When the system detects a fault in shift motor for over 1 second, the “4WD CHECK” warning lamp comes on and
ST’NG
the trouble code is stored into the memory.
2. The position encoder fault can be divided into a general encoder fault and short to ground of position encoder
circuit.
BRAKE
1) General encoder fault: Invalid position code input
2) Short to ground of position encoder circuit: Ground for encoder circuit
A / BAG
Clutch Coil Test
A / CON
1. Check the clutch coil for open and short circuit.
2. When the system detects a fault in shift motor for over 0.8 seconds, the “4WD CHECK” warning lamp comes on
and the trouble code is stored into the memory.
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
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3. SELF-DIAGNOSIS TEST
1. TCCU detects the transfer case systems malfunctions
and indicates malfunctioning part(s) through flickering
of the “4WD CHECK” indicator.
Connect Scan-I to the diagnostic connector located
under the steering wheel.
2. The transfer case system is malfunctioning when:
1) The “4WD CHECK” indicator remains on after 0.6
second when turning the ignition switch ON.
2) The “4WD CHECK” indicator continuously comes on
during driving.
3. Connect Scan-I to the diagnostic connector and read
the defective code with the ignition switch “ON” (refer
to Diagnosis Table).
4. After repairing, erase the defective code stored in TCCU.
NOTICE
• Before replacing the malfunction parts with defective
code, check the wires and connectors for looseness.
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4. DIAGNOSTIC TROUBLE CODE
A/T
Code Description Action
P1806 Defective CAN commuication - Check communication line.
M / T
- Replace TCCU if necessary.
P1805 Defective mode switch - When the mode switch is defective
T/C
- Check TCCU pin No.4 and 16.
- Mode change
• 2H (Pin No. 4: Ground)
CLUTCH
• 4H (No contact: Open)
• 4L (Pin No.16: Ground)
AXLE
P1821 Open or short to ground in magnetic - Voltage at TCCU pin No.11: 11 ~ 15 V
clutch coil circuit - EMC resistance: 2.5 Ω
- Check the relevant connectors for contact.
- Replace TCCU if necessary.
SP
P1822 Open or short to ground in hub control - When the hub control circuit is open or short to ground over
circuit 0.2 second
ST’NG
- Replace TCCU if necessary.
BRAKE
P1841 Open to ground in shift motor circuit - When TCCU detects the motor failure for 1 second
- Check the relevant harnesses for contact.
- Replace TCCU if necessary.
A / BAG
P1842 Short to ground in shift motor output - When TCCU detects the motor failure for 1 second
circuit - Check the relevant harnesses for contact.
- Replace TCCU if necessary.
A / CON
P1843 Defective position sensor in motor - 2H-4H: after 1.5 seconds
- 4H-4L: after 3 seconds
- Check the relevant harnesses for contact.
- Replace TCCU if necessary.
P1844 Stuck in 4L mode - When no shifting operation from 4L to 4H, even though the
shift conditions are satisfied and no error.
- Replace TCCU if necessary.
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Code Description Action
P1850 Defective position encoder - When the position encoder is defective
- Check the relevant harnesses.
- Check the relevant connectors for contact.
- Check the shift motor.
P1851 Short to ground for position encoder 1 - Short to ground for position encoder 1 in shift motor
- Check the relevant harnesses for short.
• TCCU pin No.18
- Check the relevant connectors for contact.
- Check the shift motor.
P1852 Short to ground for position encoder 2 - Short to ground for position encoder 2 in shift motor
- Check the relevant harnesses for short.
• TCCU pin No.5
- Check the relevant connectors for contact.
- Check the shift motor.
P1853 Short to ground for position encoder 3 - Short to ground for position encoder 2 in shift motor
- Check the relevant harnesses for short.
• TCCU pin No.19
- Check the relevant connectors for contact.
- Check the shift motor.
P1854 Short to ground for position encoder 4 - Short to ground for position encoder 4 in shift motor
- Check the relevant harnesses for short.
• TCCU pin No.17
- Check the relevant connectors for contact.
- Check the shift motor.
P1815 Abnormal CAN neutral signal - No neutral signal from automatic transmission over 1
second through CAN.
- Check CAN communication line.
- Check TCU.
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Removal and Installation of TCCU
A/T
1. Slide the drive’s seat and fold up the carpet. TCCU
M / T
T/C
CLUTCH
2. Unscrew two nuts on the TCU.
AXLE
Installation Notice
Tightening torque 10 Nm
SP
ST’NG
BRAKE
A / BAG
3. Disconnect the TCCU connect and remove the TCCU.
A / CON
NOTICE
• Be careful not to apply any impact to TCCU body.
CHANGED BY PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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CLUTCH
3010
TABLE OF CONTENTS
GENERAL................................................................ 3
1. Function and overview ........................................................... 3
2. Specifications ....................................................................... 8
3. Trouble diagnosis .................................................................. 9
4. Maintenance ....................................................................... 10
CLUTCH ASSEMBLY ............................................ 12
1. Removal and installation ..................................................... 12
2. Special tools ane epuipment ............................................... 22
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3010 3
GENERAL
A/T
1. FUNCTION AND OVERVIEW
M / T
SAT (Self Adjusting Technology) Clutch System
1. Function Internal Components of Clutch Cover
T/C
SAT is new clutch system which adjusts the clutch free
play according to the wear of clutch disc.
CLUTCH
AXLE
SP
2. Operation description
1) Diaphragm spring rotates the adjusting equipment
ST’NG
as clutch disc is wearing and so, pressure plate is
pushed to clutch disc side at the amount of wear.
2) Disc wear (Free play) →Diaphragm spring (1) →
BRAKE
Adjusting equipment (2, 3) →Pressure plate (4)
Overview
A / BAG
1. Driving Elements
The driving elements consist of two flat surfaces machined to a smooth finish.
A / CON
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.
2. Driven Elements
The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the
input shaft.
The driving and driven elements are held in contact by spring pressure. This pressure is exerted by a diaphragm
spring in the clutch cover pressure plate assembly.
3. Operating Elements
The clutch “release” system consists of the clutch pedal and clutch release cylinder.
This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases
the clutch by using release lever and release fork. This system provides higher efficiency than conventional clutch
system, and its durability is superior.
1) Clutch master cylinder (mounted on clutch pedal)
2) Concentric slave cylinder pipe (mounted inside of transmission)
CHANGED BY CLUTCH
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Functions
Components of Clutch Assembly
A. Adapter/Pipe Assembly
B. Clutch Assembly C. Concentric Slave Cylinder
Cross Sectional View of Clutch Assembly
1. Transmission housing 3. Clutch disc cover assembly 5. Washer
2. Clutch disc assembly 4. Bolt 6. Bolt
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Clutch Master Cylinder and Reservoir
A/T
The clutch master cylinder generates the hydraulic pressure by moving the piston within the cylinder. It consists of
oil tank, cylinder, piston, piston cup spring and push rod, and the clutch fluid is supplied from the brake fluid reservoir
tank.
M / T
Operation:
When depressing the clutch pedal, the push rod pushes the piston and the piston cup, which sends the oil in the oil
reservoir tank to the concentric slave cylinder through the hose and pipe. During this operation, an oil pressure is
T/C
produced within the master cylinder and transmitted as follows: concentric slave cylinder →clutch cover →clutch disc.
When releasing the clutch pedal, it returns to its original position through the motion of the clutch cover and the
spring within the cylinder, and the clutch operation stops. The piston in cylinder returns to its original position.
CLUTCH
Clutch / Brake fluid reservoir
AXLE
Nipple
SP
Clutch reservoir hose
ST’NG
Brake master Clamp Clutch master
BRAKE
cylinder cylinder
A / BAG
Clutch Release Chamber
The clutch release chamber keeps the oil pressure in the clutch hose and pipe stable and also helps the oil pressure
A / CON
to transfer quickly and generates the remaining pressure in the hose and pipe when the clutch is operated.
Cap
Chamber
assembly
Pipe
CHANGED BY CLUTCH
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Clutch Pedal
1. Pendant type clutch pedal (leverage effect is applied to
reduce the effort to the feet).
2. The clutch pedal has some free play that prohibits its
operation prior to generating the resistance by depress-
ing the pedal and touching the release bearing pressure
plate. This free play is to prevent the clutch disc from
burning out that is resulted from the overheating caused
by the clutch slipping while driving. If this free play is too
wide, engine power disconnection is difficult and the gear
damage with abnormal noise will occur.
Clutch Assembly
Clutch assembly is composed of clutch cover (diaphragm
spring, pressure plate) and clutch disc.
Clutch Disc
The clutch disc is installed between the engine flywheel and the pressure plate. The spline part is installed in the
,
center of the disc and transmits the engine s electric power to the transmission. The transmission input shaft can be
inserted into the spline part. The clutch disc has friction materials on its edges, where the engine power can be
interrupted, and the cushion spring is installed to prevent friction materials (facing) from unevenly wearing out.
Clutch Cover Assembly
When depressing the clutch pedal, the concentric slave cylinder pushes the pressure plate diaphragm and sepa-
rates the pressure plate. The advantages of using the diaphragm spring: the pressure varies only a little even when
the clutch disc facing is considerably worn out, its structure is simple, and the pedal effort is small.
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Mounting on Dash Panel
A/T
Models without ABS/ESP Models with ABS/ESP
M / T
T/C
CLUTCH
AXLE
Clutch pipe Clutch pipe mounting clip
mounting clip
SP
Tube (Master
Oil Tube (Master
Oil cylinder-oil chamber)
chamber cylinder-oil chamber)
ST’NG
chamber
BRAKE
A / BAG
A / CON
CHANGED BY CLUTCH
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2. SPECIFICATIONS
Specifications
Description Specification
Operating type Hydraulic
Clutch pedal Type Suspended
Maximum pedal stroke Diesel engine equipped vehicle: 140 mm
Pedal free play 5 ~ 10 mm
Clutch disc Type Single dry diaphragm
Dimension of facing 240 × 155 × 4.0 mm
Facing size/quantity 263 cm2 / 2
Thickness of disc Free: 9.4 ~ 10 mm
When loaded: 9.0 ± 0.3 mm
Clutch cover assembly setting force Min. 720 kg
Clutch master cylinder Stroke 28.4 mm
Inner diameter φ 17.04 mm
Concentric slave cylinder Stroke 7.0 mm
Sectional area 706 mm2
Clutch fluid DOT3 or DOT4
Tightening Torque
Description Tightening Torque
Clutch housing bolt (8 locations) 49 ~ 59 Nm
Clutch cover (pressure plate) bolt 21 ~ 27 Nm
Concentric slave cylinder bolt (3 locations) 10 ~ 16 Nm
Concentric slave cylinder flare nut 20 ~ 25 Nm
Adapter flare nut 20 ~ 25 Nm
Clutch oil pipe flange nut 15 ~ 18 Nm
Master cylinder bolt 8 ~ 18 Nm
Fulcrum (clutch pedal bushing) bolt/nut 16 ~ 22 Nm
Clutch pedal bracket mounting bolt 8 ~ 18 Nm
Stopper bolt 16 ~ 22 Nm
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3. TROUBLE DIAGNOSIS
A/T
Check Possible Cause Action
Clutch slips Excessive wear of facing Replace
M / T
Hard or oily facing Adjust or replace
Damaged diaphragm or flywheel Replace
Damaged or burnt diaphragm spring Replace
T/C
Insufficient clutch pedal free play Adjust
Faulty operation of clutch pedal Repair or replace
CLUTCH
Worn or damaged clutch disc Replace
Poor disengagement Vibration or excessive run-out of disc Replace
Rust or wear of clutch disc spline Repair or replace
Oily facing Adjust or replace
AXLE
Burnt diaphragm spring Replace
Excessive clutch pedal free play Adjust
Hard to shift or will not shift Excessive clutch pedal free play Adjust pedal freeplay
SP
Faulty clutch release cylinder Repair release cylinder
Worn disc, excessive run-out, damaged lining Repair or replace
ST’NG
Dirty or burred splines on input shaft or clutch disc Repair as necessary
Damaged clutch pressure plate Replace
Clutch chatters when starting Oily facing Repair or replace
BRAKE
Hard or faulty facing Replace
Burnt cushion spring Replace
Faulty pressure plate Replace
A / BAG
Bent clutch diaphragm spring Replace
Hard or bent flywheel Adjust or replace
Engine mounts loose or burnt lever Tighten or replace
A / CON
Difficult pedal operation Poor bleeding in hydraulic system Bleed or replace
Poor lubrication on pedal shaft Lubricate or replace
Poor lubrication on clutch pedal Repair
Not using the clutch Insufficient clutch pedal free play Adjust
Excessive wear of clutch disc facing Replace
After disengagement Worn or damaged concentric slave cylinder Replace
Clutch
noisy When disengaging Faulty installation of clutch assembly or bearing Repair
Clutch pedal is Damaged pilot bushing Replace
partially depressed
and vehicle speed is
reduced
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4. MAINTENANCE
Air Bleeding
Air bleed
Clutch
Plastic tube
NOTICE
• Keep the fluid level over MAX in reservoir during
bleeding operation.
• Do not let the fluid contact a painted surface.
1. Remove the air bleed bolt cap on the release cylinder.
Connect a plastic tube to the bolt.
2. Put the other side of the tube into a empty container.
3. Slowly pump the clutch pedal several times.
4. With clutch pedal fully depressed, undo the air bleed
bolt and bleed the air and fluid from the fluid line.
5. Repeat step 3 through 4 until no more air bubbles are in
the escaping fluid.
NOTE
• This work has to be done by two service persons.
• After bleeding, check the clutch system for operation
and noise.
• Use only the Ssangyong genuine clutch fluid, and
check the clutch fluid level in reservoir.
Clutch fluid DOT 3, 4
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3010 11
Clutch Replacement
A/T
To prevent early wear and slip in clutch disc, always use the designated tools and special
tools for maintenance.
M / T
Service Instruction
T/C
1. Replacement of clutch disc →Replace the clutch cover assembly together.
2. Reinstallation of clutch disc & cover →Apply the zig set (SST) on the clutch cover set.
(Example: engine removal and reinstallation, flywheel related job, checking the clutch assy)
CLUTCH
NOTICE
AXLE
• When reinstall the clutch assembly without the special zig, disc can be slipped and worn easily.
SP
How to Use Special Tool
How to identify SAT clutch specification
ST’NG
Identify the SAT clutch with compensation device (arrow)
on clutch cover.
BRAKE
A / BAG
A / CON
Installation of Special Zig
Remove the transmission and place the zig set (4 pieces) between the clutch cover and diaphram spring around
(refer to the picture).
* P/No: D9930 - 0010C
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CLUTCH ASSEMBLY
1. REMOVAL AND INSTALLATION
Components
1. Clutch pedal 7. Clutch housing
2. Clutch master cylinder 8. Concentric slave pipe
3. Clutch hydraulic pipe 9. Concentric slave cylinder
4. Clutch fluid chamber 10. Clutch cover
5. Clutch hydraulic hose 11. Clutch disc
6. Adapter
A-A : Connection
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Removal and Installation of Components
A/T
Clutch Assembly
1. Disconnect the clutch fluid hose from the adapter.
M / T
Hose connection (clip mounted)
T/C
CLUTCH
AXLE
2. Remove the transmission assembly.
SP
ST’NG
BRAKE
A / BAG
A / CON
3. Insert the centering pin (special tool) into center spline.
Loosen the clutch cover bolts 1/2 turns in cross sequence
until the spring tension is released.
NOTICE
• Do not remove the bolts at a time, or clutch cover may
be damaged or deformed.
Installation Notice
Tightening torque 24 ± 3 Nm
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4. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc.
NOTICE
• Be careful not to drop the pressure plate and clutch disc.
T/M installation mark
Clutch disc Pressure plate
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3010 15
Concentric Slave Cylinder
A/T
1. Unscrew the nut and remove the oil pipe from the clutch
housing.
M / T
Installation Notice
Tightening torque 20 ~ 25 Nm
T/C
CLUTCH
2. Unscrew the oil pipe adapter mounting bolt from the
clutch housing and remove the adapter and oil pipe.
AXLE
SP
ST’NG
BRAKE
3. Unscrew three bolts and remove the concentric slave cylinder assembly on the input shaft of cylinder.
A / BAG
A / CON
Tightening torque:
10 ~ 16 Nm
4. Install in the reverse order of removal.
NOTICE
• Before installation, clean all the components.
• Do not re-use the used clutch fluid.
• Apply a small amount of clutch fluid on the internal components such as piston.
• Replace parts if necessary.
Keep the specified tightening torque.
CHANGED BY CLUTCH
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16 3010
Clutch Master Cylinder
1. Drain the clutch fluid.
2. Disconnect the clutch fluid feed hose from the brake reservoir.
Brake and clutch fluid reservoir
Nipple
Clutch reservoir hose
Clutch master
cylinder
Clamp Clutch master cylinder
3. Disconnect the clutch fluid feed pipe (to chamber) and unscrew two clutch master cylinder mounting nuts (10 mm).
Tightening torque: Tightening torque:
15 ~ 18 Nm 8 ~ 18 Nm
4. Disconnect the clutch master cylinder push rod from the clutch pedal and remove the clutch master cylinder.
5. Install in the reverse order of removal and check “air bleeding and clutch pedal operation” after installation.
CLUTCH CHANGED BY
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3010 17
Clutch Pedal
A/T
1. Unscrew the clutch master cylinder mounting bolts. Dash panel
Stud bolt on clutch
Installation Notice pedal side
M / T
Tightening torque 8 ~ 18 Nm
Hexagon flange nut
T/C
Stud bolt on
clutch pedal side
CLUTCH
Cylinder module assembly
AXLE
2. Remove the snap pin from master cylinder push rod.
SP
Push rod on clutch
master cylinder side
ST’NG
Pin
BRAKE
Snap pin
A / BAG
INSTALLATION NOTICE
Clutch pedal
• Securely install the snap pin as shown in figure.
3. Unscrew the mounting nut (12 mm) and remove the pedal
Stud bolt (1EA) A / CON
box assembly.
Installation Notice
Tightening torque 8 ~ 18 Nm
Hexagon
Push rod on flange nut
master cylinder
Clutch pedal
mounting hole Pedal box assembly
CHANGED BY CLUTCH
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18 3010
Installation Notice
Install in the reverse order of removal. Adjust pedal stroke
after installation.
NOTICE
• Apply long-life grease (T/M DBL 6611.00) to the
connections.
• Remove foreign materials.
• Keep the tightening torque.
• Replace the bushings with new ones.
Inspection and Adjustment
1. Pedal Stroke (A)
Maximum pedal stroke 140 mm
2. Pedal Height (B)
Height (from carpet) 181 ± 5 mm
NOTICE
• To adjust the pedal stroke, loosen the lock nut (C) of
the stopper bolt (D) and turn the stopper bolt until the
stroke is correct. After adjustment, tighten the lock nut.
3. Pedal Free Play (E)
Free play 5 ~ 15 mm
NOTICE
• To adjust the pedal free play, loosen the lock nut (F)
of the master cylinder and turn the push rod until the
free play is correct.
4. Check the fulcrum bolt and the bushing for wear, the
pedal for bending and the spring for damage.
CLUTCH CHANGED BY
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3010 19
Clutch Chamber
A/T
Removal/Installation
1. Drain the fluid.
M / T
2. Unscrew the bolt and remove the supply pipe from clutch
master cylinder.
Installation Notice
T/C
Tightening torque 15 ~ 18 Nm
CLUTCH
3. Unscrew the supply pipe bolt and remove primary oil
AXLE
pipe from clutch fluid chamber. Tightening torque:
15 ~ 18 Nm
4. Unscrew the pipe bolt and remove the secondary clutch
fluid pipe from concentric slave cylinder adapter.
5. Install the pipes. Be careful not to mix the pipes.
SP
NOTE
• Make sure to bleed the air from the system after
ST’NG
installation.
• Check each pipe bolt for oil leaks.
• Clutch pipes are reusable. However, you must check
BRAKE
the pipes for damages and cracks.
A / BAG
Chamber and Pipe
Master cylinder
A / CON
Oil chamber
Primary oil pipe
Secondary clutch
fluid pipe
Concentric slave
cylinder adapter
CHANGED BY CLUTCH
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20 3010
Inspection and Maintenance
1. Clutch Cover Assembly
1) Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit 0.8 mm
2) Check the pressure plate surface for wear, crack and
discoloration.
3) Check the strap plate rivet for looseness and replace
the clutch cover if necessary.
2. Clutch Disc
1) Check the facing for rivet looseness, sticks, oil and
grease.
2) Measure the rivet head depth. If it is out of limit, re-
place the disc.
Wear limit 0.3 mm
3. Clutch Disc Run-Out
1) Measure the clutch disc run-out and if it is out of
limit, replace the disc.
Run-out limit Within 0.7 mm
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3010 21
A/T
4. Pressure Plate
1) Check the pressure spring for wear.
M / T
NOTICE
• The excessively worn components should be
replaced.
T/C
CLUTCH
AXLE
5. Concentric Slave Cylinder
1) Check any heat damage, abnormal noise, poor rotation and wear of the concentric slave cylinder bearing.
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY CLUTCH
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22 3010
2. SPECIAL TOOLS AND EQUIPMENT
Name and Part Number Application
D9930 - 0010C Support diaphram spring when
disassembled
Zig set - diaphram spring
CLUTCH CHANGED BY
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AXLE
4120 / 4210 / 4220
TABLE OF CONTENTS
GENERAL ................................................................ 3
1. Overview ................................................................................ 3
FRONT AXLE .......................................................... 5
FRONT AXLE ASSEMBLY ...................................... 6
REMOVAL AND INSTALLATION ............................ 8
5-LINK TYPE REAR AXLE .................................... 15
1. Location .............................................................................. 15
2. Removal and installation ..................................................... 18
INDEPENDENT SUSPENSION TYPE REAR AXLE ... 24
1. Overview .............................................................................. 24
2. Exploded view ..................................................................... 26
3. IRDA (Independent Rear Drive Axle) .................................... 28
4. Removal and installation ..................................................... 30
5. Trouble diagnosis ................................................................ 32
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4120 3
GENERAL
A/T
1. OVERVIEW
M / T
Compared to previous models, in addition to existing 5-link suspension, the IRDA (Independent Rear Drive Axle)
is adopted for the independent type suspension in this vehicle.
The below figures for rear axle show the rear axle with the independent type suspension (4WD, A/T).
T/C
Front Axle
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
Rear Axle
A / CON
IRDA (Independent Rear Drive Axle)
CHANGED BY AXLE
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4 4120
Location Front axle Rear axle
Specification M/T A/T Independent suspension 5-link
Torque - - 5,164 Nm -
D20DT D27DT D20DT D27DT
Gear ratio ← ←
4.27 3.91 3.54 3.31
Type → → Hypoid ←
Gear Size φ 198.1 mm ← 218 mm (diameter) φ 243.8 mm
Offset 30 mm ← Less than 30 mm -
Steel casting Aluminum die Steel casting
Housing ←
(steel, aluminum cover) casting (steel, aluminum cover)
SAE 75W/90
Specification SAE 80W/90 ← SAE 80W/90
(Synthetic)
Oil
Capacity 1.4 L 1.4 L 1.5 L 1.9 L
Length 448.0 mm ← 412 mm 469.0 mm
Width 681.9 mm ← 292 mm 1717.7 mm
Weight 45 kg ← 30 kg 100 kg
AXLE CHANGED BY
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4120 5
FRONT AXLE
A/T
Location
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
Sectional Diagram
Tire wheel
A / BAG
Knuckle From vacuum pump
A / CON
To air
Cap & lock nut
Tightening torque:
28 ~ 32 Nm Axle shaft
Tire fixing bolt
Tightening torque:
120 ~ 140 Nm
Brake disc
CHANGED BY AXLE
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6 4120
FRONT AXLE ASSEMBLY
Front Disc & Wheel end Assembly
Wheel speedo cable
Locking hub actuator
Brake disc
Knuckle
Front wheel speed
sensor cable
Brake disc
Disc dust cover
Axle Shaft Assembly
Front disc assembly
Wheel speed sensor
& cable
Axle shaft assembly
Locking hub actuator
AXLE CHANGED BY
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4120 7
A/T
M / T
T/C
CLUTCH
AXLE
STEERING SUSPENSION
BRAKE
Front Axle Housing Assembly
AIR BAG
Air bleed hose
Front axle housing
AIRCON
Axle mounting
bolt Front Axle mounting
axle bolt
Nut
Axle
Axle mounting mounting Axle mounting
lower bushing bolt lower bushing
Axle mounting
upper bushing
Axle mounting Axle
lower bushing mounting
bracket
Axle mounting bracket
CHANGED BY AXLE
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8 4120
REMOVAL AND INSTALLATION
Caution
1. Be careful not to damage the seal ring in the locking hub actuator when installing the front disc and the
hub end assembly.
Seal ring
1. Removal of the front tire
Remove the front tire wheel caps. Unscrew five wheel nuts (21 mm) in diagonal direction and remove tires.
Installation Notice
Tightening torque 120 ~ 140 Nm
Wheel cap
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4120 9
A/T
2. Wheel speed sensor connector and vacuum hose
M / T
Disconnect the wheel speed sensor cable and connector, and disconnect the vacuum hose from the locking hub actuator.
LH
Connector Be careful not to damage
the vacuum hose.
T/C
CLUTCH
Brake
hose
AXLE
Vacuum
hose
RH
SP
ST’NG
BRAKE
A / BAG
3. Brake disc caliper
Unscrew two mounting bolts (19 mm) and remove the brake disc caliper. Set the removed caliper on the vehicle
A / CON
frame.
Installation Notice
Tightening torque 85 ~ 105 Nm
CHANGED BY AXLE
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10 4120
Axle Shaft
Removal and Installation
1. Remove the hub bearing cap and unscrew the lock nut (14 mm) on the brake disc.
Tightening torque:
Hub bearing cap 28 ~ 32 Nm
NOTICE
• The hub bearing cap and the lock nut are not reusable. Always replace them with new ones after removal.
2. Unscrew the upper arm lock nut, the tie rod end lock nut and the lower arm lock nut from knuckle, and then
remove the front disc and the wheel end assembly.
Upper arm (1)
Tightening torque:
140 ~ 160 Nm
Lower arm (3)
Tie rod end (2)
Tightening torque:
Tightening torque:
150 ~ 170 Nm
110 ~ 130 Nm
3. Loosen the upper arm (1) and the tie rod end
(2) and remove the assembly.
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4120 11
A/T
4. Remove the axle shaft.
M / T
T/C
CLUTCH
AXLE
STEERING SUSPENSION
BRAKE
AIR BAG
AIRCON
Components
Boot band Shaft Boot band Seal
Drive shaft Boot band Boot (in-board)
Ball joint Boot (out-board) Boot band Housing (in-board)
CHANGED BY AXLE
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12 4120
Axle Housing
1. Remove the axle shaft from the axle housing. Remove the propeller shaft and secure it to frame.
2. Removal of mounting bolt
Unscrew the mounting nut (22 mm) at right side
and remove the axle mounting bolt.
Installation Notice
Tightening torque 95 ~ 142 Nm
3. Unscrew the four bolts (17 mm) on the axle
housing and remove the axle mounting
bracket.
Installation Notice
Tightening torque 80 ~ 100 Nm
AXLE CHANGED BY
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4120 13
A/T
4. Unscrew one mounting nut (22 mm) at left side of
the axle housing and four bolts on mounting bracket
M / T
(17 mm) to remove the mounting bracket.
Tightening Torque
Mounting nut (22 mm) 95 ~ 142 Nm
T/C
Bracket bolt (17 mm) 80 ~ 100 Nm
CLUTCH
NOTE
• Remove the power steering hose mounting
bracket before removing the left pin bolt.
Otherwise, it cannot be removed due to
interruption.
AXLE
5. Place a safety jack under the axle housing
and remove the axle mounting bolts (22 mm).
STEERING SUSPENSION
Installation Notice
Tightening torque 95 ~ 142 Nm
BRAKE
AIR BAG
AIRCON
CHANGED BY AXLE
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14 4120
6. Remove the fixing clip on the air bleed hose above the axle housing and carefully lower the safety jack.
Axle Housing Assembly
NOTICE
• Be careful not to damage the left and right seals in axle housing when removing the axle mounting
bracket and axle assembly.
Air bleed hose
Front axle housing
Axle mounting
bolt Front axle
Axle mounting bolt
Axle
mount- Nut
ing bolt
Axle mounting Axle mounting
lower bushing Axle mounting lower bushing
upper bushing
Axle mounting
lower bushing
Axle mount-
Axle mounting ing bracket
bracket
AXLE CHANGED BY
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4120 15
5-LINK TYPE REAR AXLE
A/T
1. LOCATION
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AXLE
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16 4120
Components
Axle Shaft
Disc type
Axle Housing
Axle Yoke
Rear Axle
Axle Housing
Axle Shaft
Drum Type
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4120 17
Specifications
A/T
Front View
M / T
T/C
CLUTCH
AXLE
Rear View
SP
ST’NG
BRAKE
A / BAG
A / CON
Specifications
Description Specification
Axle shaft type Semi-floating type
Axle housing type Build-up type
Differential Type Conventional
Gear type Hypoid
Final gear ratio DI engine + M/T (D20DT / D27DT) 4.27 / 3.91
DI engine + A/T (D20DT / D27DT) 3.54 / 3.31
Oil Capacity 1.9 L
Specification SAE 80W/90 or API GL-5
CHANGED BY AXLE
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18 4120
2. REMOVAL AND INSTALLATION
Rear Axle Shaft (Disc Brake Type)
Preceding Works: Remove the tire.
1. Unscrew the two mounting bolts (19 mm) and remove
the brake disc caliper. Set the removed caliper on the
vehicle frame.
Caliper mounting bolt 85 ~ 105 Nm
2. Unscrew the mounting bolt (10 mm) and disconnect
the wheel speed sensor cable.
Installation Notice
Tightening torque 6 ~ 8 Nm
AXLE CHANGED BY
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4120 19
A/T
3. Unscrew the adjusting nut of the parking brake cable
equalizer to loosen the parking brake cable.
M / T
Adjusting nut
T/C
CLUTCH
AXLE
4. Remove the lock pin and disconnect the parking brake cable.
SP
Parking
brake cable
Lock pin
5. Remove the brake disc. ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AXLE
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20 4120
6. Remove the plastic plug from the axle shaft flange.
7. Unscrew the four flange lock bolts (17 mm) on the axle
housing flange and remove the axle shaft.
Installation Notice
Tightening torque 50 ~ 64 Nm
AXLE CHANGED BY
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4120 21
Rear Axle Housing
A/T
Preceding Works: Remove the tire.
1. Remove the wheel speed sensor (A), the air breather lock nut (B), the parking brake cable (C) and the disc
brake caliper (D) from the rear axle.
M / T
A. Wheel Speed Sensor (10 mm - 1EA) - LH/RH B. Air Breather (Lock Bolt 10 mm - 1 EA)
Tightening torque: Tightening torque:
T/C
6 ~ 8 Nm 6 ~ 8 Nm
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
C. Parking Brake Cable - LH/RH D. Disc Brake Caliper - LH/RH
Tightening torque:
85 ~ 105 Nm
CHANGED BY AXLE
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22 4120
2. Place a safety jack under the axle housing and unscrew the connections.
A. lateral rod mounting nut (22 mm) B. Lower arm bolt/nut (22 mm) C. Shock absorber bolt/nut
(17 mm: nut, 10 mm: bolt)
Tightening torque 150 ~ 180 Nm Tightening torque 150 ~ 180 Nm Tightening torque 80 ~ 100 Nm
F. Upper arm A. Lateral rod
D. Stabilizer mounting bracket E. Propeller shaft B. Lower arm C. Shock absorber
D. Mounting bracket bolts of stabi- E. Propeller shaft F. Upper arm bolt/nut (22 mm)
lizer bar (14 mm - 2 EA: LH/RH)
Assembly mark
Tightening torque 40 ~ 60 Nm Tightening torque 70 ~ 80 Nm Tightening torque 150 ~ 180 Nm
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4120 23
3. Carefully lower the safety axle to remove the rear axle assembly from the vehicle frame.
A/T
Front View
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
Rear View
BRAKE
A / BAG
A / CON
CHANGED BY AXLE
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24 4120
INDEPENDENT SUSPENSION TYPE REAR AXLE
1. OVERVIEW
Introduction
Compared to previous models, in addition to existing 5-link suspension, the IRDA (Independent Rear Drive Axle)
is adopted for the independent type suspension in this vehicle.
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4120 25
A/T
Specifications
M / T
Description Rear axle
T/C
Type Independent suspension 5-link
Torque 5,164 Nm -
CLUTCH
M/T 4.27 / 3.91 (D20DT / D27DT)
Gear ratio ←
A/T 3.54 / 3.31 (D20DT / D27DT)
AXLE
Type Hypoid ←
Gear Size 218 mm (diameter) φ 243.8 mm
SP
Offset Less than 30 mm -
ST’NG
Steel casting
Housing Aluminum die casting
(steel, aluminum cover)
BRAKE
SAE 75W/90
Specification SAE 80W/90
Oil (Synthetic)
A / BAG
Capacity 1.5 L 1.9 L
Length 412 mm 469.0 mm
A / CON
Width 292 mm 1717.7 mm
Weight 30 kg 100 kg
CHANGED BY AXLE
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2. EXPLODED VIEW
6 7 8 9 10
1 2 5
4
3
11
12
20
18 19
13 17
14 15
16
45
44
43
42 25
41 24
40 23
39
38 22
37 21
36
35
34
33 32 31
30
29
28 27
26
1. Differential case side bearing 15. Ring gear bolt 31. Drain plug
assembly 16. Cover fan gasket 32. Drain plug washer
2. Ring gear 17. Dowel pin 33. Fill plug
3. Differential pinion thrust washer 18. Cover fan 34. Fill plug washer
4. Differential pinion gear 19. Vent connector 35. Pinion flange nut
5. Cross shaft snap ring 20. Cover fan bolt 36. Pinion flange washer
6. Differential side gear thrust 21. Dowel pin 37. Pinion flange assembly
washer
22. Pinion spacer 38. Pinion seal assembly
7. Differential side gear
23. Pinion head bearing assembly 39. Pinion tail bearing assembly
8. Differential case cross shaft
24. Pinion shim 40. Carrier housing
9. Differential gear
25. Pinion gear 41. Differential bearing assembly
10. Differential thrust washer
26. Output shaft 42. Differential case side bearing
11. Differential side gear snap ring
27. Output shaft snap ring
12. Differential side gear thrust 43. Shaft seal assembly
28. Shaft seal assembly
washer
29. Differential case side bearing 44. Output shaft snap ring
13. Differential case
snap ring 45. Output shaft
14. Differential case side bearing
30. Differential bearing race
assembly
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Sectional Drawing
A/T
M / T
T/C
CLUTCH
AXLE
Rear axle assembly
Ball joint
SP
Boot
ST’NG
BRAKE
Rear axle shaft
A / BAG
A / CON
Boot Brake disc
Ball joint
Back plate
Hub bearing
Wheel / Tire
Parking brake
Tightening torque:
Lock nut 250 ~ 350 Nm
CHANGED BY AXLE
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3. IRDA (INDEPENDENT REAR DRIVE AXLE)
IRDA Axle Mounting Bolt (30 mm - 1 EA)
Tightening torque:
95 ~ 142 Nm
Brake Disc Lock Nut (30 mm - 1 EA)
* Caulk the nut after tightening
Tightening torque:
250 ~ 350 Nm
Axle Shaft Assembly
Axle shaft Rear axle shaft
Hub plane washer
Mounting bolt
Lock nut (axle side)
Tightening torque: Tightening torque:
250 ~ 350 Nm 70 ~ 80 Nm
AXLE CHANGED BY
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A/T
Axle Housing Bracket Mounting Bolt
M / T
Rear axle Tightening torque:
bracket 9 ~ 11 Nm
T/C
CLUTCH
AXLE
STEERING SUSPENSION
Axle Housing Mounting Bracket Bolt
BRAKE
AIR BAG
AIRCON
Axle Housing Mounting Bolt
Tightening torque:
9 ~ 11 Nm
Rear axle bracket
Rear axle
CHANGED BY AXLE
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 4120
4. REMOVAL AND INSTALLATION
1. Loosen the locked positions and remove the lock nut (24 mm).
Tightening torque:
250 ~ 350 Nm
2. Make an alignment mark on the flanges of the axle shaft and the axle housing. Unscrew the six bolts (Torx 10
mm) and remove the axle shaft while lowering the axle shaft flange.
Tightening torque:
70 ~ 80 Nm
Alignment mark
Lower the axle shaft.
Remove the axle shaft.
AXLE CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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4120 31
3. Unscrew the two axle housing mounting bolts (22
mm).
A/T
M / T
T/C
CLUTCH
4. Unscrew the mounting bolt (30 mm) and carefully lower the safety jack with axle housing assembly.
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
Tightening torque:
95 ~ 142 Nm
Backlash Check
Measure the backlash between the drive pinion and
ring gear.
Specified value 0.15 ~ 0.20 mm
CHANGED BY AXLE
EFFECTIVE DATE KYRON SM - 2005.09
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32 4120
5. TROUBLE DIAGNOSIS
Symptom Cause Action
Noise Lack of oil Replenish
(during driving straight Low viscosity of oil Replace
ahead) Inferior oil Replace
Excessive backlash of ring gears Adjust
Worn or damaged tooth of ring and pinion gear Replace
Worn or damaged drive pinion bearing Replace
Wear of side bearing and side gear spline Replace
Bending of axle housing Replace
Distortion of differential case Replace
Wear of pinion shaft Replace
Incorrect drive pinion preload Adjust
Incorrect contact of ring gear and pinion Reassembly
Excessive oil Adjust
Oil leakage Fault seal of carrier contact surface Correct
Axle housing crack Replace
Worn or damaged oil seal Replace
Worn or damaged tooth of pinion or side gear Replace
Noise (during turning) Wear of pinion shaft Replace
Excessive backlash of pinion gear and side gear Replace
Excessive end-play of axle shaft Adjust
Incorrect contact of side gear and differential case Replace
Axle housing crack Replace
Distortion or poor installation of drive pinion oil seal Replace
Damaged or torn drive pinion oil seal Replace
Loosened bearing collar Replace
Worn or damaged universal joint Replace
Worn or damaged axle shaft bearing Replace
Lack of oil Replenish
Heating Insufficient backlash of gears Adjust
Excessive preload of bearing Adjust
AXLE CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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4120 33
A/T
Inspection of Ring Gear Tooth Contact Pattern
1. Normal contact
M / T
Apply gear-marking compound (Prussian blue / red
lead) on the ring gear teeth. Rotate the ring gear and
check the tooth contact pattern.
T/C
CLUTCH
AXLE
2. Abnormal contact
Tooth Contact Pattern Possible Cause Remedy
1. Heel contact Excessive backlash Adjust backlash
SP
• Noise can be occurred (Decrease backlash)
• Select proper shin to move
the drive pinion toward the
ring gear (toward toe)
ST’NG
BRAKE
2. Toe contact Insufficient backlash Adjust backlash
• Tooth can be damaged or (Increase backlash)
broken under heavy load • Select proper shim to move
the drive pinion against the
A / BAG
ring gear (toward heel)
A / CON
3. Face contact Excessive backlash Adjust backlash
• Drive pinion shaft is apart (Increase pinion shim)
from the ring gear • Move the drive pinion toward
• Noise can be occurred the ring gear (toward the
center of ring gear)
4. Flank contact Insufficient backlash Adjust backlash
• Gear contacts on the low (Decrease pinion shim)
flank • Move the ring gear toward
• Gear can be damaged or the drive pinion (toward the
worn ring gear center line)
• Noise can be occurred
CHANGED BY AXLE
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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SUSPENSION
4411 / 4510 / 4520
TABLE OF CONTENTS
FRONT SUSPENSION ............................. 2 IRS TYPE REAR SUSPENSION ........... 32
1. System overview ................................................. 2 1. Overview ............................................................ 32
2. System layout ..................................................... 6 2. Specifications ................................................... 34
3. Removal and installation ..................................... 8 3. Trouble diagnosis .............................................. 34
4. Coil spring & shock absorber assembly .......... 10 4. Removal and installation ................................... 36
5. Stabilizer bar ..................................................... 12
6. Lower arm ......................................................... 14
5-LINK (RIGID TYPE) REAR SUSPEN-
SION ........................................................ 19
1. Overview ............................................................ 19
2. System layout ................................................... 20
3. Trouble diagnosis .............................................. 25
4. Removal and installation ................................... 26
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2 4411
FRONT SUSPENSION
1. SYSTEM OVERVIEW
Overview
The suspension is the device to connect the axle and vehicle frame. It absorbs the vibrations and impacts from
road surface, which enhances the comforts, driving force, braking force and drivability.
1. Suspension type: Double Wishbone
2. Component
Knuckle, upper arm assembly, lower arm assembly, coil spring, shock absorber assembly and stabilizer
Upper Arm Assembly
The upper arm is mounted to the frame and the
knuckle and it relieves the load delivered from the
tire to the knuckle. This enables to absorb the vari-
ous impacts according to the load shapes and to
ensure the drivability.
Lower Arm Assembly
The lower arm is mounted to the knuckle and the
shock absorber. It relieves the load delivered from
the tire to the knuckle. This enables to absorb
the various impacts according to the load shapes
and to ensure the drivability.
SUSPENSION CHANGED BY
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4411 3
A/T
M / T
Stabilizer Bar
Stabilizer bar
mounting bracket
T/C
CLUTCH
Bushing
Stabilizer bar
AXLE
Link
SP
A transverse mounted spring steel bar controls and minimizes body lean or
tipping on corners. This is a round bar which connects the left wheel suspen-
sion assembly with the right side. The main function is to keep both wheels
ST’NG
rolling at the same rate when meeting bumps, but it also affects handling.
BRAKE
A / BAG
A / CON
Coil Spring
A section of spring steel rod is wound in a spiral
pattern or shape coil provides a cushion to ab-
sorb road imperfections and returns the vehicle
to a predetermined ride height. It is amajor con-
tributor to a vehicle’s handling balance and ride
quality. Higher spring rates and shorter overall
lengths are commonly used to lower the vehicle’s
ride height for enhanced appearance and im-
proved handling.
CHANGED BY SUSPENSION
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4 4411
Shock Absorber Assembly
1. This vehicle uses the strut type shock absorber. This
shock absorber is connected to the piston rod in the
strut. This relieves the vertical vibrations of vehicle to
provide ride comforts, prevents the spring break, en-
hances drivability, and extends the life span of steer-
ing components. Coil spring
Shock absorber
Yoke
2. The telescopic shock absorber consists of a tube with piston and rod, and a cylinder tube. The piston has an
orifice and valve and the cylinder is filled with oil.
This double tube type shock absorber restrains the vibrations by using oil resistance. This provides better drivability
even though the structure is complicated.
This vehicle uses the gas shock absorber with cylindrical double tube.
Amplitude
Time
without shock absorber
with shock absorber
SUSPENSION CHANGED BY
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4411 5
Sectional Drawing of Shock Absorber
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
1. Lower spring seat 10. Bumper stopper
2. Yoke bracket 11. Spring seat rubber
3. Rebound stopper 12. Upper spring seat
4. Cylinder 13. Rubber
5. Piston 14. Rubber
6. Shock absorber assembly 15. Spacer
7. Spring 16. Washer
8. Yoke 17. Nut
9. Boot 18. Bolt
CHANGED BY SUSPENSION
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6 4411
2. SYSTEM LAYOUT
Specifications
Description Specification
Suspension type Double wishbone
Spring type Coil spring
Shock absorber type Cylindrical double tube (gas type)
Stabilizer type Torsion bar
Toe-in 2 ± 2 mm
Wheel alignment Camber -0.19° ± 0.3° (the difference between both ends is should be below 30' )
Caster 4.4° ± 0.5° (the difference between both ends is should be below 30' )
Height “H” 96.5 ± 5 mm
Upper arm (on knuckle) nut
Tightening torque: 140 ~ 160 Nm Upper Arm Assembly
Coil Spring
Shock Absorber
Front axle shaft assembly
Stabilizer Bar Assembly
Steering gear box
assembly
Lower Arm Assembly
Shock Absorber Yoke
Lower arm (on knuckle) nut
Tightening torque: 140 ~ 160 Nm
Knuckle Assembly
SUSPENSION CHANGED BY
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4411 7
A/T
Stabilizer bar link upper nut Coil spring mounting nut
Tightening torque: 30 ~ 50 Nm Tightening torque: 60 ~ 80 Nm
M / T
Upper arm (on frame) bolt / nut
Tightening torque: 110 ~ 130 Nm
Stabilizer bar link lower nut
T/C
Tightening torque: 110 ~ 130 Nm
Stabilizer bar mounting clamp bolt
Tightening torque: 30 ~ 45 Nm
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
Lower arm (on frame) bolt / nut
Tightening torque: 180 ~ 190 Nm
Lower arm (on shock absorber yoke) nut
Tightening torque: 150 ~ 170 Nm
Lower arm (end yoke) bolt
Tightening torque: 50 ~ 70 Nm
CHANGED BY SUSPENSION
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8 4411
3. REMOVAL AND INSTALLATION
Upper Arm
: Remove the upper arm assembly according to the sequences shown below and keep the specified tightening
torque when reinstalling it.
Preceding Works
1. Remove the tires.
Remove the wheel cap and loosen the wheel
nuts in several steps.
Installation Notice
Tightening torque 120 ~ 140 Nm
1. Wheel speed sensor cable
: Remove the wheel speed sensor cable and the con-
nector from the upper arm.
2. Upper arm nut (19 mm, knuckle side)
: Remove the split pin first and then remove the
mounting nut.
Tightening torque: NOTICE
140 ~ 160 Nm
• Replace the split pin with a new one when installing.
SUSPENSION CHANGED BY
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4411 9
A/T
M / T
3. Upper arm bolt/nut (frame side)
: Remove the upper arm
T/C
12 mm bolt mounting bolts and nuts
(LH/RH).
CLUTCH
AXLE
12 mm nut
Tightening torque:
110 ~ 130 Nm
SP
4. Upper arm
: Separate the upper arm from the
ST’NG
frame first, and then separate it
from the knuckle with a special
tool.
BRAKE
A / BAG
A / CON
Upper Arm Assembly
Upper arm
Bolt / nut
Split pin
Castle nut
CHANGED BY SUSPENSION
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10 4411
4. COIL SPRING & SHOCK ABSORBER ASSEMBLY
Preceding Work
Remove the tire and the upper arm.
1. The upper mounting nuts of the coil spring/shock absorber assembly (14 mm - 3 EA)
: At first, unscrew the two upper mounting nuts in engine compartment.
Engine Compartment
Tightening torque: 60 ~ 80 Nm
Wheel House
Tightening torque: 60 ~ 80 Nm
: Unscrew the upper mounting nut (14 mm) under the
wheel house.
2. The lower nut of the coil spring/shock absorber yoke (24 mm - 1 EA)
Shock ab-
Stabilizer sorber yoke
link (12 mm) (24 mm)
: Unscrew the lower nut of coil
spring/shock absorber yoke
from the lower arm. Do not com-
pletely remove the nut.
Tightening torque:
150 ~ 170 Nm
SUSPENSION CHANGED BY
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4411 11
A/T
3. Remove the coil spring/shock absorber.
M / T
T/C
CLUTCH
AXLE
Coil Spring Assembly
SP
ST’NG
BRAKE
Coil spring
A / BAG
Shock absorber
A / CON
Lock bolt
When installing the yoke Tightening torque:
to the coil spring/shock 100 ~ 120 Nm
absorber, make sure
that slot B and protru-
sion A are aligned.
Yoke
CHANGED BY SUSPENSION
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12 4411
5. STABILIZER BAR
Preceding Work
Remove the tires.
1. Remove the stabilizer bar link.
Tightening torque: 30 ~ 50 Nm
Tightening torque: 110 ~ 130 Nm
: Unscrew the lower mounting nut (12 mm) and up-
per mounting nut (10 mm) to remove the stabilizer
bar link assembly.
2. Unscrew the two bracket mounting bolts (14 mm) and remove the stabilizer bar assembly.
Mounting Stabilizer bar
bracket
Bushing
Tightening torque: 30 ~ 45 Nm
SUSPENSION CHANGED BY
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4411 13
A/T
Components
M / T
Bushing
T/C
Link Nut
Washer
CLUTCH
Tightening 7 ~ 10 mm
torque: Washer
30 ~ 50 Nm
AXLE
Bushing
SP
ST’NG
NOTICE
1. Be cautious of the direction of the bushing and
washer when installing.
BRAKE
2. Be cautious of the marks on the front stabilizer bar
(LH/RH) when installing.
LH: yellow mark
RH: white mark
A / BAG
A / CON
Stabilizer Bar Assembly
Bracket Bracket
Stabilizer bar
Bushing Bushing
Link Link
Nut Nut
CHANGED BY SUSPENSION
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14 4411
6. LOWER ARM
Preceding Works: 1. Remove the tires.
2. Make an alignment mark on the camber adjusting bolt of lower arm (frame side).
Wheel Alignment
Description Specification
Toe-in 2 ± 2 mm
Camber -0.19° ± 0.3° (the difference between both ends is should be below 30' )
Caster 4.4° ± 0.5° (the difference between both ends is should be below 30' )
Front
Rear
SUSPENSION CHANGED BY
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4411 15
A/T
3. Disconnect the SSPS solenoid valve connector.
M / T
T/C
CLUTCH
AXLE
4. Loosen the steering gear box by unscrewing the steering gear box mounting bolts (arrows) and remove the
camber adjusting bolts.
SP
ST’NG
BRAKE
A / BAG
A / CON
Interference between camber Interference between camber
bolt and steering gear box bolt and steering gear box
NOTICE
• Be careful not to damage the SSPS solenoid valve connector.
CHANGED BY SUSPENSION
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Removal and Installation
1. The lower arm mounting bolts/nuts on the frame (LH/RH)
Tightening torque: 180 ~ 190 Nm
: Before removing lower arm assembly, make the alignment marks on the mounting
nut (14 mm) on the frame and camber adjusting bolt (14 mm).
NOTE
• Always perform the wheel alignment procedures af-
ter removing and reinstalling the lower arm assembly.
2. Unscrew the lower nut of stabilizer bar link and the lower nut of
coil spring/shock absorber yoke.
Lower link nut (12 mm)
Tightening torque
1. Lower link nut (110 ~ 130 Nm)
Lower yoke nut (24 mm) 2. Lower shock absorber yoke nut (150 ~ 170 Nm)
SUSPENSION CHANGED BY
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4411 17
A/T
3. Unscrew the lower mounting nut (14 mm) and re-
Tightening torque: 50 ~ 70 Nm move the lower arm from knuckle end bolt with
special tool.
M / T
T/C
CLUTCH
Knuckle lower mounting nut (14 mm)
Tightening torque: 140 ~ 160 Nm
AXLE
4. Place a safety jack under the lower arm and un-
screw the lower shock absorber yoke bolt. Re-
move the yoke while raising the safety jack with
SP
lower arm.
ST’NG
BRAKE
A / BAG
A / CON
5. Remove the lower arm assembly from the vehicle.
Components
CHANGED BY SUSPENSION
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4510 19
5-LINK (RIGID TYPE) REAR SUSPENSION
A/T
1. OVERVIEW
M / T
The rear suspension is also to keep the ride comforts and drivability and this vehicle uses 5-link suspen-
sion system. It consists of coil springs on both sides, shock absorber, upper and lower arm, lateral rod
and stabilizer bar.
T/C
1. Stabilizer Bar: 2. Lateral Rod: 3. Upper/Lower Arm:
CLUTCH
It maintains the balance of the It controls the transverse load to It controls the longitudinal load to
vehicle when turning, and mini- the vehicle. the vehicle.
mizes the vehicle’s slope when
the wheels are moving up and
AXLE
down separately.
SP
ST’NG
BRAKE
A / BAG
A / CON
4. Shock Absorber: 5. Coil Spring:
It absorbs the vertical vibration of the vehicle body. It is installed between the rear axle and body
It enhances the ride comforts and prevents the frame. It relieves the vibrations and impacts deliv-
fatigue break of the spring. ered from wheels to vehicle body.
CHANGED BY SUSPENSION
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20 4510
2. SYSTEM LAYOUT
Lower Arm (Link)
Stabilizer Bar Link
Stabilizer Bar
Upper Arm (link)
Shock Absorber
Lateral Rod
Axle Housing
Coil Spring Seat
(Upper)
SUSPENSION CHANGED BY
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4510 21
A/T
Stabilizer bar link
M / T
(lower- 17 mm + 12 mm): 60 ~ 80 Nm
T/C
Lower arm (22 mm)
150 ~ 180 Nm Stabilizer bar link
(lower- 17 mm + 12 mm): 40 ~ 60 Nm
CLUTCH
Upper arm (22 mm) Stabilizer bar link
150 ~ 180 Nm (upper- 17 mm + 14 mm): 30 ~ 45 Nm
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
Lateral rod (22 mm)
165 Nm
Shock absorber (lower: 7 mm + 10 mm)
80 ~ 100 Nm
Shock absorber (upper: 2 mm)
30 ~ 45 Nm
CHANGED BY SUSPENSION
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Location
Shock Absorber Assembly Coil Spring Assembly
Lateral Rod Assembly
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4510 23
A/T
Stabilizer Assembly
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
Stabilizer Bar Link Upper/Lower Arm Assembly
CHANGED BY SUSPENSION
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24 4510
Installation Drawing
Front View
Rear View
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3. TROUBLE DIAGNOSIS
A/T
Symptom Cause Action
Vehicle rolling Broken stabilizer bar Replace
M / T
Faulty shock absorber Replace
Abnormal noises Loosening mountings Re-tighten
Damaged or worn wheel bearing Replace
T/C
Damaged shock absorber Replace
Damaged tire Replace
CLUTCH
Poor riding Over inflated tire Pressure adjust
Faulty shock absorber Replace
Loosened wheel nut Tighten as specified torque
Bent or broken coil spring Replace
AXLE
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to right or left Deformed arm assembly Replace
SP
Worn bushing Replace
Bent or broken coil spring Replace
ST’NG
Hard steering Excessive resistance of lower arm ball joint Replace
Insufficient tire pressure Replace
Faulty power steering Adjust
BRAKE
Steering instability Worn or loosened lower arm bushing Re-tighten or replace
Vehicle bottoming Worn or broken coil spring Replace
A / BAG
A / CON
CHANGED BY SUSPENSION
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26 4510
4. REMOVAL AND INSTALLATION
System Layout
Shock
absorber
Stabilizer bar Upper
arm
Rear suspension
assembly
Stabilizer bar link
Lateral rod
Coil spring
Lower arm
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Removal of Components
A/T
Remove the rear suspension components in order.
1. Remove the coil spring using a special tool.
M / T
T/C
CLUTCH
AXLE
SP
2. Remove the lateral rod.
ST’NG
1) Unscrew the lateral rod mounting nut (22 mm) on axle.
BRAKE
Installation Notice
Tightening torque 165 Nm
A / BAG
A / CON
2) Unscrew the lateral rod mounting bolt/nut (22 mm)
on frame.
Installation Notice
Tightening torque 165 Nm
CHANGED BY SUSPENSION
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28 4510
3. Disconnect the link and the bracket from the stabilizer bar to remove the stabilizer bar.
1) Unscrew the stabilizer bar link mounting nuts (upper/lower) and remove the link.
Installation Notice
Tightening torque 30 ~ 45 Nm
Protrusion of upper bolt 7 ~ 12 mm
2) Remove the mounting cap bracket and bushing
from the stabilizer bar (LH/RH).
Installation Notice
Tightening torque 40 ~ 60 Nm
SUSPENSION CHANGED BY
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4. Remove the shock absorber between the frame and the
axle.
A/T
M / T
T/C
CLUTCH
AXLE
1) Remove the upper mounting nut (17 mm) and the
shock absorber bolt (6 mm) as shown in the figure.
Installation Notice
Tightening torque 30 ~ 45 Nm
SP
Protrusion of upper bolt 27 mm
ST’NG
BRAKE
2) Remove the lower bolt/nut (17 mm).
A / BAG
Installation Notice
Tightening torque 80 ~ 100 Nm
A / CON
CHANGED BY SUSPENSION
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5. Remove the upper arm between frame and the axle.
A. Unscrew upper arm mounting bolt/nut B. Unscrew upper arm mounting bolt/nut
(22 mm) on axle. (22 mm) on frame.
Tightening torque 150 ~ 180 Nm Tightening torque 150 ~ 180 Nm
NOTICE
• The fuel tank should be removed before removing the rear left bolts (upper arm and lower arm).
SUSPENSION CHANGED BY
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4510 31
6. Remove the lower arm from the frame and the axle.
A/T
1) Remove the wheel speed sensor cable (1) and the parking cable (2) mounting bolt (12 mm) when removing
the lower arm.
M / T
T/C
Mounting bolt
CLUTCH
AXLE
SP
2) Unscrew lower arm mounting bolt/nut (22 mm) on
frame.
ST’NG
Installation Notice
Tightening torque 150 ~ 180 Nm
BRAKE
A / BAG
A / CON
3) Unscrew lower arm mounting bolt/nut (22 mm) on
axle.
Installation Notice
Tightening torque 150 ~ 180 Nm
CHANGED BY SUSPENSION
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32 4520
IRS TYPE REAR SUSPENSION
1. OVERVIEW
Overview
The rear suspension is also to keep the ride comforts and drivability and this vehicle uses IRS (Independent
Rear Suspension) and RIGID type. It consists of coil spring, shock absorber, upper arm, track rod,
thrust link and stabilizer bar.
69 ± 5 mm
Coil Spring
This is installed between the
rear axle and body frame. It
relieves the vibrations and im-
pacts delivered from wheels to
vehicle body.
The spring should be installed
as the red mark is over the yel-
low mark.
Red
Yellow
SUSPENSION CHANGED BY
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4520 33
A/T
M / T
Stabilizer Bar
A transverse mounted spring steel bar controls and
minimizes body lean or tipping on corners. This is a
T/C
round bar which connects the left wheel suspension
assembly with the right side. The main function is to
keep both wheels rolling at the same rate when meet-
ing bumps; but it also affects handling.
CLUTCH
AXLE
SP
Shock Absorber
This relieves the vertical vibra-
ST’NG
tions of vehicle to provide ride
comforts, prevents the spring
break, enhances drivability,
and extends the life span of
BRAKE
steering components.
A / BAG
A / CON
Upper Arm/Coil Spring Link
Upper Arm: Coil Spring Link:
This is connected to the knuckle and body This is connected to the knuckle and body frame
frame and controls the longitudinal load to and reduces the weight to coil spring and shock
the vehicle. absorber. It means that this controls the verti-
cal load to the vehicle.
CHANGED BY SUSPENSION
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34 4520
2. SPECIFICATIONS
Description Specification
Suspension type IRS type
Spring type Coil spring
Stabilizer bar type Torsion bar
Shock absorber Type Cylindrical double tube
Max. length 463 mm
Min. length 310 mm
Coil spring Coil thickness 14.9 mm
Inner diameter of coil (A) φ 70.1 mm
Free length (B) 344.9 mm
Length at load (C) 252.1 mm
Spring rate 8.68 ± 5 %
3. TROUBLE DIAGNOSIS
Trouble Diagnosis
Symptom Cause Action
Vehicle rolling Broken stabilizer bar Replace
Faulty shock absorber Replace
Abnormal noises Loosening mountings Re-tighten
Damaged or worn wheel bearing Replace
Damaged shock absorber Replace
Damaged tire Replace
Poor riding Over inflated tire Pressure adjust
Faulty shock absorber Replace
Loosened wheel nut Tighten as specified torque
Bent or broken coil spring Replace
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to right or left Deformed arm assembly Replace
Worn bushing Replace
Bent or broken coil spring Replace
Hard steering Excessive resistance of lower arm ball joint Replace
Insufficient tire pressure Replace
Faulty power steering Adjust
Steering instability Worn or loosened lower arm bushing Re-tighten or replace
Vehicle bottoming Worn or broken coil spring Replace
SUSPENSION CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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34 4520
2. SPECIFICATIONS
Description Specification
Suspension type IRS type
Spring type Coil spring
Stabilizer bar type Torsion bar
Shock absorber Type Cylindrical double tube
Max. length 463 mm
Min. length 310 mm
Coil spring Coil thickness 14.9 mm
Inner diameter of coil (A) φ 70.1 mm
Free length (B) 344.9 mm
Length at load (C) 252.1 mm
Spring rate 8.68 ± 5 %
3. TROUBLE DIAGNOSIS
Trouble Diagnosis
Symptom Cause Action
Vehicle rolling Broken stabilizer bar Replace
Faulty shock absorber Replace
Abnormal noises Loosening mountings Re-tighten
Damaged or worn wheel bearing Replace
Damaged shock absorber Replace
Damaged tire Replace
Poor riding Over inflated tire Pressure adjust
Faulty shock absorber Replace
Loosened wheel nut Tighten as specified torque
Bent or broken coil spring Replace
Damaged tire Replace
Worn bushing Replace
Vehicle pulls to right or left Deformed arm assembly Replace
Worn bushing Replace
Bent or broken coil spring Replace
Hard steering Excessive resistance of lower arm ball joint Replace
Insufficient tire pressure Replace
Faulty power steering Adjust
Steering instability Worn or loosened lower arm bushing Re-tighten or replace
Vehicle bottoming Worn or broken coil spring Replace
SUSPENSION CHANGED BY
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4520 35
A/T
Inspection
Wheel Bearing End Play
M / T
1. Release the parking brake.
2. Raise the rear wheel.
T/C
3. Check if the wheel bearing end play exists while rock-
ing the wheel.
4. If the end play is excessive, retighten the castle nut.
CLUTCH
5. If the end play still exists, replace the wheel bearing.
AXLE
SP
ST’NG
Wheel Bearing Preload
BRAKE
1. Release the parking brake.
2. Raise the rear wheel and rotate it several times.
3. Remove the tire.
A / BAG
4. Hook a spring gauge on a hub bolt and pull it. Read the
scale on the gauge at the point when the drum starts to
move. It is preload.
A / CON
5. Check if the preload is within the specified range.
Specified value 1.4 ~ 4.3 kg.cm
6. If the measured preload is out of the specified range,
retighten the castle nut to the specified torque.
7. If the trouble still exists, replace the wheel bearing with
a new one.
CHANGED BY SUSPENSION
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36 4520
4. REMOVAL AND INSTALLATION
Components and Tightening Torque
Upper Arm Coil Spring
Stabilizer bar link:
40 ~ 60 Nm
Body:
110 ~ 130 Nm
Red
Body:
110 ~ 130 Nm Yellow
Knuckle: * The spring should be in-
140 ~ 160 Nm stalled so that the red mark
is over the yellow mark.
Track Rod
Body:
150 ~ 170 Nm
Knuckle:
11 ~ 13 Nm
Stabilizer Bar
Stabilizer bar link: Stabilizer bar mounting Stabilizer bar link:
40 ~ 60 Nm bracket bolt: 40 ~ 60 Nm 40 ~ 60 Nm
SUSPENSION CHANGED BY
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4520 37
A/T
M / T
Thrust Link Wheel Speed Sensor
Mounting bolt: 6 ~ 8 Nm
T/C
CLUTCH
AXLE
Body: Knuckle:
150 ~ 170 Nm 110 ~ 130 Nm
SP
Coil Spring Link
ST’NG
Body:
110 ~ 130 Nm
BRAKE
A / BAG
A / CON
Knuckle:
120 ~ 150 Nm
Shock Absorber
Body:
30 ~ 45 Nm
Coil spring link:
60 ~ 80 Nm
CHANGED BY SUSPENSION
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38 4520
Rear Suspension Module
1. Remove the tire (21 mm - 5 wheel nuts).
Installation Notice
Tightening torque 120 ~ 140 Nm
Remove and tighten the wheel
nuts in several steps in a
crisscross sequence.
2. Remove the brake disc caliper and set the removed caliper on the frame (17 mm - 2 bolts).
Tightening torque: 85 ~ 105 Nm
3. Unscrew the two stabilizer bar mounting bracket bolts (14 mm) from body (frame) and remove the stabilizer bar.
Mounting bracket
Tightening torque: 40 ~ 60 Nm
SUSPENSION CHANGED BY
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4520 39
A/T
4. Install the special tool to the coil spring and compress the coil spring with the tool. Unscrew the upper nut (17 mm) on the
shock absorber.
M / T
Tightening torque: 30 ~ 45 Nm
T/C
CLUTCH
AXLE
5. Tighten the special tool to compress the coil spring. Remove the coil spring and spring seat while pulling down
the coil spring link.
SP
ST’NG
BRAKE
A / BAG
A / CON
6. Unscrew the bolt (10 mm) and remove the parking brake cable and wheel speed sensor.
Tightening torque: 6 ~ 8 Nm
CHANGED BY SUSPENSION
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7. Place the safety jack under the rear sub frame and unscrew the sub frame mounting bolts (body side : 22 mm -
4 EA) and the axle housing hexagon nut (22 mm - 1 EA). Unscrew the thrust link mounting bolt/nut (14 mm) on
body.
A. Axle housing mounting nut (22 mm) B. Thrust link bolt/nut on body
Tightening torque: 95 ~ 142 Nm Tightening torque: 150 ~ 170 Nm
C. Sub frame coil bolt (front - 14 mm) D. Sub frame bolt (rear - 14 mm)
Tightening torque: 95 ~ 142 Nm Tightening torque: 95 ~ 142 Nm
SUSPENSION CHANGED BY
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4520 41
8. Lower the safety jack and remove the sub frame from
the vehicle.
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY SUSPENSION
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42 4520
Shock Absorber Assembly
Preceding Work: Remove the tire.
1. Compress the coil spring with special tool and unscrew the shock absorber upper nut on body (frame)
(17 mm - 1EA).
Tightening torque: 30 ~ 45 Nm
2. Unscrew the shock absorber lower bolt/nut (bolt: 14 mm / nut: 17 mm) on coil spring link.
Tightening torque: 60 ~ 80 Nm
3. Remove the shock absorber from the rear suspension.
SUSPENSION CHANGED BY
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4520 43
Coil Spring Assembly
A/T
Preceding Works: 1. Remove the tires.
2. Unscrew the bolt and lower the stabilizer bar.
M / T
1. Compress the coil spring with special tool.
T/C
CLUTCH
AXLE
SP
2. Release the compression force of coil spring by loosening the lower shock absorber bolt/nut and remove the coil
spring and upper spring seat.
ST’NG
BRAKE
Upper spring seat
A / BAG
A / CON
Coil spring
Red
Yellow
NOTICE
• The spring should be installed so that the red
mark is over the yellow mark.
CHANGED BY SUSPENSION
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44 4520
Stabilizer Bar Assembly
Preceding Work: Remove the tires.
1. Unscrew the two bolts (14 mm) and remove the stabilizer bar bracket.
Tightening torque: 40 ~ 60 Nm
Bracket
Bushing
Bolt
Stabilizer bar
2. Unscrew the bolt/nut (14 mm) on the link and stabilizer bar and remove the stabilizer bar. Also, unscrew the bolt
(12 mm) on the knuckle and remove the link.
Link mounting nut
Tightening torque: 40 ~ 60 Nm
Stabilizer bar mounting nut
Tightening torque: 40 ~ 60 Nm
SUSPENSION CHANGED BY
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4520 45
A/T
3. Install the stabilizer link. Be cautious of the installing direction.
M / T
LH/RH Link
T/C
CLUTCH
AXLE
SP
Link Link
ST’NG
mounting mounting
nut Link Link nut
BRAKE
Stabilizer bar
A / BAG
A / CON
Bracket and
Bracket and
bushing
bushing
CHANGED BY SUSPENSION
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46 4520
Suspension Assembly
Preceding Work: Install a special tool to the coil spring.
Upper Arm
: Unscrew the bolt/nut and remove the upper arm.
Upper Arm
19 mm - 1EA: nut
(Tightening torque: 110 ~ 130 Nm)
Stabilizer Bar Link (upper)
12 mm - 1EA: nut
(Tightening torque: 40 ~ 60 Nm)
Upper Arm (Knuckle Side)
19 mm - 1EA: bolt/nut
(Tightening torque: 140 ~ 160 Nm)
Upper Arm
19 mm - 1EA: bolt/nut
(Tightening torque: 110 ~ 130 Nm)
SUSPENSION CHANGED BY
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4520 47
A/T
Track Rod
M / T
: Unscrew the nut and remove the track rod.
Track Rod on Sub Frame Upper Arm
T/C
CLUTCH
AXLE
17 mm - 1EA: nut
(Tightening torque: 150 ~ 170 Nm) Make an alignment mark on toe-in
adjusting nut.
SP
Track Rod on Knuckle
ST’NG
BRAKE
A / BAG
19 mm - 1EA: bolt/nut
(Tightening torque: 110 ~ 130 Nm)
A / CON
Thrust Link
: Unscrew the bolt/nut and remove the thrust link.
Thrust Link on Body Thrust Link on Knuckle
22 mm - 1EA: bolt/nut 19 mm - 1EA: bolt/nut
(Tightening torque: 150 ~ 170 Nm) (Tightening torque: 110 ~ 130 Nm)
CHANGED BY SUSPENSION
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Coil Spring Link Assembly
Preceding Works:
1. Remove the tires.
2. Unscrew the bracket bolts and lower the stabilizer bar.
3. Remove the coil spring.
Unscrew the lower shock absorber bolt on coil spring link and the bolt/nut on sub frame of the coil spring link and
knuckle to remove the coil spring link assembly.
Camber Adjustment
Make an alignment mark on camber
adjusting nut/bolt before removing them.
Bolt/Nut on Lower Shock Rear Suspension (Module Side)
Absorber (Knuckle Side)
Tightening torque: Tightening torque:
60 ~ 80 Nm 110 ~ 130 Nm
Tightening torque:
120 ~ 150 Nm
1. Bolt and nut (lower shock absorber) Bolt and nut (sub frame, 22 mm)
2. Bolt and nut (knuckle, 22 mm)
SUSPENSION CHANGED BY
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POWER STEERING SYSTEM
4610 / 4620
TABLE OF CONTENTS
GENERAL INFORMATION ...................................... 3
1. Overview ................................................................................ 3
2. System layout ......................................................................4
SSPS (SPEED SENSING POWER STEERING) .... 8
1. General information ...............................................................8
2. Trouble diagnosis ................................................................ 15
3. Removal and installation ..................................................... 24
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4610 3
GENERAL INFORMATION
A/T
1. OVERVIEW
M / T
The power steering has been designed to make the wheel move more easily than in a manual steering system. The
hydraulic power assists the process utilizing hydraulic fluid. The fluid increases pressure in the power steering pump
and aids the movement of the steering mechanism.
T/C
The power steering system consists of pump, oil reservoir, rack and gear box.
The power steering pump is a vane type and delivers hydraulic pressure to operate the power steering system.
The pressure relief valve in the pump controls the discharging pressure.
CLUTCH
The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack
piston. The integrated rack piston converts the hydraulic pressure to linear movement. The operating force of the
rack moves the wheels through the tie rod, the tie rod end and the steering knuckle. Even though the hydraulic
pressure cannot be generated, a driver can steer the vehicle without power assist but it needs very high steering
AXLE
force.
In this case, the operating force of the steering wheel is conveyed to the pinion, and the movement of the pinion
moves the rack through the pinion gear combined to the rack gear.
SP
Specifications
Description Specification
ST’NG
Steering wheel Type 4-spoke type
Outer diameter (mm) 390
Steering gear box Type Rack and pinion
BRAKE
Gear ratio ∞
Steering angle Inner 36° 20'
Outer 32° 40'
A / BAG
Oil pump Type Vane type
Maximum pressure (kgf/cm2) 85 ~ 92
A / CON
Displacement ( /min) 10.5
Pulley size (mm) 124
Tilt column adjusting angle Up 4°
Down 8°
Minimum turning radius (m) 5.7
Oil Specification ATF Dexron III
Capacity ( ) 1.0
CHANGED BY POWER STEERING SYSTEM
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2. SYSTEM LAYOUT
Steering gear box
mounting bracket bolts
(14 mm - 2EA): 30 ~ 40 Nm
Power steering gear
box assembly
Power steering
pump assembly
Power steering gear
box pipe
Feed pipe nut
Tightening torque:
40 ~ 50 Nm
Power steering high
pressure hose and pipe Tie rod end
Power steering return pipe
With SSPS
Gear box pipe
Power steering Power steering high pressure
gear box hose and pipe
SSPS Solenoid Valve
* cannot be replaced
Return hose and pipe
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4610 5
A/T
Pipe bracket bolt (10 mm)
Tightening torque: 9 ~ 14 Nm
M / T
Pipe bracket bolt (10 mm)
Tightening torque: 9 ~ 14 Nm
T/C
CLUTCH
AXLE
SP
ST’NG
Pipe mounting nut
BRAKE
Tightening torque: 20 ~ 26 Nm
A / BAG
Gear box mounting bolt
A / CON
Installation Drawing of SSPS
CHANGED BY POWER STEERING SYSTEM
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Components
Steering wheel Column shaft
Tightening torque: Tightening torque: Tightening torque: Tightening torque:
20 ~ 25 Nm 40 ~ 60 Nm 20 ~ 25 Nm 7 ~ 11 Nm
Lower shaft
Tightening torque:
18 ~ 25 Nm
Tightening torque: Tightening torque: Tightening torque:
65 ~ 80 Nm 70 ~ 90 Nm 30 ~ 40 Nm
Tightening torque:
45 ~ 50 Nm
Steering gear box Tie rod end
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A/T
Steering wheel
M / T
T/C
CLUTCH
AXLE
Lower shaft
SP
ST’NG
Column shaft
BRAKE
A / BAG
A / CON
Steering gear box
CHANGED BY POWER STEERING SYSTEM
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SSPS (Speed Sensing Power Steering)
1. GENERAL INFORMATION
Overview
In the conventional constant power assist steering system, the steerability gets lighter as vehicle speed rises, and
this may cause a dangerous situation. Where as having heavy steerability in high speed driving makes it difficult to
manipulate the steering wheel when vehicle is in stop. This steering system solves this problem as the steerability
is changed according to the vehicle speed, which is called Speed Sensitive Power Steering (SSPS).
SSPS, by providing appropriate steerability to a driver according to the changes of vehicle speed, gives steering
stability. The power steering control unit adjusts the hydraulic pressure to reaction plunger by controlling the pres-
sure solenoid valve located in the gear box to optimize the steerability. In other words, the steering wheel gets lighter
by adjusting steerability in stop or low speed and provides steering stability by adjusting steering wheel to become
heavier in high speed.
SSPS (Speed Sensitive
Power Steering)
NOTICE
• If the SSPS solenoid valve is defective, the power steering assembly should be replaced.
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Function
A/T
Input/Output of SSPS Control Unit
M / T
IG Power
Solenoid Valve
T/C
Ground
SSPS Meter Cluster
CLUTCH
CONTROL
UNIT (SSPS warning lamp)
CAN HIGH
AXLE
Trouble Diagnosis
CAN LOW
SP
SSPS Configuration
ST’NG
PCV Pinion valve
Valve body
BRAKE
Spring
Filter Balance line Right
Spool cylinder
Pressure
A / BAG
Connector
Left
A / CON
cylinder
Solenoid
valve Plunger
˙ˆ•– œ
Reaction device
Steering gear box
Reaction
‚fi …˙ ¶line
˛
PCV (Pressure Control Valve) Reaction device
This valve controls the hydraulic pressure supplied to This device increases the steerability effect by binding
reaction device by moving the spool valve according to the input shaft with supplied hydraulic pressure from PCV.
the changes of solenoid valve.
Solenoid valve
This valve determines the valve spool position in PCV
with the electric current supplied from SSPS control unit.
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Solenoid Valve
Location
Cannot be replaced
The SSPS control unit controls the amount of electric current to the solenoid valve according to the vehicle speed.
In other words, the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve
spool position that is linked with solenoid valve according to the amount of electric current. The changes of hydraulic
pressure applied to input shaft according to the pressure changes applied to the reaction plunger provide proper
steerability based on the amount of electric current.
Specifications
Description Specification
Voltage Rating DC 12 V
Current Rating 1.0 A
Resistance 6.7 ± 1 Ω
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A/T
Operation
1. During parking and low speed driving
M / T
T/C
Solenoid
valve
CLUTCH
Hydraulic pressure
(cut off)
AXLE
Return port Inlet port
SP
1) The SSPS control unit outputs nearly maximum electrical current.
2) The solenoid rod pushes the PCV spool to the right side.
ST’NG
3) The hydraulic pressure coming from pump is not supplied to the reaction device as the spool orifice is cut off.
4) The hydraulic pressure is cut off and the manipulation of steering wheel becomes lighter.
BRAKE
2. In medium and high speed driving
A / BAG
Solenoid
valve
A / CON
Hydraulic pressure
(cut off)
Return port Inlet port
1) The shaft operating force of solenoid rod is reduced due to the reduction of output current from the SSPS control
unit.
2) The coil spring pulls the PCV spool toward solenoid valve to open it.
3) The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to
reaction plunger.
4) At this time, the reaction plunger transmits the reaction force to V-groove in input shaft to provide heavy steerability.
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SSPS Control Unit
1. To provide proper steerability to a driver, the SSPS control unit controls the solenoid valve by receiving the vehicle
speed and the throttle position data via CAN communication.
2. The SSPS control unit controls the working current for the solenoid valve with PWM type duty ratio of 333 Hz
frequency and sets the target current to 1A during 1 second after the ignition is “ON”.
3. When a trouble occurs in the system, the SSPS control unit generates a trouble code using fail safe function.
4 3 2 1
8 7 6 5
Pin No. Function
1 Ignition Power Supply
2 CAN HIGH
3 Solenoid
4 Solenoid
5 Ground
6 Warning Lamp (SSPS)
7 CAN LOW
8 Self Diagnosis
Location
SSPS unit
POWER STEERING SYSTEM CHANGED BY
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System Control Current [A]
A/T
The SSPS system, according to the vehicle speed, en-
ables to achieve proper steering characteristics by con-
trolling hydraulic pressure to reaction plunger located in
M / T
input shaft of power steering gear box. In other words,
the SSPS control unit enhances the parking conve-
niences by controlling duty type current control. It pro-
vides heavy steerability with low current as the vehicle
T/C
speed increases. Also, it provides light steerability with
high current as the vehicle speed decreases.
CLUTCH
Vehicle speed [km/h]
AXLE
1. During parking and low speed driving
During parking and driving in low speed, the control unit supplies approx. 1 A of electric current to solenoid valve.
Then, the spool located in PCV compresses the upper spring and elevates upward, and the working pressure from
SP
oil pump (A port) is not able to flow to the reaction plunger (C port). As a result, the pressing force from the reaction
plunger disappears and the steerability enhances.
ST’NG
BRAKE
PCV Pinion valve
Valve body
Balance line
Spring
Filter Right
A / BAG
Spool cylinder
Pressure
A / CON
Connector
Left
cylinder
Solenoid valve
Plunger
Reaction device
Steering gear box
Reaction line
CHANGED BY POWER STEERING SYSTEM
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2. During high speed driving
During high speed driving, the control unit supplies weak electric current to solenoid valve. Then, the spool located
PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C
port) through B port. As a result, the pressing force from reaction plunger against input shaft is increased and the
steerability becomes heavier.
PCV Pinion valve
Valve body
Balance line
Spring Right
Filter cylinder
Spool
Pressure
B Port
Connector
Left
cylinder
Solenoid valve
Plunger
Reaction device
Steering gear box
Reaction line
POWER STEERING SYSTEM CHANGED BY
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2. TROUBLE DIAGNOSIS
A/T
Electric Current Check SSPS solenoid valve
1. Disconnect the solenoid valve connector (waterproof
M / T
connector) and install the ammeter between the sole-
noid valve connector and the wiring harness.
T/C
NOTICE
• Do not ground the solenoid terminal.
CLUTCH
AXLE
2. When the vehicle speed is at 0 km/h, check whether
the electric current for solenoid is in specified range and
SP
check that the current is reduced as the vehicle speed
increases. Current [mA]
Current 0.9 ~ 1.1 A (vehicle speed at 0 km/h)
ST’NG
BRAKE
Vehicle speed [km/h]
A / BAG
A / CON
CHANGED BY POWER STEERING SYSTEM
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Flow Chart for Trouble Diagnosis
NOTE
• Use a Scan-I to check.
• Refer to the circuit diagram for the SSPS ECU.
Any problem with ECU No
Open wiring (damaged harness) Repair harness/replace fuse.
power supply fuse?
Yes
Check ignition switch
with ECU disconnected
Reconnect or repair harness.
and ignition switch
If normal, replace ECU.
“ON”.
Is the voltage between
No Damaged or disconnected
ground terminal and ECU
harness between fuse and ECU Repair harness.
harness connector No.4
No.5 terminal
measured by 12 V?
Yes
Disconnect battery (-)
terminal and check.
Check the continuity No Disconnect the SSPS solenoid
between No.1 and No.2 valve connector in engine
connector in compartment and check.
ECU harness.
Yes
Check the continuity between 2 No Damaged or disconnected
connectors in steering gear box wiring in SSPS solenoid valve
solenoid. coil
Yes
Damaged or disconnected wiring Replace power steering assem-
between ECU and SSPS solenoid bly or repair connection area.
valve connector
Is the resistance
between terminal No.1 No Poor contact in SSPS solenoid Repair solenoid valve
and No.2 measured by 5.7 valve connector connector.
~ 7.7 W (at 20°C) during
integrity check?
Yes
Poor contact in SSPS solenoid Check solenoid valve connector
valve connector or defective ECU or replace ECU.
POWER STEERING SYSTEM CHANGED BY
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4610 17
Fail Safe Function
A/T
Detecting Trouble
No. Trouble Trouble Condition Action Description
Time Code
M / T
1 Over voltage VIG > 17 V 1 sec C1104 Solenoid 10 V < VIG < 16 V
current: 0 A
2 Low voltage VIG < 8 V 1 sec C1105 Solenoid 10 V < VIG < 16 V
T/C
current: 0 A
3 Vehicle PW > 30 %, vehicle speed 60 sec *C1212 Vehicle speed: Input signal of vehicle
speed 0 km/h 80 Km/h speed of 5 km/h for
CLUTCH
sensor over 1 second
4 ECU error Faulty EEPROM Read/Write, 1 sec C1604 Solenoid IGN ON/OFF
PWM management error current: 0 A
AXLE
5 Detected Detected current > 1.28 A 1 sec C2203 Solenoid Power On
current current: 0 A
When solenoid is disconnected 1 sec Reset
Target current - detected cur- 2 sec
rent > 0.2 A and VIG > 13 V
SP
6 CAN error No CAN messages 30 sec C1623 Vehicle speed: Received messages
80 Km/h more than once
ST’NG
C1212 Help
C1212 Trouble Code: displayed when the vehicle speed sensor is faulty.
BRAKE
1. If the vehicle is 0 km/h for 60 seconds while depressing the accelerator pedal, it is determined by 80 km/h.
2. Release condition: goes back to normal status when the vehicle speed is over 5 km/h for 1 second.
3. Check for CAN communication line (pin No. 3 and 6).
4. Check the connectors for poor contact.
A / BAG
NOTICE
A / CON
• When the Fail Safe function is activated, the steering wheel operation needs much more force due to no cur-
rents to SSPS solenoid.
CHANGED BY POWER STEERING SYSTEM
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Circuit Diagram
YR
SSPS
Control Unit
LG BrB BG G GB LgY
GB LgY
LG BrB BG G B
SSPS
Solenoid
Diagnosis Cluster
"12" "B11"
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4610 19
Trouble Diagnosis
A/T
Symptom Cause Action
Hard steering Lack of lubrication, Abnormal wear or binding of Lubricate or replace
steering ball joint
M / T
Damaged or faulty steering gear Replace gear assembly
Improper preload of steering pinion Adjust
Faulty steering shaft joint Replace
T/C
Steering fluid leaks Repair or replace
Lack of fluid or air-in system Replenish or bleed
CLUTCH
Faulty steering oil pump Replace
Damaged or loosened pump drive belt Adjust or replace
Clogging oil line Repair or replace
AXLE
Damaged wheel tire Repair or replace
Faulty suspension system Repair or replace
Steering pulls to one side Damaged steering linkage Replace
Damaged wheel or tire Repair or replace
SP
Faulty brake system Repair or replace
Faulty suspension system Repair or replace
ST’NG
Excessive wheel play Worn steering gear Replace gear assembly
Worn or damaged steering ball joint Replace
Loosened steering gearbox mounting bolts Retighten
BRAKE
Poor return of steering Damaged or binding steering ball joint Replace
wheel Improper preload of steering pinion Replace gear assembly
Damaged wheel or tire Repair or replace
A / BAG
Faulty suspension system Repair or replace
Steering wheel shimmy Damaged steering linkage Replace
A / CON
Loosened steering gearbox mounting bolt Retighten
Damaged or binding steering ball joint Replace
Worn or damaged front wheel bearing Replace
Damaged wheel or tire Repair or replace
Faulty suspension system Repair or replace
Abnormal noise from Loosened steering gearbox mounting bolt Retighten
steering system Faulty steering gear Replace gear assembly
Steering column interference Repair
Loosened steering linkage Retighten
Damaged or loosened oil pump drive belt Adjust or replace
Loosened oil pump bracket Retighten
Loosened oil pump mounting bolt Retighten
Air-in system Bleed
Faulty oil pump Replace
CHANGED BY POWER STEERING SYSTEM
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General Inspection
Power Steering Wheel Free Play Check
1. Start the engine and place the wheels at straight ahead
direction.
2. Turn the steering wheel until the tires starts to move
and measure the distance on the circumference of the
steering wheel.
Specified value 30 mm
NOTICE
• If the free play is out of the specified value, check
the free play in steering column shaft connection and
steering linkage. Replace or repair if necessary.
Steering Effort Check
1. Park the vehicle on a paved and flat ground and place
the front wheels at straight ahead direction.
2. Start the engine and let it run around 1,000 rpm.
3. Install the spring scale on the circumference of the steer-
ing wheel and measure the steering effort in both
directions.
Steering effort below 3.0 kg
NOTICE
• The difference between both sides should be within
0.6 kg.
Steering Angle Check
1. Place the front wheel on a turning radius measuring tool.
2. Turn the steering wheel to the its both ends and mea-
sure the maximum steering angle.
Inner 36° 20'
Specified value
Outer 32° 40'
NOTICE
• If the free play is out of the specified value, check
and adjust the toe-in.
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A/T
Oil Pump Pressure and Oil Level Check
Oil Pump Pressure
M / T
Check the oil pump pressure to locate any defect in oil pump.
1. Unscrew the pressure line fitting in power steering
T/C
pump.
2. Install the pressure gauge between the power steer-
ing pump and the power steering oil pressure line.
CLUTCH
3. Place the shift lever to neutral position.
4. Apply the parking brake.
5. Open the valve in pressure gauge.
AXLE
6. Start the engine and let it run at idle speed.
7. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level (oil
temperature: 50 ~ 80°C).
SP
8. Fully close the valve in pressure gauge and measure
the oil pressure.
9. Measure the oil pressure with the gauge valve fully
ST’NG
open.
10. If the pump pressure is in specified range, the pump
is normal. If not, replace the power steering pump.
BRAKE
NOTICE
• To prevent internal damage, do not close the gauge
valve over 10 seconds.
A / BAG
Pump relief valve pressure 89 ~ 97 kg/cm2
Pump pressure at no load 3 ~ 5 kg/cm2
A / CON
CHANGED BY POWER STEERING SYSTEM
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Oil Level Check
The power steering oil level have to be checked by Displacement of oil level
two conditions; one is checked at normal operating
temperature, and the other one is checked when it is cooled.
If the difference between two measurements is below 5 mm
and the level is between MAX and MIN level, it’s normal. If it
is over 5 mm, bleed air from the system.
Checking Engine off Engine on
1. Place the vehicle on a flat ground and start the engine
and let it run at idle speed.
2. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level (oil
temperature: 50 ~ 80°C).
3. Place the steering wheel at straight ahead direction.
4. Measure the oil level in the power steering oil reservoir.
5. Adjust the oil level between MAX and MIN.
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AIR BLEEDING
A/T
M / T
T/C
CLUTCH
AXLE
Checking Bubble is Found
SP
ST’NG
BRAKE
A / BAG
Air Bleeding
1. Lift up the vehicle in straight ahead direction of the steering wheel (No-load to tires).
2. Add the specified oil into reservoir up to the max level.
A / CON
3. Turn the steering wheel to its both ends repeatedly until any bubble cannot be seen in the reservoir.
4. If any bubble is not found anymore, add the specified oil into the reservoir to the specified level.
* Checking *
1. Start the engine and repeat the second and third step above.
2. This process should be performed to check if air still exists in the power steering system.
NOTICE
• Position the gear shift lever to “N (M/T)” or “P (A/T)”, and apply the parking brake before starting the engine.
CHANGED BY POWER STEERING SYSTEM
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3. REMOVAL AND INSTALLATION
The SSPS unit is installed on the bottom of engine ECU located in the passenger foot wall.
NOTICE
• If the SSPS solenoid valve is defective, the power steering assembly should be replaced.
SSPS Control Unit
Preceding Work: Disconnect the negative battery cable.
1. Remove the engine ECU under the floor carpet.
2. Disconnect the SSPS control unit connector and
separate the SSPS control unit from engine ECU.
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A/T
SSPS Control Unit
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY POWER STEERING SYSTEM
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Steering Column Shaft
Preceding Work: Disconnect the negative battery cable and place the tires to straight ahead direction.
Removal and Installation
1. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the
airbag module connector.
2. Unscrew the steering wheel lock nut and remove the wheel with special tool.
NOTICE
• Make an alignment marks on the column shaft and steering wheel for correct installation.
Tightening torque: 40 ~ 60 Nm
3. Remove the instrument panel side cover and unscrew the side lock bolt and screws to remove the instrument lower panel.
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A/T
4. Remove the protective panel and undercover from the lower panel and remove the upper/lower column covers.
M / T
T/C
CLUTCH
AXLE
5. Disconnect the contact coil and connector from the column shaft and remove the contact coil assembly.
SP
ST’NG
BRAKE
A / BAG
Contact coil mounting screw
A / CON
Inlet portDisconnect the connector Align the alignment marks when installing
CHANGED BY POWER STEERING SYSTEM
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6. Disconnect connectors and remove the combination switch from the steering column.
Unscrew the mounting screws Disconnect the connectors
Combination Switch Assembly
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7. Unscrew the bolts and nuts and remove the steering column shaft assembly while pulling down it.
A/T
Mounting Bolts (3 EA) Mounting Bolts (2 EA)
M / T
T/C
CLUTCH
Tightening torque: 20 ~ 25 Nm Tightening torque: 20 ~ 25 Nm
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
Lower Shaft Mounting Bolt (1 EA)
Tightening torque: 18 ~ 25 Nm
CHANGED BY POWER STEERING SYSTEM
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Lower Shaft
1. Remove the upper lock bolt inside the vehicle and the lower lock bolt in underbody.
Tightening torque: 18 ~ 25 Nm Tightening torque: 18 ~ 25 Nm
2. Remove the lower shaft mounting nuts on floor.
Installation Notice
Tightening torque 7 ~ 11 Nm
3. Remove the lower shaft.
NOTICE
• Install the lower shaft so that the lock bolt can be in-
serted into the point without spline.
• Be cautious of the alignment marks.
Lower Shaft Assembly
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Steering Gear Box
A/T
Preceding Works: 1. Disconnect the negative battery cable.
2. Remove the tire.
M / T
1. Remove the cotter pin and lock nut. Remove the tie rod from steering knuckle by using a special tool.
661 589 13 33 00 (W 99 44 002 0A)
T/C
Ball Joint Puller
CLUTCH
AXLE
Tightening torque: 35 ~ 45 Nm
SP
2. Remove the SSPS connector.
ST’NG
BRAKE
A / BAG
A / CON
3. Unscrew the lower bolts and remove the lower shaft and
gear box.
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4. Disconnect the power steering pipes and remove the steering gearbox mounting bolts.
Supply and Return Pipes
NOTICE
• Plug the pipe openings with caps.
• Be careful not to spill the oil on the floor and
vehicle body.
Tightening torque: 20 ~ 26 Nm
Gear Box Mounting/Gear box Cross Member Gear box Mounting
Clamping Bolt
Tightening torque: Tightening torque: Tightening torque:
70 ~ 90 Nm 70 ~ 90 Nm 30 ~ 40 Nm
NOTICE
• Tighten the center bolt/nut first, and then tighten the left mounting bolt with the specified tightening torque.
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Steering Gear Pump
A/T
1. Remove the drive belt.
M / T
T/C
CLUTCH
AXLE
2. Disconnect the power steering return hose and remove
the high pressure pipe nut.
Installation Notice
SP
Tightening torque 40 ~ 50 Nm
ST’NG
NOTICE High pressure pipe
• Plug the openings so that power steering fluid doesn't
leak out.
BRAKE
Return
hose
A / BAG
3. Unscrew the nuts and remove the pump assembly with
bracket.
A / CON
Installation Notice
Tightening torque 20 ~ 23 Nm
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ABS/ESP SYSTEM
4890 / 4891
TABLE OF CONTENTS
GENERAL INFORMATION ...................... 2 ABS SYSTEM ......................................... 60
1. General information .......................................... 2 1. General information ........................................ 60
2. Specifications ................................................... 5 2. Configuration of ABS system ......................... 63
3. Brake operation and noise ............................... 6 3. Input and output diagram ................................ 64
4. Hydraulic circuit of ABS ................................. 65
ESP SYSTEM ........................................... 7 5. ABS circuit in each operation range .............. 66
1. General information .......................................... 7 6. Components and location ............................... 67
2. General information of ESP system ................. 8 7. Components description ................................. 68
3. Principle of ESP ............................................. 12 8. Removal and installation ................................. 69
4. HBA (Hydraulic Brake Assist system) ........... 15
5. ARP (Active Roll-over Protection) .................. 16
6. HDC (Hill Descent Control) ............................. 17
7. Components and locations ............................. 24
8. Input and output diagram ................................ 26
9. ESP system related precautions ................... 27
10. Hydraulic circuit diagram ................................ 28
11. Hydraulic pressure for each ESP operating
range ............................................................... 29
12. Hydraulic circuit of HBA
(Hydraulic Brake Assist) ................................. 31
13. Components description ................................. 32
14. Bleeding ESP system .................................... 46
15. ABS/ESP trouble diagnosis ........................... 48
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2 4890
GENERAL INFORMATION
1. GENERAL INFORMATION
For the front brake system, the ventilated disc type is
applied regardless of the ABS/ESP system installation. Two Front Disc
43 mm diameter calipers (non-ABS/ESP equipped vehicles)
and two 45 mm diameter calipers (ABS/ESP equipped
vehicles) are installed.
Front Ventilated Disc and Caliper
(2 internal Cylinders)
For the rear brake system, specifications differ between
ABS/ESP system equipped vehicles and non-ABS/ESP Rear Disc
system equipped vehicles. The drum type brake is installed
on non-ABS equipped vehicles. When ABS/ESP is installed
on the 5-link type suspension, the solid disc (disc thickness:
approx. 10.4 mm) is installed. When ABS/ESP is installed
on the independent suspension, the ventilated disc (disc
thickness: approx. 20 mm) is installed.
ABS/ESP + 5Link Suspension: solid type disc
ABS/ESP + Independent suspension: ventilated disc
Rear Disc and Caliper (1 Internal Cylinder)
Parking brake system: The hand operated type parking brake is installed on vehicles with the manual transmission
and the foot operated type parking brake is installed on vehicles with the automatic transmission.
Hand Operated Type Foot Operated Type
(Vehicle with Manual Transmission) (Vehicle with Automatic Transmission)
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Sectional Drawing
A/T
Front Disc Brake
M / T
Two internal
T/C
cylinders
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
Rear Disc Brake
A / CON
One internal
cylinder
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Non-ABS Equipped Vehicle – With One Wheel Speed Sensor
The wheel speed sensor is installed on the rear right wheel regardless of the ABS/ESP installation.
This sensor is to signal the vehicle speed to the engine ECU, TCCU, transmission, and instrument panel. There is
no separate unit to process the wheel speed sensor signal. The wheel speed sensor is connected to the engine ECU
(terminal 36), where its signal is processed, and is connected to other related systems through CAN communication.
36 Battery (B+)
Wheel speed sensor
KYRON
D27DT
CAN HI
E 54 Instrument panel
C CAN LO TCU
U 73
TCCU
Location of the wheel speed sensor (rear right wheel)
Location of the Sensor Connector
Tightening torque:
6 ~ 8 Nm
Connector Appearance
In vehicle without ABS In vehicle with ABS/ESP
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2. SPECIFICATIONS
A/T
NON-ABS ABS/ESP
Description
(5-link suspension) 5-link suspension Independent suspension (IRS)
M / T
Brake pedal Pedal ratio 4.0 : 1
Max. operating stroke 150 mm
Free play 1 ~ 4 mm
T/C
Brake master Type Tandem type (with level sensor)
cylinder I.D. of cylinder φ 25.4 mm
CLUTCH
Brake Type Vacuum assisted type
booster Booster pressure ratio 9:1
Front brake Type Ventilated disc type
I.D. of caliper cylinder 2 x φ 43 mm 2 x φ 45 mm
AXLE
Pad thickness 10.5 mm 10.5 mm
Brake pad wear limit 2 mm 2 mm
Disc plate thickness 26 mm 28 mm
SP
Disc plate wear limit 24 mm 25.4 mm
I.D./O.D. of disc plate φ 294 /φ 184 mm φ 294 /φ 184 mm
ST’NG
Rear brake Type Drum type Solid disc type Ventilated disc type
I.D. of drum φ 254 mm - -
WxLxT 55 x 243 x 5 - -
BRAKE
I.D. of wheel cylinder φ 23.81 mm - -
I.D. of caliper cylinder - φ 42.9 mm φ 42.9 mm
Brake pad thickness - 10 mm 10 mm
A / BAG
Wear limit of brake pad - 2 mm 2 mm
Disc plate thickness - 10.4 mm 20 mm
Wear limit of disc plate - 8.5 mm 18.4 mm
A / CON
I.D./O.D. of disc plate - φ 299/φ 220 mm φ 307/φ 214 mm
Parking Mechanical type, rear
brake Type Mechanical type, rear wheels operated wheels operated
Operation type Manual type - Hand (MT)/Foot (AT) Manual type - Foot
I.D. of drum φ 254 mm φ 190 mm φ 190 mm
Brake fluid Capacity 0.7 ~ 0.8
Specification DOT4
CHANGED BY ABS/ESP SYSTEM
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3. BRAKE OPERATION AND NOISE
This section describes the noise phenomena possibly occurring in the brake system operation. Distinguish between
the information given below and the actual problems and then, inspect the vehicle and take appropriate measures.
Noise Phenomena and Causes
Phenomenon 1. If depressing the brake when the engine is cold, “screeching” sound always occurs and, after
driving for a while, it disappears.
This usually occurs in the morning. When the temperature goes down, the dew condensation phenomenon sets
moisture on the brake disc as the window frost forms. Due to this moisture, the iron within the brake disc and pad
oxidizes, forming undetectable micro-rusts on the disc surface. When starting the engine under this condition, noise
may sound due to the friction of micro-rusts. When operating the brake several times, the disc temperature goes up
and the micro-rusts come off and the noise goes away. Depending on the driving conditions, noise gets louder when
slightly depressing the brake pedal and oppositely, noise is smaller when deeply depressing the brake pedal. This
is simply a physical phenomenon, called “morning effect” in professional terms, and does not imply any problems
with the brake system.
Phenomenon 2. Slip or screech after the brake pad replacement.
This usually occurs when the bed-in is not made between the disk and the pad’s friction material. The bed-in is a
state that the brake system normally works and gives no noise out, when, after about 300 km city driving, the
contact area of the pad friction material is enlarged and the disk is in complete contact with the pad’s friction
material. Therefore, for some time after the brake disk/pad replacement, the brake system poorly operates or noise
(abnormal sound) occurs due to the partial contact.
Phenomenon 3. “Groaning” sound occurs in the automatic transmission vehicle when slightly taking the foot off
the brake pedal to slowly start after waiting for the signal, or slightly depressing the brake pedal.
This is the noise “Creep groan” that occurs when, in both the automatic and manual transmission, slightly releasing
the brake pedal in the neutral gear at downhill roads. It frequently occurs at the low braking power and low speed,
through the following process. When operating the brake system at low speed and low pressure, adhesion and slip
repeatedly take place between the brake disk and the friction material, and this makes the braking power inconstant,
instantly increasing or decreasing, and gives out the brake noise. It is also a physical phenomenon and has no
relation with the brake performance.
ABS/ESP SYSTEM CHANGED BY
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ESP SYSTEM
A/T
1. GENERAL INFORMATION
M / T
The ESP system consists of basic ABS functions, the vehicle position control depending on the driving conditions
and the road conditions, the HBA (Hydraulic Brake Assist System) that improves the braking power in an emergency,
the ARP (Active Rollover Protection) that obstructs the physical tendency to rollover during sharp turns and prevents
the vehicle rollover by quickly and firmly controlling the engine output and the brake.
T/C
The HDC (Hill Descent Control) is newly introduced function that helps drivers maintain their speed auto-
matically by switch operation when driving slowly on steep hills (over 10%: about 5.71° (degree)).
CLUTCH
ESP HECU HDC Switch / Indicator
AXLE
SP
ST’NG
BRAKE
Functions applied on ESP system are as follows.
1. ABS (Anti-Lock Brake System)
A / BAG
2. EBD (Electronic Brake-Force Distribution)
3. ABD (Automatic Braking Differential)
4. ASR (Acceleration Slip Regulation)
A / CON
5. AYC (Active Yaw Control, Understeer Oversteer control)
6. HBA (Hydraulic Brake Assist System)
7. ARP (Active Rollover Protection)
8. HDC (Hill Descent Control)
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2. GENERAL INFORMATION OF ESP SYSTEM
Differences compared to other models: Appearance of wheel speed sensor, Location, Layout of relevant components
ESP HECU Active Wheel Speed Sensor HDC Switch
The transfer case (T/C) installed on this vehicle doesn’t have the internal speed sensing device and receives the
speed signal for T/C control from ESP HECU via CAN bus.
[Conventional T/C] [New T/C]
Without speed sensor
With speed sensor
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A/T
Cautions When Removing the Front Wheel Speed Sensor
The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the
M / T
conventional approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending
on the vacuum condition within the actuator.
Thus, the wheel speed sensor is installed on the front wheel end area. It is installed inside the
backing plate to be protected from heat and foreign materials. Therefore, the front wheel end
T/C
system (including disc) should be removed before removing the front wheel speed sensor.
CLUTCH
Front Wheel Speed Sensor (4WD) Rear Wheel Speed Sensor (IRS Type)
AXLE
Backing plate
SP
ST’NG
Wheel speed sensor
BRAKE
A / BAG
Wheel Speed Sensor
A / CON
Backing plate
Wheel speed sensor
CHANGED BY ABS/ESP SYSTEM
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The rubber O-ring in IWE (Integrated Wheel End) should be replaced with new one when the front wheel end has
been removed.
The rubber O-ring prevents moisture and foreign materials from entering the IWE system.
In addition, when installing the hub actuator of the IWE system, you must install it from the same angle as the drive
shaft to prevent the rubber seal ring inside the actuator from being squeezed.
Rubber
O-ring
Rubber seal ring
(Internal steel spring included)
Please refer to the part time transfer case section for more specific information.
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A/T
When the ESP system is added to the ABS system, some devices will be added to the HECU (Hydraulic &
Electronic Control Unit) and wheel speed sensor used in the ABS system. The devices are as follows:
1. 2 pressure sensors installed on the master cylinder
M / T
2. Sensor cluster (integrated yaw rate sensor and lateral sensor) and longitudinal sensor installed in IP.
3. SWAS (Steering Wheel Angle Sensor) installed in the steering column.
T/C
Comparison with ABS System
CLUTCH
Specifications
Name Location
ABS ESP
AXLE
HECU CPU: PEC 1 (32 bit) CPU: PEC 1 (32 bit) beside of brake booster
(Hydraulic & Clock Frequency: 28 MHz Clock Frequency: 33 MHz
Electronic
Memory: 512 KB Memory: 512 KB
Control Unit)
EEP ROM: 1 KB EEP ROM: 1 KB
SP
New software version: KM 20
Wheel Speed Active Type Active Type Mounted in each wheel (× 4EA)
Sensor Front airgap: 0.335 ~ 0.945 mm
ST’NG
Rear airgap: 0.309 ~ 0.958 mm
Steering Wheel N/A Maximum angular velocity: In steering wheel
Angle Sensor 1500°/sec
BRAKE
Working voltage: 9 ~ 16 V
Sensor Cluster N/A Integrated yaw rate sensor and Behind the center audio in
lateral sensor. Also, used for instrument panel
A / BAG
sensing G value for HDC (Hill
Descent Control).
Pressure Sensor N/A Analog Output Under master cylinder
A / CON
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3. PRINCIPLE OF ESP
Understeer & Oversteer Control
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous
situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for
actuating the brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle
stability due to under-steering or over-steering during cornering.
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 spin present at any wheels during over-steering, under-steering or
cornering. The ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle
stability using the input values from the sensors and applying the brakes independently to the corresponding wheels.
The system also controls during cornering by detecting the moment right before the spin and automatically limiting
the engine output (coupled with the ASR system).
Under Steering Over Steering
Desired
course
Desired With
course Without ESP
ESP
With
ESP
Braked
Braked wheel
wheel Without
ESP
Compen-
Braking sating yaw
force moment Compensating
yaw moment
Braking
force
Understeering Oversteering
Understeering is when the steering wheel is steered to Oversteering is when the steering wheel is steered to a
a certain angle during driving and the front tires slip to- certain angle during driving and the rear tires slip out-
ward the reverse direction of the desired direction. ward losing traction.
Generally, vehicles are designed to have under steering. When compared with under steering vehicles, the con-
The vehicle can return back to inside of cornering line trolling of the vehicle is difficult during cornering and the
when the steering wheel is steered toward the inside vehicle can spin due to rear wheel moment when the
even when the vehicle front is slipped outward. As the rear tires lose traction and the vehicle speed increases.
centrifugal force increases, the tires can easily lose the
traction and the vehicle tends to slip outward when the
curve angle gets bigger and the speed increases.
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A/T
ESP controls during under steering ESP controls during oversteering
M / T
The ESP system recognizes the directional angle with The ESP system recognizes the directional angle with
the steering wheel angle sensor and senses the slip- the steering wheel angle sensor and senses the slip-
ping route that occurs reversely against the vehicle cor- ping route that occurs towards the vehicle cornering di-
nering direction during understeering with the yaw rate rection during oversteering with the yaw rate sensor and
T/C
sensor and the lateral sensor. Then the ESP system the lateral sensor. Then the ESP system applies the
applies the brake at the rear inner wheel to com- brake at the front outer wheel to compensate the
pensate the yaw moment value. In this way, the vehicle yaw moment value. In this way, the vehicle does not
CLUTCH
does not lose its driving direction and the driver can steer lose its driving direction and the driver can steer the
the vehicle as driver intends. vehicle as he or she intends.
AXLE
ESP Control
As the single-track vehicle model used for the calculations is only valid for a vehicle moving forward, ESP
intervention never takes place during backup. The ESP system includes the ABS/EBD and ASR systems
allowing the system to be able to operate depending to the vehicle driving conditions. For example, when the brakes
SP
are applied during cornering at the speed of 100 km/h, the ABS system will operate at the same time the ASR or
ABD systems operate to reduce the power from the slipping wheel. And when yaw rate sensor detects the rate
exceeding 4 degree/seconds, the ESP system is activated to apply the brake force to the corresponding wheel to
ST’NG
compensate the yaw moment with the vehicle stability control function.
When various systems operate simultaneously under a certain situation, there may be vehicle control problems due
to internal malfunction of a system or simultaneous operations. In order to compensate to this problem, the ESP
BRAKE
system sets the priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS.
The order may be changed depending on the vehicle driving situations and driving conditions.
A / BAG
A / CON
Operating
range
Turning Turning
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Vehicle Control During Cornering
The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is
pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operating
during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating.
Operations Understeering Control Oversteering Control
ESP auto brake
Only ESP operating e
Engin l
o
No braking by driver contr
ESP auto brake
ESP
+
Conventional
brake
(ABS not operating)
ESP auto brake
Driver foot brake operation
ESP
+
ABS brake
The slip occurs
under ESP operation
ABS operation
ESP
nt e
e
c o gin
Engin l
l
ro
En
+ o n t r o
c
TCS (Engine Control)
The slip occurs
under ESP operation
TCS operation
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4. HBA (HYDRAULIC BRAKE ASSIST SYSTEM)
A/T
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.
M / T
An inexperienced, elderly or physically weak driver may Experienced drivers
suffer from the accident by not fully pressing the brake pedal 10
when hard braking is required under emergency. The HBA
T/C
System increases the braking force under urgent situations 8
Deceleration -m/s
to enhance the inputted braking force from the driver. Inexperienced
drivers
Based on the fact that some drivers depress the brake pedal
CLUTCH
too soft even under when hard braking is necessary, the 4
Elderly and physically
HECU system is a safety supplementary system that builds weak drivers
high braking force during initial braking according to pres- 2
sure value of the brake pressure sensor and the pressure
AXLE
changes of the pressure sensor intervals. When the sys-
tem is designed to apply high braking force when brake
pedal is depressed softly by an elderly or physically weak 0 0.2 0.4 0.6 0.8 1.0
driver, the vehicle will make abrupt stopping under normal Time (s)
SP
braking situation due to high braking pressure at each
wheels.
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System
ST’NG
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. If the drive depresses the brake pedal slowly, the
BRAKE
pressure change is not high. In this case, only the conventional brake system with booster is activated.
A / BAG
A / CON
Pressure
sensor
HECU
Hydraulic line
Operating conditions:
1. Pressure: over 20 bar
2. Pressure changes: over 1500 bar/sec
3. Vehicle speed: over 7 Km/h
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5. ARP (ACTIVE ROLL-OVER PROTECTION)
The ARP (Active Roll-over Protection) system is a safety assistant device that minimizes, by controlling brakes and
the engine, the physical tendency of the vehicle rollover during sharp lane changes or U-turns. For the system,
software is added to the existing ESP system and no additional device or switch is needed.
One must note that the ARP system, just as general assistant devices including the ABS, is only a safety assistant
device using the ESP system and its function is useless when the situation overcomes the physical power.
Following picture shows how the ARP compensates the vehicle position by varying each wheel’s braking power to
overcome the physical tendency of the vehicle rollover during sharp turns.
!"# $%
Lateral sensor
&$% '()"*+,
123force
Brake
Vehicle
-./0speed Radius
4567
The vehicle driving condition is controlled by the internally programmed logic according to the input signals from
wheel speed sensor, steering angle sensor and lateral sensor.
Steering wheel
angle sensor Input data signal Yaw rate torque value Comparative Actuator
processing calculation data processing operation
Lateral sensor
ESP AREA
Driving conditions
Wheel speed
sensor
Yaw rate value
Yaw rate
sensor
Other reference
values
ARP AREA
Assess whether vehicle
Input data signal
condition meets ARP Adjust with ARP function
processing
operation condition
NOTICE
• During the ARP operation, vehicle safety (rollover prevention) takes the first priority and thus, stronger engine
control is in effect. Consequently, the vehicle speed decreases rapidly, so the driver must take caution for
the vehicle may drift away from the lane.
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6. HDC (HILL DESCENT CONTROL)
A/T
System Overview
The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about
M / T
7 km/h by 0.1G, on steep roads (slope level exceeding 10%) through a separately installed switch operation. When
the vehicle speed reaches below 7 km/h (refer to the information below), the HDC automatically terminates the
operation.
HDC Switch
T/C
When you see a steep downhill ahead, press the HDC
switch and the green HDC indicator comes on. When
the G sensor within the sensor cluster detects a slope
CLUTCH
level exceeding 10%, the ESP’s HDC function operates.
When this occurs, the green HDC indicator flashes
along with a loud operation sound.
AXLE
SP
ST’NG
BRAKE
Sensor Cluster (G Sensor) HDC Indicator (Instrument Panel)
The G Sensor within the sensor cluster detects the A / BAG
A / CON
steepness of driving roads. When the HDC switch When you press the HDC switch, the green
is in operation, if the G sensor detects a downhill HDC indicator comes on, and when the HDC
steepness exceeding 10%, it transmits the HDC operates, the green HDC indictor flashes at
operation signal to the ESP HECU. 0.5 second of interval.
HDC HDC
NOTICE
• The G sensor in sensor cluster measures the actual Red letters Green letters
road steepness. However, it may recognize a sharp
turn or rough road as a downhill road with a slope
level exceeding 10%, and the HDC may operate.
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HDC (Hill Descent Control) System Operating Conditions
1. When HDC switch is turned ON and
2. Gearshift lever position (Forward/Reverse) and
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in neutral position).
Automatic transmission: operates in any position except for P (parking) or N (neutral) positions.
NOTICE
• The vehicles with manual transmission do not have a separate device or switch that detects the 1st
gear. It only detects the forward/reverse driving direction of the vehicle through backup lamp switch and
neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above,
though the HDC also operates in 2nd gear position, is because the engine may turn off during the HDC
operation process. You may face a very dangerous situation if the engine turns off at a steep hill.
• The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. For manual
transmission equipped vehicle, HDC system should operated only in 1st gear.
3. When not depressing the accelerator pedal or brake pedal. and
4. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode). and
NOTE
• The vehicle speed given in step (3) varies according to the vehicle driving mode, and the speed ranges by
the vehicle driving mode and condition are as follows.
1) Speed available in HDC mode (slope)
2H/4H mode: vehicle speed below 50 km/h (operation slope level: 10%, termination
Forward slope level: when it reaches 8%)
driving 4L mode: vehicle speed below 25 km/h (operation slope level: 10%, termination slope
level: when it reaches 5%)
2H/4H mode: vehicle speed below 50 km/h (operation slope level: 8%, termination slope
Reverse level: when it reaches 5%)
driving 4L mode: vehicle speed below 25 km/h (operation slope level: 8%, termination slope
level: when it reaches 4%)
2) HDC target speed in 2H/4H mode
(The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches
7 km/h, but is converted to the stand-by mode. When the vehicle speed increases again as a result of
the increase of the road steepness, etc., the HDC goes into operation.)
Forward driving: 7 km/h
Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission)
3) HDC target speed in 4L mode
Forward and reverse driving: 3 km/h
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A/T
5. Vehicle position control function in ESP and HBA function are not in operation: and
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP
function is in operation, HDC operation is overridden.
M / T
6. Slope level exceeds 10%.
T/C
When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed value given in step (4).
CLUTCH
When the slope level is between 10% and 20% during the HDC operation
When depressing the accelerator pedal or brake pedal, HDC system is changed to stand-by mode. When
depressing the accelerator pedal again, HDC starts its operation again. Therefore, drivers can control the
vehicle speed to a desired level by operating the accelerator pedal.
AXLE
When the slope level exceeds 20% during the HDC operation
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the
SP
brake pedal, HDC continues its operation and the braking power is increased.
In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal
condition due to HDC operation.
ST’NG
BRAKE
A / BAG
A / CON
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HDC (Hill Descent Control) System Non-Operation Conditions
1. When HDC switch is turned OFF or
2. Gearshift lever has passed neutral (N) position. or
NOTICE
• Vehicle with manual transmission: Sensing at the neutral switch
• Vehicle with automatic transmission: Sensing at the selector lever unit
3. When the vehicle speed is out of the specified values. or
4. When the ESP related functions, e.g. vehicle position control, or
HBA, ARP is activated during HDC operation.
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP
function is in operation, HDC operation is overridden.
5. When the internal temperature of HDC system goes over 450°C or
due to long downhill driving on a steep hill with HDC operated.
There is no specific temperature sensor in the system, but a programmed logic inside the HECU predicts the
temperature based on the operating numbers and conditions of HDC.
NOTICE
• The red HDC warning lamp blinks when the internal temperature goes over 350°C. When it reaches 450°C,
the HDC warning lamp comes on. The HDC can be operated in the range even where the HDC warning
lamp blinks.
6. When the slope level is below 10%
When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed condition given in
step (4).
When the slope level is between 10% and 20% during the HDC operation
When depressing the accelerator pedal or brake pedal, HDC system is changed to stand-by mode. When
depressing the accelerator pedal again, HDC starts its operation again. Therefore, drivers can control the
vehicle speed to a desired level by operating the accelerator pedal.
When the slope level exceeds 20% during the HDC operation
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the
brake pedal, HDC continues its operation and the braking power is increased.
In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal
condition due to HDC operation.
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Input/Output Signals for HDC Operation
A/T
M / T
HDC switch Modulator pump
T/C
Gear position
sensing
CLUTCH
Manual transmission:
E
Neutral position →Neutral switch (N)
Reverse position →Backup lamp switch S
AXLE
HECU (Valve
Automatic transmission: Selector lever modulator)
P
LDF Valve and MCI valve
Engine condition
SP
monitoring
1. RPM
H
ST’NG
2. Engine torque
E
3. Gas pedal module
(monitoring gas pedal depression)
C
BRAKE
Stop lamp
When depressing accelerator pedal dur-
ing HDC operation, it is deactivated
(regardless of the slope level). U When the HDC operates,
A / BAG
HECU turns on the stop
lamp by supplying 12V
power (separate relay).
Brake pedal switch
A / CON
When depressing brake pedal during HDC
(HDC
operation, HDC indicator and
1. If the slope level is between 10% and CONTROLLER)
warning lamp
20: HDC is deactivated. (instrument panel)
2. If the slope level exceeds 20%, HDC
function is still activated and the brake
pressure is added.
Sensor cluster
Longitudinal acceleration sensor
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Operation of HDC Indicator Controller
This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF).
The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC
switch is a push & self return type switch – when you press it once, it starts to operate and when you press it again,
it stops the operation.
HDC Indicator HDC Warning Lamp
Green Red
HDC Operation Mode
HDC HDC
Initial ignition ON (From hence, this signifies operation mode ON
after the engine starts. Even when HDC switch is ON, if the OFF (goes off after
ignition is OFF, HDC operation stops automatically.) 1.8 seconds)
Not available HDC switch OFF OFF OFF
HDC system error OFF ON
Stand-by HDC switch ON ON OFF
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating
requirements are not met.
In operation HDC system is operating. Blinking (0.5 seconds
OFF
of interval)
The HDC switch is turned ON, and the operating requirements are met. HDC is operating with
operating sound.
System High brake system HDC stand-by mode OFF Blinking
overheat temperature
HDC is operating Alternate blinking of green and red lamp
(over 350°C)
(0.5 seconds of interval)
Too high brake system temperature
(over 450°C) OFF ON
There is no specific temperature sensor in the system, but a programmed logic inside the HECU
predicts the temperature based on the operating numbers and conditions of HDC (HDC cannot be
operated).
NOTICE
Basically, the brake system’s basic functions can work even when there are problems with the HDC system.
As given in the table above, the HDC warning lamp comes on when:
• Initial ignition ON
• HDC system error occurs
• Brake system overheat
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Cautions When Using HDC System
A/T
Customers must first acquaint themselves with the HDC operation related information, e.g. operation conditions and
non-operation conditions, because they may feel unfamiliar with its function and operation process. The noise during
the HDC operation is very different from that during the ABS/ESP operation. This noise may be irritating and accom-
pany some vibration, because, on steep hills, it attempts to control the physical properties of the vehicle weight with
M / T
the braking power.
Below is the summary of precautions to remember in HDC operation.
T/C
NOTICE
• The HDC system is intended for use only on off-roads with a slope level exceeding 10%. Thus, do not use it on
CLUTCH
public road.
• Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems.
• Driver must turn the HDC switch to OFF position when driving on public and level roads. As mentioned previously,
when a driver make sharp turns or drive on rough roads, the HDC may suddenly operate for these sudden
AXLE
shocks influence the G sensor values. When such occurs, the driver may panic because the vehicle speed
drops sharply and the driver will experience difficulty in controlling the vehicle.
• During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and the brake
system, but this is a normal condition during the HDC operation.
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 4890
7. COMPONENTS AND LOCATIONS
Master cylinder Sensor cluster: Steering wheel angle sensor
pressure sensor (Yaw rate + lateral sensor +
longitudinal sensor)
HECU (Valve body and ECU
integrated type)
Valve body
Motor pump
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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4890 25
Comparison with ABS System
A/T
No Name ESP Component Remark
1 HECU 0 0
2 Pressure sensor 0 N/A ESP system contains
M / T
3 Wheel speed sensor 0 0 ESP OFF switch and
HDC switch.
4 Sensor cluster 0 N/A
5 Steering wheel angle sensor 0 N/A
T/C
CLUTCH
AXLE
Active Wheel Speed Sensor HDC Switch HDC Indicator
SP
ST’NG
BRAKE
A / BAG
ESP OFF Switch
A / CON
ABS / ESP Indicator
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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8. INPUT AND OUTPUT DIAGRAM
Input/Output of ESP System
Battery+ (voltage to hydraulic v/v, ECU) 32 15 CAN LO
Battery+ (voltage to pump) 1 11 CAN HI
Sending and receiving the informa-
IG1 4 tion such as speed signal of ABS
HECU from/to ECUs through CAN
communication.
Brake switch 41
41 Stop lamp power supply
ESP switch 40 Supplying power to brake lamp
when operating HDC.
Wheel speed sensor (FL)
Signal
45 E HDC relay power supply
Ground
46
S
Signal
Wheel speed sensor (FR) Ground
34
33
P 9 HDC switch
HDC operation switch
Signal
Wheel speed sensor (RL) 36
Ground
37 H Power
source
6
Wheel speed sensor (RR)
Signal
Ground
43 E 29
CAN-H
Sensor cluster
42 CAN-L
C 25
Ground
31
Power
source
18
U
Pressure sensor 1 Signal
20 2 Diagnostic connector pin No. 8
Ground
19
This line is used to send the error code
to diagnostic connector when an
Power ABS related component is defective.
source
22
Pressure sensor 2 Signal
23
Ground
21
In ESP equipped vehicle, the sig-
nals from SWAS are sent to ECS
IG1 ECU.
7
ST1 28
SWAS 47 Ground (Pump)
ST2 30
(Steering wheel angle sensor)
STN
3
16 Ground (Valve)
Ground
5
ABS/ESP SYSTEM CHANGED BY
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4890 27
9. ESP SYSTEM RELATED PRECAUTIONS
A/T
1. The HDC system is intended for use only on off-roads with a slope level exceeding 10%. Thus, do
not use it on public road.
M / T
2. Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems.
T/C
3. Driver must turn the HDC switch to OFF position when driving on public and level roads.
As mentioned previously, when a driver make sharp turns or drive on rough roads, the HDC may suddenly
operate for these sudden shocks influence the G sensor values. When such occurs, the driver may panic
CLUTCH
because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle.
4. During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and
AXLE
the brake system, but this is a normal condition during the HDC operation.
5. The warning lamp flashes and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flashes
SP
and beep comes on every 0.1 seconds.
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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10. HYDRAULIC CIRCUIT DIAGRAM
Pressure
sensor
Damper Damper
(primary circuit) (secondary circuit)
Separation
valve (NO) Separation valve
(NO)
Damping chamber
Shuttle
Pump Shuttle valve
valve
Low pressure
accumulator
FR FL inlet RR RL
inlet valve valve inlet valve inlet valve
(NO) (NO) (NO) (NO)
FR FL RR RL
outlet outlet outlet outlet
valve (NC) valve (NC) valve (NC) valve (NC)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)
ABS/ESP SYSTEM CHANGED BY
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AFFECTED VIN
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4890 29
A/T
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And
when equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS
system only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD
M / T
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. When the ESP system is operating, the normally-open separation valve
T/C
will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve. Then,
the inlet and outlet valves will be closed or open depending on the braking pressure increase, decrease or un-
changed conditions.
CLUTCH
For details, refer to “Hydraulic Pressure for each ESP Operating Range”.
AXLE
11. HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE
SP
1 2
ST’NG
Low Low
pressure Shuttle pressure
chamber valve chamber Shuttle
valve
BRAKE
Separation Separation
valve valve
Pump Pump
A / BAG
Outlet Inlet
Inlet valve valve Outlet
valve
A / CON
valve
ESP Hydraulic unit in idling and normal braking po- ESP Hydraulic unit (decreased pressure)
sition The pressure decreases just before the wheel speed
In this position, the separation valve and the inlet valve drops and the wheels. The inlet valve closes and the
are open (normal open), the electrically operated shuttle outlet valve opens as in the ABS HECU and the oil is
valve and the outlet valve are closed. gathered at the low pressure chamber while no addi-
When the brake is applied under these conditions, the tional oil is being supplied. Then the pump operates to
brake fluid will be sent to each wheel via the separation allow fast oil drainage.
valve and inlet valve.
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4890 29
A/T
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And
when equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS
system only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD
M / T
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. When the ESP system is operating, the normally-open separation valve
T/C
will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve. Then,
the inlet and outlet valves will be closed or open depending on the braking pressure increase, decrease or un-
changed conditions.
CLUTCH
For details, refer to “Hydraulic Pressure for each ESP Operating Range”.
AXLE
11. HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE
SP
1 2
ST’NG
Low Low
pressure Shuttle pressure
chamber valve chamber Shuttle
valve
BRAKE
Separation Separation
valve valve
Pump Pump
A / BAG
Outlet Inlet
Inlet valve valve Outlet
valve
A / CON
valve
ESP Hydraulic unit in idling and normal braking po- ESP Hydraulic unit (decreased pressure)
sition The pressure decreases just before the wheel speed
In this position, the separation valve and the inlet valve drops and the wheels. The inlet valve closes and the
are open (normal open), the electrically operated shuttle outlet valve opens as in the ABS HECU and the oil is
valve and the outlet valve are closed. gathered at the low pressure chamber while no addi-
When the brake is applied under these conditions, the tional oil is being supplied. Then the pump operates to
brake fluid will be sent to each wheel via the separation allow fast oil drainage.
valve and inlet valve.
CHANGED BY ABS/ESP SYSTEM
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AFFECTED VIN
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30 4890
ESP unit circuit (when the pressure is maintained)
3
Low
pressure
chamber Shuttle
valve
Separation
valve
Pump
Inlet Outlet
valve valve
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. During ESP
operation, the separation valve closes and only the shuttle valve at the pump
opens.
ESP unit circuit (when the pressure is increased)
Low
pressure
chamber Shuttle
valve
Separation
valve
Pump
Outlet
Inlet valve
valve
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.
ABS/ESP SYSTEM CHANGED BY
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4890 31
12. HYDRAULIC CIRCUIT OF HBA (HYDRAULIC BRAKE ASSIST)
A/T
M / T
T/C
Low
pressure
CLUTCH
chamber
Shuttle
valve
AXLE
Outlet
Separation valve valve
Inlet
valve
SP
Pump
ST’NG
Rear wheel
Outlet
BRAKE
Inlet valve
valve
A / BAG
A / CON
Front wheel
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. Then, the pressure in the pump increases until just before
the corresponding wheel gets locked. The motor still keeps rotating and the outlet valve and the separation valve are
will stay closed.
When the wheel starts to lock, the HBA function cancels and switches to ABS operation.
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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13. COMPONENTS DESCRIPTION
HECU (Hydraulic & Electronic Control Unit)
1. HECU installed in a vehicle
HECU consists of motor pump, solenoid valve
and ECU.
Rear RH (only ECU connector has 47 pins and the number of
applicable to ESP) valves in valve body is 12 when equipped with
Front RH
ESP (6 valve for ABS), and they cannot be
disassembled.
Front LH
Rear RH and LH (Rear LH
when ESP is applied) Primary
Secondary
ESP
ECU
2. Comparison ESP HECU and ABS/EBD HECU
ABS HECU ESP HECU
3. Other components
HECU Pump Motor Valve Body
ABS/ESP SYSTEM CHANGED BY
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A/T
Removal and Installation
M / T
1. Disconnect the control unit connector.
T/C
CLUTCH
AXLE
2. Disconnect the primary and secondary master cylinder
pipes from HECU.
SP
Tightening torque
Master cylinder to HECU 13 ~ 20 Nm
ST’NG
BRAKE
A / BAG
3. Disconnect the front and rear wheel brake pipes.
Tightening torque
A / CON
HECU to each hydraulic line 13 ~ 20 Nm
NOTICE
• Be careful not to damage the HECU pipes and nut
threads when reinstalling.
CHANGED BY ABS/ESP SYSTEM
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Pressure Sensor
Location
1
2
3
1. Master cylinder 5. Hydraulic pipe in secondary circuit
2. Primary pressure sensor 6. Inside of pressure sensor
3. Second pressure sensor 7. Connector
4. Hydraulic pipe in primary circuit
Specifications
Supplying voltage 4.75 ~ 5.25 V
0.25 ~ 4.75 V (This is linearly changed from 0.5 V (brake not applied) to
Output voltage
4.75 V (brake applied))
Output range 0 ~ 170 bar
ABS/ESP SYSTEM CHANGED BY
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A/T
Description
Master Master
M / T
cylinder cylinder
T/C
Brake not Brake
applied applied
CLUTCH
The sensor consists of two ceramic The pressure sensors operate on the When brake pressure is applied
disks, one of which is stationary and principle of changing capacitance from the master cylinder, the ce-
the other movable. The distance be- (a). ramic disk moves towards the fixed
AXLE
tween these disks changes when The distance (S) between the disks ceramic disk and the electric
pressure is applied. and, thus, the capacitance changes charge volume changes accordingly.
when pressure is applied to the mov-
The voltage value is linearly changed
able disk by a braking intervention.
from 0.5 V (brake not applied) to 4.
SP
The voltage value is approx. 0.5 V 75 V (brake applied).
when the brake is not operated.
ST’NG
BRAKE
A / BAG
Pressure Sensor Circuit
The ESP unit supplies around 5V power to two pres-
Ground sure sensors installed on the ESP system when the
A / CON
1 19 ignition switch is ON.
Power
2 20 Each sensor’s pin no. 1 is its ground and pin no. 3
3 18 outputs the sensor output voltage to the ESP unit. When
Signal output
the brake is not in operation, this voltage is about 0.5V
< Primary pressure and, during the brake operation it increases linearly to
sensor >
about 0.5 ~ 4.75V.
Ground
Power
1 21
2 23
HBA operating conditions:
3 22
Signal output 1. Pressure: 20 bar
< Secondary
< ESP unit >
2. Pressure changes: over 1500 bar/sec
pressure sensor >
3. Vehicle speed: over 7 km/h
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Removal and Installation
1. Disconnect the battery negative terminal.
2. Remove the connector of the pressure sensor.
3. Remove the fuel filter bracket to remove the pressure
sensor.
4. Place an empty container under the pressure sensors
to collect the oil.
5. Remove the primary and secondary pressure sensors.
When installing
Tightening torque 33 ~ 37 Nm
6. Install in the reverse order of removal.
7. Bleed the brake system after installation.
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Sensor Cluster
A/T
Location
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
1. Center fascia panel (left/right) 3. Installed sensor cluster
BRAKE
2. Sensor cluster 4. Inside of sensor cluster
A / BAG
Specification (sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal
acceleration sensor)
A / CON
Supplying voltage Approx. 5V (4.75 ~ 5.25V)
Output voltage during stopping Approx. 2.5V (Ignition switch “ON”)
Yaw rate sensor operating range -75°/S ~ +75°/S
Lateral acceleration sensor operating range -1.7 ~ +1.7g (16.7m/s2 )
Longitudinal acceleration sensor operating range -1.7 ~ +1.7g (16.7m/s2 )
Sensor Cluster Operation and Principles
The lateral sensor, longitudinal sensor and the yaw rate sensor are integrated into the sensor cluster. There is an
additional electronic circuit to communicate with CAN.
During the vehicle cornering, the microscopic tuning forks installed in the yaw rate sensor detects the yaw rate
(acceleration around the vertical axis of the vehicle) and transmits it through the CAN communication line to the
ESP unit, using the electronic signal. Especially, the longitudinal acceleration sensor detects the slope level of the
driving road and provides important information for the HDC operation.
CHANGED BY ABS/ESP SYSTEM
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AFFECTED VIN
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The Microscopic tuning forks in the yaw rate sensor
measures the acceleration on the vertical axis of the
vehicle. When the angular acceleration occurs on the
vertical axis of the vehicle (Z axis) and this acceleration
occurs more than 4° (4 degree) per second, vibration
occurs at the top and bottom as shown in the figure.
This vibration is transmitted through the CAN communi-
cation line by the form of voltage value. In other words, it
detects the yawing of the vehicle.
The ESP control operates when a divergence occurs between the vehicle yawing and the steering angle (i.e. the
ESP operates when the driver’s intent differs from the vehicle position). Therefore, the occurrence of vehicle yawing
does not imply the ESP operation.
Sensor Cluster Circuit
1 CAN -L
25
Power
4
2 CAN -H
29
5 Ground
31
3 Power
6
<Sensor Cluster> <ESP Unit>
The ESP sensor cluster can be considered as one module. The measured value by lateral/longitudinal and yaw rate
sensors is transmitted to ESP unit via two CAN lines. The supplied voltage from ESP unit is approx. 5 V with ignition
key “ON” and the output range through CAN line is approx. 0.2 ~ 4.8 V. When a sensor is faulty, the sensor cluster
produces an output signal of 0 V (fail safe function).
Power supply
circuit Yaw rate sensor
A/D converter
Micro controller Lateral sensor
CAN module Longitudinal
sensor
< Internal electric circuit of sensor cluster >
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Removal and Installation
A/T
Preceding Work: Disconnect the battery negative cable.
1. Remove the center fascia panels (left/right).
M / T
T/C
CLUTCH
AXLE
Remove three screws before removal
SP
2. Remove the AV head unit assembly.
ST’NG
BRAKE
A / BAG
Remove four screws
A / CON
NOTE
• AV head unit may have different connectors according to the specifications.
CHANGED BY ABS/ESP SYSTEM
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3. Disconnect the sensor cluster connector and unscrew
the cluster mounting bolts.
When installing
Tightening torque 7 ~ 9Nm
4. Install in the reverse order of removal.
NOTICE
• The installing direction and location are very impor-
tant when installing the sensor cluster. Make sure
that there are not any foreign material and interfer-
ence with floor carpet on the mounting surface.
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SWAS: Steering Wheel Angle Sensor
A/T
Location
SWAS is installed at the bottom of air bag clock spring in steering handle and sends the steering angle signal to
M / T
ESP HECU.
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
1. SWAS (Steering Wheel Angle Sensor)
A / BAG
2. Combination switch assembly
A / CON
Specifications
Working voltage 9 ~ 16V
Max. output current 10 mA
Detected max. angular velocity 1500°/S
Working temperature - 30 ~ 75°C
Supplying voltage 9 ~ 16V (battery voltage)
Output voltage (HI) Approx. 3.50V (3.0 ~ 4.1V)
Output voltage (LO) Approx. 1.50V (1.3 ~ 2.0V)
CHANGED BY ABS/ESP SYSTEM
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LED
Steering wheel angle Phototransistor
sensor connector
Steering
column Slotted plate
Steering wheel angle sensor
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate
between them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is
turned, the voltage occurs through the holes. The detected voltage will be transmitted to the ECS unit as a pulse
from the 3 terminals. Then, the two voltage pulses are used to get the average value for detecting the steering wheel
position and its angle speed. And the other pulse is used for checking the alignment of the steering wheel.
IGN1
Steering ESP
Wheel STN
H
Angle E
ST2
Sensor C
(SWAS) U
ST1
Ground
Working
9 ~ 16 V
voltage
VHigh
Number of
ST1
pulse per 45 Pulses /1 rev VLow
revolution
Duty Approx. 50 %
VHigh
ST2
High - V 3.0 ~ 4.1 V VLow
Low - V 1.3 ~ 2.0 V
VHigh 2°
Detects steering wheel STN
ST1 and VLow
angle and angular velocity
ST2
as an average value
Center line of
Detects the center value steering wheel
STN
of steering wheel
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ESP OFF Switch
A/T
Location
M / T
T/C
CLUTCH
AXLE
ESP OFF Switch
SP
ST’NG
BRAKE
A / BAG
ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds
to warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is
A / CON
operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds.
ON
ESP operation
(including TCS)
OFF
175ms
ON
ESP warning lamp
OFF
175ms
Min. 4 times
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ESP System Cancellation Using the ESP OFF Switch
When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be
cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the
ESP warning lamp on the instrument panel comes on.
The detailed operation procedures are as follows:
1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
3. The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx.
150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately
when the ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by
pressing the ESP switch for over 150 ms, the TCS system (including ABD function) is turned off. And the ABS
system is still operated.
Resuming the ESP System by Using the ESP OFF Switch
The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch
is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
1. The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
3. The ESP system will be resumed after approx. 150 ms.
PUSH RELEASE PUSH
RELEASE
350 ms
HI
ESP operation Disabled
LO range
150 ms 150 ms
ON
ESP function
(including TCS)
OFF
150 ms
150 ms
ON
ESP warning lamp
OFF
NOTICE
• When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed
when ignition switch is turned on again.
• When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
• The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the
ESP OFF mode and the ESP warning lamp will not be changed.
• When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP sys-
tem will not be turned on.
ABS/ESP SYSTEM CHANGED BY
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ESP OFF Switch Monitoring
A/T
When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds, the ESP unit determines
it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 10
seconds. However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and
then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP
M / T
unit resets the ESP OFF switch for approx. 3.5 seconds.
Push Release
Detect
T/C
HI failure
ESP operation
LO
CLUTCH
10 3.5
sec sec
Return to switch signal Reset to normal condition
AXLE
ON
ESP function
(including TCS)
OFF
Cancellation of ESP OFF mode
SP
Turning the ESP warning lamp off
ON
ESP warning lamp
ST’NG
OFF
ESP Warning Lamp Operation Depending on System Conditions
BRAKE
The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is working.
Warning Lamp Controls
A / BAG
Vehicle yaw
ABS W/L ESP W/L ABS ASR ABD
control
Initial start (for 1.8 sec) ON ON NO NO NO NO
A / CON
BLINKS WHEN
Normal mode OFF OK OK OK OK
ESP OPERATION
ESP fault OFF OK NO NO NO
ABS fault ON ON NO NO NO NO
System fault ON ON NO NO NO NO
Low batt. voltage ON ON NO NO NO NO
High battery voltage ON ON NO NO NO NO
High brake pad temp. OFF ON OK NO NO NO
ESP-OFF mode OFF ON OK NO NO OK 1)
Entering diag. mode ON ON NO NO NO NO
NOTICE
• When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen-
sate the vehicle stability (posture) during ESP operation.
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14. ESP SYSTEM AIR BLEEDING
The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the
vehicle equipped with ESP should use the oil supply device using a compressor inorder to bleed the air.
Air Bleeding Should Be Done When
1. After removal and installation of the brake master cylinder.
2. After removal and installation of the ABS HECU.
3. After removal and installation of the brake oil pipes and hoses.
4. After replacing the brake fluid.
Air Bleeding Procedures
1. Apply the parking brake and start the engine when the shift lever is at "P" position.
2. Connect the oil supply device (air bleeding device) with air compressor to brake reservoir. The oil supply device
should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an empty container under the screw.
4. Bleed the air in each wheel by using diagnostic device. At this time, the modulator motor runs for 180 seconds.
5. Simultaneously, run the oil supply device to supply oil and depress the brake pedal repeatedly.
This procedure needs at least 3 persons for doing below jobs:
1) Collect the bleeding oil into the container.
2) Depress the brake pedal repeatedly.
3) Check the conditions of oil supply device.
The air bleeding procedure should be started from the rear right wheel.
6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw.
7. Perform the same procedures at each wheel.
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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A/T
Air Bleeding by Using Scan-100
M / T
AIR BLEEDING(TEVES ABS/ESP) AIR BLEEDING(TEVES ABS/ESP)
1] REAR/RIGHT CHANNEL >>>> REAR/RIGHT AIR BLEEDING <<<<
T/C
2] REAR/LEFT CHANNEL
1. OPEN THR BLEED SCREW.
3] FRONT/LEFT CHANNEL
2. CONTINUALLY PUMPING BRAKE PEDAL.
CLUTCH
4] FRONT/RIGHT CHANNEL (PUMP MOTOR & VALVE ACTIVATING)
3. TOTAL ACTIVE TIME : 180 [Sec]
Select one of the above items
AXLE
DO YOU START AIR BLEEDING ?
(Yes / No)
SP
ST’NG
AIR BLEEDING(TEVES ABS/ESP) AIR BLEEDING(TEVES ABS/ESP)
>>>> REAR/RIGHT AIR BLEEDING <<<< >>>> REAR/RIGHT AIR BLEEDING <<<<
BRAKE
ACTIVATING PUMP MOTOR & VALVE
FINISHED BLEEDING.
THE WHEEL MUST BE BLEED UNTILE
CLOSE BLEEDER SCREW. THERE IS FOAMLESS AND BUBBLE FREE
A / BAG
BRAKE FLUID SEEN AT THE BLEED
PRESS “ENTER”. SCREW.
TIME : xxx [Sec]
A / CON
BUBBLE FREE(FOAMLESS) ?
(Yes / No)
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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15. ABS/ESP TROUBLE DIAGNOSIS
o: Applied x: N/A
Function Defective Components Trouble Code Descriptions System
Wheel speed sensor
Front LH C1011 (5011) front left-electrical
ABS ESP
Wheel speed sensor C1012 (5012) Wheel speed sensor
front left-other
1. C1011 (5011)
Cause
- Defective front LH wheel speed sensor
- Short or poor contact wire to sensor
Action
- Check the wheel speed sensor connector
- Check HECU connector
- Check the harness connection
2. C1012 (5012)
Cause
O O
- Defective front LH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
- Too large air gap between wheel speed sensor and tooth wheel
- Different number of teeth in tooth wheel
Sensor Action
- Check the wheel speed sensor connector
Monitoring
- Check HECU connector
- Check air gap and tooth wheel mounting (Specified air gap: 0.335 ~ 0.945 mm)
- Check the number of teeth (48) in tooth wheel
Wheel speed sensor
Front RH C1021 (5021) front right-electrical
Wheel speed sensor C1022 (5022) Wheel speed sensor
front right-other
1.C1021 (5021)
Cause
- Defective front RH wheel speed sensor
- Short or poor contact wire to sensor
Action
- Check the wheel speed sensor connector
- Check HECU connector
- Check the harness connection
2.C1022 (5022) O O
Cause
- Defective front RH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
- Too large air gap between wheel speed sensor and tooth wheel
- Different number of teeth in tooth wheel
Action
- Check the wheel speed sensor connector and HECU connector
- Check air gap and tooth wheel mounting (Specified air gap: 0.335 ~ 0.945 mm)
- Check the number of teeth (48) in tooth wheel
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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A/T
Function Defective Components Trouble Code Descriptions System
M / T
Wheel speed sensor
Rear RH C1031 (5031) rear left-electrical
ABS ESP
Wheel speed sensor C1032 (5032) Wheel speed sensor
rear left-other
T/C
1. C1031 (5031)
Cause
- Defective rear RH wheel speed sensor
CLUTCH
- Short or poor contact wire to sensor
Action
- Check the wheel speed sensor connector
- Check the HECU connector
AXLE
- Check the harness connection
2. C1032 (5032)
Cause
O O
- Defective rear RH wheel speed sensor
SP
- No signals from wheel speed sensor and tooth wheel
- Too large air gap between wheel speed sensor and tooth wheel
- Different number of teeth in tooth wheel
ST’NG
Sensor Action
- Check the wheel speed sensor connector
Monitoring
- Check the HECU connector
- Check air gap and tooth wheel mounting (Specified air gap: 0.309 ~ 0.958 mm)
BRAKE
- Check the number of teeth (48) in tooth wheel
Wheel speed sensor
Rear LH C1041 (5041) rear left-electrical
A / BAG
Wheel speed sensor C1042 (5042) Wheel speed sensor
rear left-other
1. C1041 (5041)
A / CON
Cause
- Defective rear LH wheel speed sensor
- Short or poor contact wire to sensor
Action
- Check the wheel speed sensor connector
- Check the HECU connector
- Check the harness connection
2. C1042 (5042) O O
Cause
- Defective rear LH wheel speed sensor
- No signals from wheel speed sensor and tooth wheel
- Too large air gap between wheel speed sensor and tooth wheel
- Different number of teeth in tooth wheel
Action
- Check the wheel speed sensor connector and HECU connector
- Check air gap and tooth wheel mounting (Specified air gap: 0.309 ~ 0.958 mm)
- Check the number of teeth (48) in tooth wheel
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Function Defective Components Trouble Code Descriptions System
Pressure sensor C1051 (5051) Defective input sensor ABS ESP
Cause
- Abnormal signals from pressure sensor
- Defective pressure sensor or harness X O
Action
- Check the pressure sensor connector
Steering wheel angle Defective steering wheel
C1061 (5061)
sensor angle sensor
Cause
- Internally defective steering wheel angle sensor
- Abnormal signals from steering wheel angle sensor
- Short circuit between supplying voltage output and ground
- Abnormal signal voltage from steering wheel angle sensor
- Poor installation of steering wheel angle sensor and abnormal signal
Action
- Check the supplying voltage: (Specified voltage: 9 ~ 16 V) X O
- Check the output voltage: Check voltage between ESP unit terminals with ignition ON
Sensor
• ST1 voltage check: between ESP unit terminal No. 5 and ground (Specified voltage:
Monitoring 1.3 ~ 4.1V)
• ST2 voltage check: between ESP unit terminal No. 2 and ground (Specified voltage:
1.3 ~ 4.1V)
• STN voltage check: between ESP unit terminal No.12 and ground (Specified voltage:
1.3 ~ 4.1V)
C1073 (5073) Sensor cluster -electrical
Sensor cluster
C1074 (5074) Sensor cluster-internal
1. C1073 (5073)
Cause
- Operating voltage exceeds specified range (Hi: 18.0 ± 1.0 V / Lo: 6.5 ± 0.5 V )
- Poor contact or installation of harness
Action
- Check the sensor cluster connector
- Replace the sensor cluster
2. C1074 (5074)
Cause
- Internally defective HECU
- Abnormal A/D converter voltage: 5.0 ± 3 % X O
- Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor cluster
→ Short circuit between supplying voltage output of sensor cluster and ground
- Poor ground of sensor cluster (0.0 ~ 0.5 V)
→ Short to ground on sensor cluster
- Abnormal signals from lateral acceleration sensor
- Abnormal signals from yawing sensor
- Poor installation of sensor
- Defective sensor cluster
- Defective or short circuit of CAN communication line
Action
- Replace the sensor
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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Function Defective Components Trouble Code Descriptions System
A/T
C1101 (5101) Battery under voltage
Battery ABS ESP
C1102 (5102) Battery over voltage
M / T
1. C1101 (5101)
Cause
- Low voltage out of specified range (9.7 ± 0.3 V)
Battery
Action
T/C
Voltage - Check the supplying voltage
O O
Monitoring 2. C1102 (5102)
CLUTCH
Cause
- Over voltage out of specified range (18.0 ± 1.0 V)
Action
- Check the supplying voltage
AXLE
Brake disc C1111 (5111) Disk temperature is high
Cause
SP
- Overheated brake disk due to braking force: over 500°C
X O
Action
- Stop driving for a period of time after turning off the ESP
ST’NG
Brake lamp switch C1201 (5201) Defective brake lamp switch
Brake ESP OFF switch C1202 (5202) Defective ESP OFF switch
Monitoring
BRAKE
1. C1201 (5201)
Cause
- Mechanical defective in brake switch
- Defective brake switch harness
A / BAG
Action
- Check the harness and connector
X O
2. C1202 (5202)
A / CON
Cause
- Mechanical defective in ESP OFF switch
- Defective ESP OFF switch harness (short to ground)
Action
- Check the harness and connector for ESP OFF switch
Defective valve,
Valve, valve relay C1301 (5301)
valve relay in HECU
Cause
Valve - Abnormal supplying voltage to valve solenoid
- Internally defective HECU
Monitoring
Action O O
- Replace the HECU
- Check the battery voltage
- Check the HECU connector
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Function Defective Components Trouble Code Descriptions System
Motor pump C1302 (5302) Defective motor pump ABS ESP
Cause
- Too low (below 6.0 V) or no supplying voltage to pump motor
- Over 0.93 V from pump motor voltage
Pump - Poor contact in pump motor connector
Monitoring - Poor ground O O
Action
- Check the supplying voltage
- Check the HECU connector
- Replace the HECU
HECU C1401 (5401) HECU hardware
Cause
- Internally defective HECU
- Defective A/D converter, internal voltage regulator, and controller
- Defective sensor and short to supplying voltage line O O
- Abnormal temperature sensor signal
Action
- Replace the HECU
Abnormal sensor
Sensor initialization C1501 (5501)
HECU initialization
and Sensor Cause
Monitoring - Abnormal signals from sensors
- Abnormal sensor data
O O
Action
- Check the sensors
- Initialize the sensors
Variant coding error, or
Vehicle coding C1170 (5170)
misinstallation HECU
Cause
- Discrepancy between HECU coding and vehicle coding
- Defective CAN communication line
- Misinstallation HECU
Action (O) O
- Check the HECU coding and vehicle coding
- Perform vehicle coding
- Replace the exact HECU
- Check engine ECU variant coding
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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Function Defective Components Trouble Code Descriptions System
A/T
CAN communication C1601 (5601) CAN communication error ABS ESP
M / T
Cause
- Short or open to CAN communication line
- Poor connection of CAN communication line (O) O
Action
T/C
- Check the CAN communication line
- Check the HECU connector
Communication error between
CLUTCH
engine ECU and HECU
C1602 (5602) Communication error
C1603 (5603) between TCU and HECU
CAN communication
C1604 (5604) Communication error between
AXLE
C1605 (5605) TCCU (4WD) and HECU
Communication error between
cluster (Meter) and HECU
1. C1602 (5602)
SP
Cause
- Short to CAN communication line
- Overload to CAN communication Action
ST’NG
Action
- Check the engine ECU
- Check the CAN communication line
BRAKE
- Check the engine ECU connector
2. C1603 (5603)
Cause
A / BAG
- Short to CAN communication line
- Overload to CAN communication Action
Action
- Check the TCU
X O
A / CON
- Check the CAN communication line
- Check the TCU connector
3. C1604 (5604)
Cause
- Short to CAN communication line
- Overload to CAN communication Action
Action
- Check the TCCU
- Check the CAN communication line
- Check the TCCU connector
4. C1605 (5605)
Cause
- Short to CAN communication line
- Overload to CAN communication Action
Action
- Check the cluster (meter)
- Check the CAN communication line
- Check the cluster (meter) connector
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Function Defective Components Trouble Code Descriptions System
Signal from engine
CAN signal error EMS C1612 (5612) ABS ESP
ECU is abnormal
CAN
Cause
Communica-
- Engine ECU is defective
tion - Signal from engine ECU error
X O
Monitoring Action
- Check engine ECU
- Check ECU S/W version
ABS/ESP SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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ABS/ESP Sensor Value
A/T
No Content Unit ESP ABS
M / T
1 Wheel Speed FR 1 km/h O O
2 Wheel Speed FL 1 km/h O O
T/C
3 Wheel Speed RR 1 km/h O O
4 Wheel Speed RL 1 km/h O O
CLUTCH
5 Battery Voltage 0.1V O O
AXLE
6 Longitudinal Acceleration Sensor 0.01 g-: Straight ahead O O
7 Lateral Aceleration Sensor 0.01 g +: Left Turn O X (Fixed Value: 0)
SP
8 Yaw Rate Sensor 0.5 deg/s +: Left Turn O X (Fixed Value: 0)
9 Steering Wheel Angle sensor 5 deg +: Left Turn O X (Fixed Value: 0)
ST’NG
10 Pressure Sensor (Primary) 1 bar O X (Fixed Value: 0)
BRAKE
11 Pressure Sensor (Secondary) 1 bar O X (Fixed Value: 0)
12 EBD Control Operation / Non-operation O O
A / BAG
13 BTCS Control Operation / Non-operation O X
14 Engine TCS Control Operation / Non-operation O X
A / CON
15 ESP Control Operation / Non-operation O X
16 ESP/TCS OFF Switch ON / OFF O X
17 ABS Control Operation / Non-operation O O
18 Stop Lamp Switch ON / OFF O O
(O: Applied, X: N/A)
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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ABS / ESP Forced Operation
No Name Operation
1 FL Inlet Valve Operation / Non-operation
2 FL Outlet Valve Operation / Non-operation
3 FR Inlet Valve Operation / Non-operation
4 FR Outlet Valve Operation / Non-operation
5 Rear (or RL) Inlet Valve (*1) Operation / Non-operation
6 Rear (or RL) Outlet Valve (*1) Operation / Non-operation
7 RR Inlet Valve (*2) Operation / Non-operation
8 RR Outlet Valve (*2) Operation / Non-operation
9 TCS Valve Primary (*3) Operation / Non-operation
10 TCS Valve Secondary (*3) Operation / Non-operation
11 ESV Valve Primary (*3) Operation / Non-operation
12 ESV Valve Secondary (*3) Operation / Non-operation
13 - -
14 - -
15 Motor Pump Operation / Non-operation
ABS/ESP SYSTEM CHANGED BY
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Sensor Initialzation (ABS & ESP)
A/T
SENSOR INITIALIZE (Only ESP) SENSOR INITIALIZE
M / T
1] LONGITUDINAL SENSOR LONGITUDINAL ACCEL SENSOR(4WD only)
(4WD only) DO YOU START INITIALIZE ? (Yes/No)
T/C
2] LATERAL SENSOR
CONDITION :
3] PRESSURE SENSOR
- ENGINE IS NOT RUNNING.
4] ABOVE 1,2,3 ALL SENSOR
CLUTCH
- VEHICLE STATUS IS FLAT.
- DO NOT PUT THE BRAKE PEDAL.
Select one of the above items
PROCEDURE :
AXLE
MUST BE FOLLOW THE ABOVE CONDITION.
IF YOU START "INITIALZE SENSOR"
ADAPT TO AUTOMATIC.
SP
Initialize both the primary and secondary pres-
sure sensors when initializing a pressure sensor.
ST’NG
Steering wheel angle sensor
BRAKE
The steering wheel angle sensor automatically searches for a center position when the vehicle is driving straight
forward with 20 km/h of driving speed (no additional diagnostic menu).
A / BAG
A / CON
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Actuator
ACTUATOR TEST
ACTUATOR TEST
1. FRONT/LEFT INLET VALVE
2. FRONT/LEFT OUTLET VALVE
3. FRONT/RIGHT INLET VALVE
4. FRONT/RIGHT OUTLET VALVE
5. REAR(ESP: REAR/LEFT) INLET VALVE
6. REAR(ESP: REAR/LEFT) OUTLET VALVE
7. REAR/RIGHT(Only ESP) INLET VALVE
8. REAR/RIGHT(Only ESP) OUTLET VALVE
9. 1st TCS VALVE(Only ESP)
10. 2nd TCS VALVE(Only ESP)
11. 1st ESV VALVE(Only ESP)
12. 2nd ESV VALVE(Only ESP)
13. PUMP MOTOR
Select one of the above items
FRONT/LEFT INLET VALVE
----------------------------------------------------
ON(ACTIVE): “YES” KEY
OFF(STOP): “NO” KEY
OTHER ITEM : “ , ”
----------------------------------------------------
ACTIVE TIME : Max. 10 Sec
CONDITION : IG. ON or IDLE
ABS/ESP SYSTEM CHANGED BY
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Clearing Code
A/T
CLEAR VARIANT CODE
M / T
T/C
VEHICLE CODING CLEAR
--------------------------------------------------
CLUTCH
DO YOU START TO CLEAR?
( YES / NO )
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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ABS SYSTEM
1. GENERAL INFORMATION
Differences compared to other models: Appearance of wheel speed sensor, Location, Layout of relevant components
ABS HECU Active Wheel Speed Sensor (for 4WD)
The transfer case (T/C) installed on this vehicle doesn’t have the internal speed sensing device and receives the
speed signal for T/C control from ABS HECU.
Conventional Transfer Case New Transfer Case
With Speed Sensor
Without Speed Sensor
ABS/ESP SYSTEM CHANGED BY
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Cautions When Removing the Front Wheel Speed Sensor
A/T
The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the conventional
approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition
within the actuator.
Thus, the wheel speed sensor is installed on the front wheel end area. It is installed inside the backing plate to
M / T
be protected from heat and foreign materials. Therefore, the front wheel end system (including disc) should be
removed before removing the front wheel speed sensor.
T/C
Front Wheel Speed Sensor Rear Wheel Speed Sensor
CLUTCH
Backing Plate
AXLE
SP
ST’NG
BRAKE
Wheel Speed Sensor
A / BAG
Backing Plate
Wheel Speed Sensor
A / CON
CHANGED BY ABS/ESP SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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The rubber O-ring in IWE (Integrated Wheel End) should be replaced with new one when the front wheel end has
been removed.
The rubber O-ring prevents moisture and foreign materials from entering the IWE system.
In addition, when installing the hub actuator of the IWE system, you must install it from the same angle as the drive
shaft to prevent the rubber seal ring inside the actuator from being squeezed.
Rubber O-ring
Rubber seal ring
(Internal steel spring included)
Please refer to the part time transfer case section for more specific information.
ABS/ESP SYSTEM CHANGED BY
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2. CONFIGURATION OF ABS SYSTEM
A/T
The following figure shows the basic system components of the ABS. This system consists of HECU (valve body
and ECU integrated type), front wheel speed sensor, and rear wheel speed sensor.
M / T
Front Wheel Speed Sensor Rear Wheel Speed Sensor
(for 4WD)
T/C
CLUTCH
AXLE
HECU (Valve body and ECU
integrated type)
SP
ST’NG
Rear wheel
BRAKE
speed sensor
(RR)
A / BAG
Valve body
Front wheel
speed
sensor (FR)
A / CON
Rear wheel speed
ABS HECU sensor (RL)
Front wheel speed sensor (FL)
B: Plunger C: Can bushing
ABS warning lamp
Motor pump
CHANGED BY ABS/ESP SYSTEM
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3. INPUT AND OUTPUT DIAGRAM
Input/Output of ABS (without TPMS)
Battery + (hydraulic valve 32
and ECU power supply)
Battery + (pump supply power) 1
ABS HECU supplies battery power to
operate hydraulic pump and hydraulic
valve even when the ignition switch is
OFF.
NOTICE
IG1 4
• No specific terminal exists to
display vehicle speed or ABS
warning lamp. Data is transmit-
ted through CAN communication.
Brake switch 41
H
CAN LO 15 E
CAN HI 11
Sending and receiving the information C
such as speed signal of ABS HECU from/
to ECUs through CAN communication.
Wheel speed sensor (FL)
Signal
Ground
45 U 2 Diagnosis connector pin no.8
46
This line is used to send the error code
Signal
34 to diagnostic connector when an ABS
Wheel speed sensor (FR) Ground
33 related component is defective.
Signal
36
Wheel speed sensor (RL) Ground
37 47 Ground (pump)
Signal
43
Wheel speed sensor (RR) Ground
42
Currently applied wheel speed sensors 16 Ground (valve and ECU)
are active type and have the PCB with
resistance. It measures wheel speed by
using current value changing when wheel
rotates.
ABS/ESP SYSTEM CHANGED BY
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4. HYDRAULIC CIRCUIT OF ABS
A/T
M / T
Master cylinder
T/C
Primary Secondary circuit
CLUTCH
circuit
AXLE
Damping
chamber
Pump
SP
Low pressure Low pressure
accumulator accumulator
ST’NG
BRAKE
Inlet Inlet valve
Inlet valve
valve (all rear
(FR)
(FL) wheel)
A / BAG
Outlet valve Outlet valve Outlet valve
A / CON
(FR) (FL) (all rear wheel)
Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL)
The vehicle equipped only with the ABS controls the wheel’s braking force using or 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. The rear wheels that are the secondary circuit of
the brake system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is
similar to the one from the previous model.
CHANGED BY ABS/ESP SYSTEM
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5. ABS CIRCUIT IN EACH OPERATION RANGE
1 2
Low pressure Low pressure
chamber chamber
Inlet valve
Pump Pump
Inlet valve
Outlet valve Outlet valve
Hydraulic Pressure Circuit when ABS is Not Operating No Hydraulic Pressure Circuit when ABS is Operating
The hydraulic pressure in the master cylinder increases As hydraulic pressure on each wheel increases, the wheel
through the vacuum booster and it is delivered to the wheel tends to lock. In order to prevent the wheel from locking, the
via the normal open inlet valve. At this moment, the nor- hydraulic valve modulator operates the inlet valve control
mally-closed outlet valve is closed. The speed of the wheel solenoid to close the inlet valve and stop the hydraulic pres-
that hydraulic pressure is delivered reduces gradually. sure increases. At this moment, the outlet valve is closed.
This procedure helps the wheel to maintain a stable hy-
draulic pressure.
3 4 Low
pressure
Low pressure
chamber
chamber
Pump Pump Inlet valve
Inlet valve Outlet valve
Outlet valve
Pressure Decreases in the Circuit when ABS is Operating Pressure Increases in the Circuit when ABS is Operating
Even when the hydraulic pressure on each circuit is stable, As the wheel speed increases, the inlet valve opens and
the wheel can be locked as the wheel speed decreases. the wheel’s pressure increases due to the master cylinder
This is when the ABS ECU detects the wheel speed and pressure. The oil in the low pressure chamber circulates
the vehicle speed and gives the optimized braking without to the wheel by the pump and the wheel speed decreases
locking the wheels. In order to prevent from hydraulic pres- as the hydraulic pressure at wheel increases. This opera-
sure increases, the inlet valve is closed and the outlet valve tion continues repetitively until there are no signs that the
is opened. Also, the oil is sent to the low pressure cham- ABS ECU is locking the wheels. When the ABS hydraulic
ber and the wheel speed increases again. The ABS ECU pressure control takes place, there may be some vibration
operates the pump to circulate the oil in the low pressure and noises at the brake pedal.
chamber to the master cylinder. This may make the driver
to feel the brake pedal vibration and some noises.
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6. COMPONENTS AND LOCATION
A/T
M / T
Front LH wheel
Primary master cylinder
T/C
CLUTCH
Front RH wheel
AXLE
Secondary master cylinder
Rear RH/LH wheel
SP
ST’NG
BRAKE
Wheel Speed Sensor - Front (for 4WD) Wheel Speed Sensor - Rear
A / BAG
A / CON
CHANGED BY ABS/ESP SYSTEM
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7. COMPONENTS DESCRIPTION
1) HECU (Hydraulic & Electronic Control Unit)
This section is provided only for the understanding of
HECU. Note that this component cannot be disas-
sembled for repair and maintenance. HECU consists of
motor pump, valve body, solenoid valve and ECU.
ECU connector has 47 pins and the number of valves in
valve body is 6 when equipped with only ABS and 12
when equipped with ESP system.
1. Motor pump 2. Valve body <Pumping>
The motor is operated when ABS is The cam bushing (c) is installed be- When the cam pushes the left plunger
activated. The cam-shaped output tween plungers (b) and it draws and during motor operation, the system
shaft of the motor (a) enables the discharges the brake fluid. pressure is generated in the left
brake system to receive and supply cylinder. At this time, the right
the brake fluid during the motor plunger is expanded by spring force
operation. and the expanded volume of the right
cylinder draws the brake fluid.
3. ECU (Including Solenoid Valves) <ECU lower cover>
HECU controls the hydraulic valves by supplying or cut-
ting off the voltage to solenoid valves depending on the
wheel speed and other information from wheel speed
sensors. The ABS ECU has 6 solenoid valves. It has
three channels; 2 channels for front wheels and 1 chan-
nel for rear wheels Each channel has one inlet and one
outlet valve, therefore, there are six solenoid valves.
Main functions are
1) Overall control of ABS functions
The electrical components are weak to moisture. To pro-
2) Monitoring of ABS electric components
tect ECU, Gore Tex-based plate is used at ECU lower
3) Diagnosis function support cover. The vent hall (arrow) allows air to ventilate but
does not allow moisture to penetrate.
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8. REMOVAL AND INSTALLATION
A/T
HECU Assembly
1. Disconnect the battery negative cable.
M / T
2. Disconnect the ABS hydraulic unit connector.
T/C
CLUTCH
AXLE
3. Disconnect the primary and secondary master cylinder
pipes from HECU.
SP
Tightening torque
Master cylinder - HECU 20 ~ 24 Nm
ST’NG
BRAKE
A / BAG
4. Disconnect the front and rear wheel brake pipes.
A / CON
Tightening torque
HECU - Each hydraulic line 15 ~ 19 Nm
NOTICE
• Be careful not to damage the HECU pipe and nut
thread when reinstall.
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5. Unscrew two mounting nuts and carefully remove HECU.
Tightening torque
HECU mounting nut 4 ~ 8 Nm
NOTICE
• Do not attempt to disassemble the HECU assembly.
• Wrap the opening of pipes and HECU to prevent
contamination.
6. Install in the reverse order of removal.
7. After reinstallation, add some oil and perform the brake
air bleeding.
NOTICE
• When you install a new HECU to the vehicle, coding
is executed automatically. Thus, no additional coding
is necessary.
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AWSS: Active Wheel Speed Sensor
A/T
The speed sensor used in traditional ABS is made of permanent magnet and transmits the output voltage that
changes as the wheel rotor rotates to the HECU system. New wheel speed sensor detects the wheel speed
through the current value that depends on the resistance that changes according to the magnetic field by using
four resisters and supplying the 12 V power supply to the sensor.
M / T
<Front wheel speed sensor> <Rear wheel speed sensor>
T/C
CLUTCH
AXLE
SP
<Active wheel speed sensor> <Wheatstone bridge type>
ST’NG
BRAKE
A / BAG
This sensor contains:
A / CON
1. Four resistance 2. Supply voltage from HECU (12 V) 3. Internal printed circuit board
The system uses the wheatstone bridge that detects and compares the changes in each resistance value. Before
passing through the comparison measuring device, the sine wave current is obtained. But, after passing through it,
a square wave, that is recognized by ECU, will be generated.
Specification
Air gap between sensor and rotor Front: 2WD: 0.475 ~ 1.453 mm (Tightening torque: 6 ~ 8 Nm)
4WD: 0.1 ~ 0.7 mm (Tightening torque: 15 ~ 20 Nm)
Rear: 0.037 ~1.175 mm (5-link suspension)
0.489 ~1.039 mm (Independent suspension)
Wheel speed sensor current IHIGH : Approx. 14 mA
(vehicle speed: at approx. 2.75 Km/h) ILOW : Approx. 7 mA
Wheel speed sensor voltage
7.5 ~ 20 V
(one rotation per a second at -40 ~ +60)
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Front Wheel Speed Sensor
1. Disconnect the front wheel speed sensor connector.
2. Remove the front brake disc. Loosen the hub end bolts (do not remove) and disconnect the wheel speed sensor.
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A/T
3. Remove one of self-locking hexagon bolt.
M / T
T/C
CLUTCH
AXLE
When Installing
SP
Keep the specified tightening torque and air gap.
Tightening torque
ST’NG
Front wheel 2WD 6 ~ 8 Nm
speed sensor 15 ~ 20 Nm
BRAKE
4WD 0.475 ~ 1.453 mm
Airgap
0.1 ~ 0.7 mm
A / BAG
NOTICE
• Tighten the bolts with the specified tightening
torque.
A / CON
• Otherwise, the air gap between the wheel speed
sensor and wheel rotor may be out of specified
value, and this may cause an incorrect input
value to HECU.
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Rear Wheel Speed Sensor
1. Disconnect the speed sensor connector. Set aside the wheel speed sensor cable.
2. Remove one of self-locking bolt (10 mm). Remove rear wheel speed sensor.
When Installing
Keep the specified tightening torque and air gap.
Tightening torque
Wheel speed sensor 6 ~ 8 Nm
Airgap (mm) 0.037 ~ 1.175 (5-link)
0.489 ~ 1.039 (IRS)
NOTICE
• Tighten the bolts with the specified tightening
torque.
• Otherwise, the air gap between the wheel speed
sensor and wheel rotor may be out of specified
value, and this may cause an incorrect input
value to HECU.
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AIR BAG SYSTEM
8810
TABLE OF CONTENTS
AIR BAG SYSTEMS (INCLUDING CURTAIN
AIR BAGS) .............................................................. 3
1. Overview ............................................................................. 3
2. Locations and related components ................................... 4
3. Air bag system operation process ....................................6
4. Air bag module and other components ............................. 8
5. Electrical wiring diagram ................................................. 16
6. Air bag system deploy (firing loop) ................................. 17
7. Air bag deployment signal output (crash out) ................. 18
8. Air bag warning lamp operational conditions .................. 19
9. Reminder for air bag related component replacement .... 20
10. Servicing the air bag system ........................................... 21
11. Diagnosis ......................................................................... 31
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AIR BAG SYSTEMS (INCLUDING CURTAIN AIR BAGS)
A/T
1. OVERVIEW
M / T
The air bag systems for this vehicle are not much different from the previous air bag system installed in REXTON.
The curtain air bags are installed at the bottom of the roof trim and they
enhance the passenger’s safety. The driver’s and passenger’s curtain
air bags individually deploy.
T/C
When the front air bags deploy, the seat belt pretensioners retract the
seat belts too.
CLUTCH
Collision sensors, a kind of impact G (acceleration) sensor, detect the
front and longitudinal collisions and determine whether or not the air
bags are deployed. The roles of each collision sensor are as below:
AXLE
Front G sensors (inside the air bag unit)
1. Send signals to the front air bags and the driver’s and front passenger’s seat belt pretensioners.
SP
2. By the signal from this sensor, front air bags (driver’s and passenger’s air bags) deploy and the seat belt
pretensioners of the driver’s and passenger’s seat belts retract seat belts.
ST’NG
Curtain air bag G sensors
1. These are located inside the left and right B-pillar panel bottoms. When a collision occurs, the air bag at the
side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the
BRAKE
air bag at the side of collision deploys, not both.
Once an air bag deploys, its repair parts vary according to the deployment situation and damage to the vehicle from
A / BAG
collision. Needed repairs also slightly vary between the front air bags and the curtain air bags. The following are the
differences:
Replacement parts when the front air bags deploy: the air bag units and their connection wires (connectors
A / CON
included), the seat belt pretensioners and their connection wires (connectors included), the entire front air bags,
and the instrument panel (IP).
Replacement parts when a curtain air bag deploys: the new curtain air bag for the deployed side, the air
bag unit and its connection wires (connectors included), the collision G sensor assembly for the curtain air bag,
and the trims and roof headlining for the broken parts.
NOTICE
• When an air bag deploys (curtain air bags and seat belt pretensioners included), the air bag unit must be
replaced. Please do not attempt to delete the failure code with SCAN-100 because some data about the de-
ployment situation are stored in the unit.
• The air bag related components, especially the air bag unit, must be stored in a sealed case to prevent any
damage.
• Please do not connect a tester to any air bag connector or single item to measure the supplied power or
resistance. The detonator may explode due to a sudden extra power supplied by the tester.
• Before removing or installing any air bag related components, disconnect the negative battery cable.
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2. LOCATIONS AND RELATED COMPONENTS
LH
When the curtain air
bag (LH) deploys
Curtain air bag collision G sensor
RH
BPT: Belt Pretensioner
When the curtain air
bag (RH) deploys
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A/T
M / T
T/C
DAB: Driver Air Bag
CLUTCH
Air bag warning lamp
AXLE
SP
ST’NG
STICS
40 ms after receiving the air bag deployment signal at
the vehicle speed 3 or higher km/h, it sends out the door
UNLOCK signal for 5 seconds.
BRAKE
A / BAG
A / CON
Air Bag Unit (SDM)
The collision G sensor is installed inside this. And it
sends out signals to deploy the front air bags (driver’s
and passenger’s air bags) and (or) the driver’s and
passenger’s seat belt pretensioners or the driver’s and
passenger’s curtain air bag. When the front collision G
sensor sends out only the air bag deployment signal,
the signal deploys the two front air bags and activates
their seat belt pretensioners.
PAB: Passenger Air Bag
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3. AIR BAG SYSTEM OPERATION PROCESS
The overall air bag operation process and its functions and roles are broadly explained in this block diagram.
This diagram summarizes and highlights the functions adopted by Ssangyoung Motors.
Air Bag System Block Diagram (Functions and Roles Included)
Battery
Load Dump
Protection
Security
DC/DC Converter
Circuit
Converts the battery voltage into the
air bag operation voltage (5V) and the
energy reservoir voltage (about 30V)
that is transmitted at the moment of
the air bag deployment.
Longitudinal/Lateral
Direction Collision
(G) Sensor
Micro Controller
(MI-COM)
Sends out signals to operate the front
air bags and the seat belt pretensioners.
This sensor detects any longitudinal/lat-
eral deceleration occurring when vehicle
collides. Then, the sensor supplies the
data to the micro controller.
When the initial ignition ON: blinks 6 times at 1Hz.
When the system error: after coming on for 6 seconds,
goes off for 1 second and then stays on.
When outside system error: after coming on for 6
seconds, goes off.
Warning Lamp Diagnosis
Output Output
The Air Bag Waning Diagnose with the K-line Diagnosis
Lamp on the Instru- and use the 9th diagnosis Connector
connector
ment Panel
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A/T
The watchdog monitors the micro controller, the air bags, When the front air bags deploy, the driver’s air bag and
and the seat belt pretensioners. When any error occurs, the front passenger’s air bag deploy simultaneously and
it turns on the air bag warning lamp. their seat belt pretensioners also simultaneously retract
M / T
their seat belts.
The air bag unit monitors conditions of the air bags and
the seat belt pretensioners. When any error occurs, it
stores the failure diagnostic code or turns on the air bag
T/C
warning lamp on the instrument panel.
CLUTCH
Driver’s air bag
Watch Dog Check module
AXLE
Passenger’s air
Check bag module
SP
Driver’s
Check pretensioner
ST’NG
Micro Controller
(MI-COM)
Passenger’s
BRAKE
pretensioner
Check
A / BAG
Curtain air bag
A / CON
Check module (LH)
Curtain air bag
Check module (RH)
Each curtain air bag independently op-
Communicating Communicating erates from the front air bags. Depend-
ing upon the severity of impact, only the
With the Curtain With the Curtain left or right air bag may deploy.
Air Bag Sensor Air Bag Sensor
The Collision G The Collision G The collision G sensors for the curtain air bags are installed at the
bottom of left and right B-pillars. Each measures deceleration rate at
Sensor for the Sensor for the
time of collision and supplies information about the collision to the air
Curtain Air Bag (LH) Curtain Air Bag (RH) bag unit. Each sensor measures the G value from its side and trans-
mits the decesion to its air bag unit.
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4. AIR BAG MODULE AND OTHER COMPONENTS
This section describes the air bag module installed in Kyron. The module consists of the inflator, the cushion, and
the mounting cover.
DAB: Driver Air Bag
The driver’s air bag is installed inside the steering wheel. If the acceleration sensor (inside the air bag unit) is
activated by the deceleration from vehicle collision, the detonation is fired by the electrical signal of the air bag unit.
Then, the detonation sets off explosives and nitrogen gas is generated.
At this point, the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon
the driver.
Front View Rear View
Components
1. Air bag cover
2. Air bag housing
6
3. Air bag cushion (approx. 50 liters)
4. Inflator* (approx. 190 Kpa)
5. Retainer ring
6. Horn switch
Inflator *
The inflator is composed of the detonator, explosives,
and the gas generator. It inflates air bag when vehicle
collides.
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A/T
PAB: Passenger Air Bag
The passenger’s air bag is installed inside the instrument panel above the glove box. Its operation process is the
same as the driver’s one. The driver’s air bag, the passenger’s air bag, and the seat belt pretensioners on both seats
M / T
are made to operate together.
When the collision G sensor inside the air bag unit sends a collision signal, the air bag unit instantaneously applies
a high current to the driver’s and passenger’s air bags and the seat belt pretensioners on both seats, fires the
T/C
detonator in the inflator, and inflates the air bag cushions (curtain air bags independently operate in case of the side
collisions).
CLUTCH
AXLE
SP
Front View Rear View
ST’NG
BRAKE
Components
±¸¼ºÀåÄ¡
A / BAG
A / CON
1. Passenger’s air bag
module housing
2. Inflator
3. Air bag cushion
4. Retainer
5. Nut
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Curtain Air Bag (CAB)
The curtain air bags are installed on both sides of the roof side rails and inside the headlinings. Each curtain air bag
is also composed of the air bag cushion and the inflator that has the detonator, explosives, and the gas generator.
A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B-pillar. The
signal is transmitted to the air bag unit. The air bag unit instantly inflates the necessary air bag necessary by
sending a high current.
When the Curtain Air Bag is Installed
Terms of the Curtain Air Bag
oi nt
tin g p
m oun
bag
air
tain
Cur
int Nut and bolt
po
nt ing Wrapper cover
u
mo
or
lat
Inf Air bag cushion
Gas guide
Inflator
When the Curtain Air Bag Deploys
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A/T
Components
M / T
Tightening torque: 8 ~ 10 Nm
T/C
CLUTCH
AXLE
SP
Tightening torque: 8 ~ 10 Nm
ST’NG
BRAKE
A / BAG
a-a b-b
A / CON
Sectimal view a-a Sectimal view b-b
CHANGED BY AIR BAG SYSTEM
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Driver and Passenger BPT (Belt Pre-Tensioner)
The belt pretensioner retracts the seat belt to tighten or take up slack in the wearer's belt. When a collision occurs
or when brakes are applied, a seat belt with a pretensioner detects the stopping action and tightens the belt before
the wearer is propelled forward. This holds the occupant more securely in the seat.
Belt Pretensioner (Driver Side) Belt Pretensioner (Passenger Side)
Tightening
torque:
35 ~ 55 Nm
Curtain air bag G sensor
Belt pretensioner (LH)
Belt pretensioner (RH)
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A/T
Components
Belt Pretensioner
M / T
20
18
10
17
7
T/C
19
CLUTCH
16
AXLE
SP
6
ST’NG
5
BRAKE
13
15 1. Pretensioner reel assembly
A / BAG
2. Reel bracket
14
3. Ring upper stay
4. D-ring
4 9
A / CON
5. Bending tongue
6. Tongue stopper
7. Mini anchor
8. D-bolt
9. Washer
3
10. Fiber washer
11. Rivet
12. ID label
12 13. Plastic washer
14. Steel washer
15. D-bolt
16. Label
1 11 17. D-bolt
18. Spacer
10
2 8 19. Bush
9 20. Mini anchor cover
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Air Bag Unit
Air bag unit is installed under the AV head unit in center fascia panel.
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Curtain Air Bag Sensor
A/T
The curtain air bag sensor is installed inside each B-pillar of the driver’s and passenger’s seats (that is, around the
pretensioner reel). The body panel has guiding holes to ensure its correct installation. But incorrect tightening torque
may break the sensor or make it insecure. As a result, the sensor may have inaccurate judgment and have the air
bag deployed inaccurately.
M / T
Driver’s Side Passenger’s Side
T/C
CLUTCH
AXLE
SP
ST’NG
Tightening torque:
BRAKE
9 Nm ± 1 Nm
A / BAG
A / CON
Signal Ground Connector
terminal
CHANGED BY AIR BAG SYSTEM
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5. ELECTRICAL WIRING DIAGRAM
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6. AIR BAG SYSTEM DEPLOY (FIRING LOOP)
A/T
According to the collision deceleration rate that each collision G sensor reads, the air bag unit sends out about 2~4
or higher Amp current. This current generates some heat, which fires the detonator in the inflator.
This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for
M / T
a firing.
Driver/passenger air bag Belt pretensioner Curtain air bag
Air bag module
T/C
(DAB / PAB) (BPT) (CAB)
Resistance (at -30 ~ 85°C) 2 ± 0.3 Ω 2.15 ± 0.35 Ω 2 ± 0.3 Ω
Firing current for 2msec
CLUTCH
1.2 Amp 0.8 Amp 1.0 Amp
(at -35°C)
AXLE
NOTICE
• Please do not connect a tester to any air bag connector or single item to measure the supplied power or
resistance. The detonator may explode due to a sudden extra power supplied by the tester.
• Before removing or installing any air bag related components, disconnect the negative battery cable.
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AIR BAG SYSTEM
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7. AIR BAG DEPLOYMENT SIGNAL OUTPUT (CRASH OUT)
When any air bag deploys, another signal is sent to the sticks to do two basic security operations. One operation is
the automatic door unlock function that cancels the automatic door lock mode.
200 ms
Deployment signal output
(Crash out)
Automatic Door Unlock (Crash unlock: unlock when colliding)
1. When the ignition key is the ON position, the air bag signal is not accepted for the first 7 seconds.
2. When the ignition key is the ON position and the vehicle speed is 3 km/h or higher, 40 ms after receiving the air
bag deployment signal, the sticks sends out the door UNLOCK signal for 5 seconds.
3. Even though the ignition switch is turned off in the middle of the unlock signal being sent out, the unlock signal
continues for the remaining time.
4. This function cancels when the ignition key is withdrawn.
ON
ING KEY
SW (*1)
OFF
T1
AIR BAG ON
DEPLOYMENT
SIGNAL OFF
T2
DOOR ON
UNLOCK
RELAY OFF T3
T1 : 200 ms T2 : 40 ms T3 : 5 sec
NOTICE
Reminder for door lock/unlock control
• The unlock function by the air bag signal takes priority over any other lock/unlock operations.
• While or after the automatic unlock is made by the air bag system, any lock or unlock request by other func-
tions is ignored unless the ignition key switch is turned off.
• When another lock or unlock output is requested while the door is being either locked or unlock, the new
request will be ignored. But, if an unlock request is made by the air bag signal or the remote control key, the
request will be accepted.
• When the lock and unlock functions are simultaneously requested, the lock will be performed and the unlock
will be ignored.
AIR BAG SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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8. AIR BAG WARNING LAMP OPERATIONAL CONDITIONS
A/T
The air bag warning lamp on the instrument panel has a few operational conditions. The following are the conditions:
When Turning the Ignition Switch to ON Position
M / T
The air bag unit performs a turn-on test when the ignition is turned on. The air bag unit flashes the air bag warning
lamp six times by supplying an intermittent ground to the warning lamp circuit. After flashing six times, the air bag
warning lamp will turn off if no more malfunctions have been detected.
T/C
ON
CLUTCH
Ignition
OFF
Air bag ON
AXLE
warning
lamp OFF
SP
When Turning the Ignition Switch to the ON Position
When the air bag unit detects any malfunctions in its unit
ST’NG
When it is recorded as a system failure in the air bag unit, the air bag warning lamp on the instrument panel comes
on for about 6 seconds and goes off for 1 second. Then the waning lamp stays on.
BRAKE
ON
Ignition
OFF
A / BAG
Air bag ON
warning
lamp OFF 6 seconds
A / CON
When the Air Bag Unit Receives Any Malfunction Signals from the
Other Systems
When, due to an error from outside the system, the intermittent failure signal is received 5 times or less, the air bag
warning lamp comes on for about 6 seconds and then, goes off.
ON
Ignition
OFF
Air bag ON
warning
6 seconds
lamp OFF
CHANGED BY AIR BAG SYSTEM
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9. REMINDER FOR AIR BAG RELATED COMPONENT REPLACEMENT
NOTICE
• When an air bag deploys (curtain air bags and seat belt pretensioners included), the air bag unit must be
replaced. Please do not attempt to delete the failure code with scan-100 because some data about the de-
ployment situation are stored in the unit.
• The air bag related components, especially the air bag unit, must be stored in a sealed case to prevent any
damage.
• Please do not connect a tester to any air bag connector or single item to measure the supplied power or
resistance. The detonator may explode due to a sudden extra power supplied by the tester.
• Before removing or installing any air bag related components, disconnect the negative battery cable.
Collision sensors, a kind of impact G (acceleration) sensor, detect the front and longitudinal collisions and deter-
mine whether or not the air bags are deployed. The roles of each collision sensor are as below:
Front G sensors (inside the air bag unit)
1. Send signals to the front air bags and the driver’s and front passenger’s seat belt pretensioners.
2. By the signal from this sensor, front air bags (driver’s and passenger’s air bags) deploy and the seat belt
pretensioners of the driver’s and passenger’s seat belts retract seat belts.
Curtain air bag G sensors
1. These are located inside the left and right B-pillar panel bottoms. When collision occurs, the air bag at the
side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the
air bag at the side of collision deploys, not both.
Once an air bag deploys, its repair parts vary according to the deployment situation and damage to the vehicle from
collision. Needed repairs also slightly vary between the front air bags and the curtain air bags. The following are the
differences:
Replacement parts when the front air bags deploy: the air bag units and their connection wires (connectors
included), the seat belt pretensioners and their connection wires (connectors included), the entire front air bags,
and the instrument panel (IP).
Replacement parts when a curtain air bag deploys: the new curtain air bag for the deployed side, the air
bag unit and its connection wires (connectors included), the collision G sensor assembly for the curtain air bag,
and the trims and roof headlining for the broken parts.
AIR BAG SYSTEM CHANGED BY
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10. SERVICING THE AIR BAG SYSTEM
A/T
DAB: Driver Air Bag
Preceding Work: Disconnect the negative battery cable.
M / T
1. Remove the air bag module assembly from steering
wheel.
T/C
CLUTCH
AXLE
SP
2. Disconnect all connectors and remove the air bag assembly.
ST’NG
BRAKE
A / BAG
Release the hook before
disconnecting the connector.
A / CON
Components
Front View Rear View
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Contact Coil
Preceding Work: Disconnect the negative battery cable and remove the steering wheel.
1. Disconnect the connector of the contact coil.
2. Unscrew four screws and remove the contact coil.
Place the contact coil at the center position when installing.
Align the arrows when installing.
Components
NOTICE
• If the contact coil is not properly aligned, the
steering wheel may not be able to rotate com-
pletely during a turning. Restricted turning abil-
ity may cause the vehicle to crash. Improper
alignment of the contact coil also may make
the SIR system inoperative, preventing the air
bags from deploying during a crash.
• Turn the contact coil clockwise until it stops
and turn it counterclockwise approx. 2.9 ± 0.2
turns to align the “ ” marks.
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PAB: Passenger Air Bag
A/T
Preceding Work: Disconnect the battery nagative cable and remove the instrument panel assembly.
(For details, refer to “Body” section.)
M / T
1. Remove the lower air duct from the removed instrument panel assembly.
2. Unscrew five nuts on the air bag module (10 mm). T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
CHANGED BY AIR BAG SYSTEM
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3. Remove the air bag module assembly from the instrument panel.
WARNING
• The air bag module cannot be removed. Below pic-
ture is only for reference.
Components
Retainer
Air bag cushion
Inflator
Air bag module housing
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CAB: Curtain Air Bag
A/T
Preceding Work: Disconnect the battery negative cable and remove the instrument panel assembly.
(For details, refer to “Body” section.)
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
1. Disconnect the connector of the curtain air bag while releasing the hook.
CHANGED BY AIR BAG SYSTEM
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2. Remove the handle bracket and then remove the curtain air bag assembly.
Components
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Air Bag Unit (SDM)
A/T
Preceding Work: Disconnect the negative battery cable.
1. Remove the center fascia, driver’s lower panel, passenger’s lower panel and center console.
M / T
(For details, refer to “Body” section.)
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
1. Center fecia (LH/RH) 3. Passenger’s lower panel
2. Driver’s lower panel 4. Center console
2. Remove the AV head unit assembly.
(For details, refer to “AV System” section.)
CHANGED BY AIR BAG SYSTEM
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3. Unscrew the screws on the instrument panel and remove the relevant components (power socket/shift lever
cover).
Mounting Screw (Same at Both Sides) Power Socket Cover Mounting Screw
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4. Unscrew two screws and remove the lower center air duct.
A/T
M / T
T/C
CLUTCH
5. Disconnect the connector and remove the air bag unit.
AXLE
SP
ST’NG
BRAKE
A / BAG
Components
NOTICE
A / CON
• When an air bag deploys (curtain air bags and
seat belt pretensioners included), the air bag unit
must be replaced. Please do not attempt to de-
lete the failure code with scan - I because some
data about the deployment situation are stored in
the unit.
• The air bag related components, especially the air
bag unit, must be stored in a sealed case to pre-
vent any damage.
• Please do not connect a tester to any air bag con-
nector or single item to measure the supplied
power or resistance. The detonator may explode
due to a sudden extra power supplied by the
tester.
• Before removing or installing any air bag related
components, disconnect the negative battery
cable.
CHANGED BY AIR BAG SYSTEM
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Curtain Air Bag G Sensor
Preceding Work: Disconnect the negative battery
Passenger’s Side
cable.
1. Remove the B-pillar panel at both sides. Disconnect the
connector and remove the G sensor.
Installation Notice
Tightening torque 9 Nm ± 1 Nm
NOTICE
• The body panel has guiding holes to ensure its cor-
rection installation. But incorrect tightening torque
may break the sensor or make it insecure. As a
result, the sensor may have inaccurate judgment and
have the air bag deployed inaccurately.
• Because the gap between the installation bolt and the
sensor is small, grind the bolt-locking socket to
around 1.5 mm before mounting the curtain air bag
sensor fixation bolt.
Components
AIR BAG SYSTEM CHANGED BY
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11. DIAGNOSIS
A/T
Trouble
Defections Action
Code
1101 High battery voltage • Check alternator output voltage.
M / T
• Check battery condition (over 21.4 V for 16 seconds).
• Check air bag unit terminals for damage.
1102 Low battery voltage • Check alternator output voltage.
T/C
• Check battery condition (below 7.2 V for 16 seconds, resumes
when the voltage is normal level for 9.6 seconds)
• Check air bag unit terminals for damage.
CLUTCH
1103 Low communication voltage • Check curtain air bag sensor connector.
for curtain air bag sensor • Check curtain air bag sensor wiring.
• Check air bag unit terminals for damage.
• Check if curtain air bag sensor is short to battery voltage or
AXLE
ground.
• Check if curtain air bag sensor is defective.
• Check battery condition (below 10.6 V for 16 seconds, resumes
when the voltage is normal level for 9.6 seconds).
SP
1346 Driver’s air bag circuit • Check driver air bag connector.
resistance is too high • Check driver air bag wiring (including clock spring).
• Check air bag unit terminals for damage.
ST’NG
• Resistance of squib: over 6.1 Ω
1347 Driver’s air bag circuit • Check driver air bag connector.
resistance is too low • Check driver air bag connector (including clock spring).
BRAKE
• Check air bag unit terminals for damage.
• Resistance of squib: below 1.1 Ω
1348 Driver’s air bag circuit is short • Check driver air bag connector.
to ground • Check driver air bag wiring (including clock spring).
A / BAG
• Check air bag unit terminals for damage.
• Resistance of Firing Loop: below 2 kΩ
1349 Drivers air bag circuit is short • Check driver air bag connector.
A / CON
to battery voltage • Check driver air bag wiring (including clock spring).
• Check the air bag unit terminals for damage.
• Resistance of Firing Loop: below 2 kΩ
1352 Passengers air bag circuit • Check passenger air bag connector.
resistance is too low • Check passenger air bag wiring.
• Check the air bag unit terminals for damage.
• Resistance of squib: below 0.8 Ω
1353 Passengers air bag circuit • Check passenger air bag connector.
resistance is too high • Check passenger air bag wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: over 4.0 Ω
1354 Passengers air bag circuit is • Check passenger air bag connector.
short to ground • Check passenger air bag wiring.
• Check the air bag unit terminals for damage.
• Resistance of Firing Loop: below 2 kΩ
CHANGED BY AIR BAG SYSTEM
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Trouble
Defections Action
Code
1355 Passenger’s air bag circuit is • Check passenger air bag connector.
short to battery voltage • Check passenger air bag wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 2 kΩ
1361 Driver’s pretensioner circuit • Check driver pretensioner connector.
resistance is too high • Check driver pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: over 4.2 Ω
1362 Driver’s pretensioner circuit • Check driver pretensioner connector.
resistance is too low • Check driver pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 0.8 Ω
1363 Driver’s pretensioner circuit is • Check driver pretensioner connector.
short to ground • Check driver pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 2 kΩ
1364 Driver’s pretensioner circuit is • Check driver pretensioner connector.
short to battery voltage • Check driver pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 2 kΩ
1367 Passenger’s pretensioner • Check passenger pretensioner connector.
circuit resistance is too high • Check passenger pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: over 4.2 W
1368 Passenger’s pretensioner • Check passenger pretensioner connector.
circuit resistance is too low • Check passenger pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 0.8 Ω
1369 Passenger’s pretensioner • Check passenger pretensioner connector.
circuit is short to ground • Check passenger pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 2 kΩ
1370 Passenger’s pretensioner cir- • Check passenger pretensioner connector.
cuit is short to battery voltage • Check passenger pretensioner wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 2 kΩ
1378 Driver’s curtain air bag circuit • Check driver curtain air bag connector.
resistance is too high • Check driver curtain air bag wiring.
• Check the air bag unit terminals for damage.
• Resistance of squib: over 4.3 Ω
1379 Driver’s curtain air bag circuit • Check driver curtain air bag connector.
resistance is too low • Check driver curtain air bag wiring.
• Check the air bag unit terminals for damage.
• Resistance of squib: below 0.6 Ω
AIR BAG SYSTEM CHANGED BY
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Trouble
Defections Action
A/T
Code
1380 Driver’s curtain air bag is • Check driver curtain air bag connector.
short to ground • Check driver curtain air bag wiring.
• Check air bag unit terminals for damage.
M / T
• Resistance: below 2 kΩ
1381 Driver’s curtain air bag is • Check driver curtain air bag connector.
short to battery voltage • Check driver curtain air bag wiring.
T/C
• Check air bag unit terminals for damage.
• Resistance: below 2 kΩ
1382 Passenger’s curtain air bag • Check passenger curtain air bag connector.
CLUTCH
circuit resistance is too high • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: over 4.3 Ω
1383 Passenger’s curtain air bag • Check passenger curtain air bag connector.
AXLE
circuit resistance is too low • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
• Resistance of squib: below 0.6 Ω
1384 Passenger’s curtain air bag • Check passenger curtain air bag connector.
SP
is short to ground • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
• Resistance: below 2 kΩ
ST’NG
1385 Passenger’s curtain air bag • Check passenger curtain air bag connector.
is short to battery voltage • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
BRAKE
• Resistance: below 2 kΩ
1395 Air bag connector problem • Check passenger curtain air bag connector.
• Check passenger curtain air bag wiring.
A / BAG
• Check air bag unit terminals for damage.
1400 Driver’s curtain air bag sensor • Check driver curtain air bag connector.
problem • Check driver curtain air bag wiring.
• Check air bag unit terminals for damage.
A / CON
1401 Driver’s curtain air bag sensor • Check driver curtain air bag connector.
circuit is short to ground • Check driver curtain air bag wiring.
• Check the air bag unit terminals for damage.
• Resistance: below 250 Ω
1402 Driver’s curtain air bag sensor • Check driver curtain air bag connector.
circuit is short to battery volt- • Check driver curtain air bag wiring.
age • Check air bag unit terminals for damage.
• Resistance: below 25 Ω
1409 Communication error in • Check driver curtain air bag connector.
driver’s curtain air bag • Check driver curtain air bag wiring.
• Check air bag unit terminals for damage.
• If the voltage drops below 10.6 V during normal system
operation, the trouble code is generated. This trouble code is
linked with B1 400, B1 401, B1 402, B1 414.
CHANGED BY AIR BAG SYSTEM
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Trouble
Defections Action
Code
1414 Wrong driver’s curtain air bag • Check driver curtain air bag connector.
sensor • Check driver curtain air bag wiring.
• Check air bag unit terminals for damage.
1403 Passenger’s curtain air bag • Check passenger curtain air bag connector.
sensor • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
1404 Passenger’s curtain air bag • Check passenger curtain air bag connector.
sensor circuit is short to ground • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
• Resistance: below 250 Ω
1405 Passenger’s curtain air bag • Check passenger curtain air bag connector.
sensor circuit is short to bat- • Check passenger curtain air bag wiring.
tery voltage • Check air bag unit terminals for damage.
• Resistance: below 25 Ω
1410 Communication error in • Check passenger curtain air bag connector.
passenger’s curtain air bag • Check passenger curtain air bag wiring.
• Check the air bag unit terminals for damage.
• If the voltage drops below 10.6 V during normal system
operation, the trouble code is generated. This trouble code is
linked with B1 403, B1 404, B1 405, B1 415.
1415 Wrong driver’s curtain air bag • Check passenger curtain air bag connector.
sensor • Check passenger curtain air bag wiring.
• Check air bag unit terminals for damage.
1620 SDM internal fault • Replace SDM.
1650 Frontal impact record • Replace SDM.
1651 Driver’s curtain air bag impact • Replace SDM.
record
1652 Passenger’s curtain air bag • Replace SDM.
impact record
1657 Belt pretensioner operation • Replace SDM.
record
2500 Warning lamp error • Check wiring to warning lamp.
• Check warning lamp bulb.
• Check SDM unit terminal.
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AIR CONDITIONING SYSTEM
6810 / 6910 / 6810
TABLE OF CONTENTS
AIR CONDITIONING SYSTEM ................. 2 FFH (FUEL FIRED HEATER) SYSTEM 61
1. System layout and components ...................... 2 1. Overview .......................................................... 61
2. Ventilation system ............................................ 4 2. FFH layout ...................................................... 62
3. Air conditioner module wiring and layout ......... 5 3. Specifications ................................................. 64
4. Air conditioner controller (unit) ......................... 9 4. FFH operating process ................................... 65
5. Self diagnosis (only for FATC air conditioner) 18 5. Components and functions ............................. 70
6. System diagram .............................................. 23 6. Removal and installation ................................. 75
7. Sensors and actuators ................................... 24 7. Trouble diagnosis ............................................ 82
8. Air quality system (AQS) ............................... 26
9. Air conditioner module sensors and actuators30 PTC (Positive Temperature Coefficient)
10. Removal and installation ................................. 40 SYSTEM .................................................. 86
1. Overview .......................................................... 86
2. Components .................................................... 87
3. PTC operating process ................................... 88
4. Removal and installation ................................. 90
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AIR CONDITIONING SYSTEM
1. SYSTEM LAYOUT AND COMPONENTS
Type Air Conditioner Controller
FATC
Manual air
conditioner
Sun Sensor - Instrument
Panel Upper Left
It changes sun load coming through
front windshield into current to in-
put to FATC controller.
AQS Sensor and Ambient
AQS Switch Compressor
Temperature Sensor
AQS sensor
Ambient tempera-
ture sensor
A function that turns on/off the air This sensor is installed at the front bottom
source selection and air quality of engine compartment. This changes the
system. air source mode by detecting the air pollution.
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A/T
Front Air Conditioner Module Assembly - Inside of Instrument Panel
Heater Unit Side
Air source door
M / T
actuator
Coolant temperature sensor
Air mix door actuator
T/C
Air conditioner filter
CLUTCH
Mode door
actuator
AXLE
Power transistor
Thermo AMP
SP
Air conditioner
controller wire Main wire Bloor Unit Side
ST’NG
Condenser
BRAKE
A / BAG
A / CON
Installed in front of vehicle and condenses
vapor refrigerant into low temperature and
high pressure liquid refrigerant.
Coolant Temperature Sensor
Receiver Drier (LH) Engine ECU (Passenger Footstep)
(On Engine)
* Absorbs moisture in the refrigerant * Detects A/C switch position, coolant * A sensor that detects coolant tem-
and reserves refrigerant to supply temperature, engine condition and perature and transmits to engine
smoothly. driving condition to control the air ECU.
conditioner.
CHANGED BY AIR CONDITIONING SYSTEM
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2. VENTILATION SYSTEM
Locations of Vents
Air Duct
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Air Duct Layout
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
3. AIR CONDITIONER MODULE WIRING AND LAYOUT
BRAKE
Front Air Conditioner Module Wiring Layout
Coolant temperature detection sensor
A / BAG
Mode door actuator
Air source door actuator
Power transistor
A / CON
Main wire Air mix door
connector actuator
Blower motor
Intake sensor
Active incar sensor
(interior temperature sensor)
and humidity sensor
Air conditioner controller unit
CHANGED BY AIR CONDITIONING SYSTEM
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Air Duct Layout
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
3. AIR CONDITIONER MODULE WIRING AND LAYOUT
BRAKE
Front Air Conditioner Module Wiring Layout
Coolant temperature detection sensor
A / BAG
Mode door actuator
Air source door actuator
Power transistor
A / CON
Main wire Air mix door
connector actuator
Blower motor
Intake sensor
Active incar sensor
(interior temperature sensor)
and humidity sensor
Air conditioner controller unit
CHANGED BY AIR CONDITIONING SYSTEM
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Air Conditioner Module And Sensors
Locations
Air Source Door Actuator Air Conditioner Filter
Coolant Temperature Sensor
Mode Door Actuator
Intake Sensor
Interior Temperature Sensor
A/C Controller Unit
(Interior Humidity Sensor)
Power Transistor/Blower Motor
Power transistor
Interior temperature and
Blower motor
humidity sensor
AIR CONDITIONING SYSTEM CHANGED BY
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6810 7
Components
A/T
A/C filter
Air source door case
M / T
Blower unit case (upper)
T/C
CLUTCH
Interior/Ambient Blower
door actuator motor assembly
AXLE
Blower unit case
(lower)
SP
Evaporator
ST’NG
Coolant
temperature Power transistor
detection sensor A/C cable assembly
BRAKE
Intake sensor
Heater unit case (right)
A / BAG
Air mix
door actuator
A / CON
Lower duct
Heater core
Mode door
Heater unitcase (left) Mode door
link assembly
Mode door actuator
CHANGED BY AIR CONDITIONING SYSTEM
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PTC Heater and FFH Heater Layout
PTC Heater Assembly Layout
PTC
FFH Heater Assembly Layout
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4. AIR CONDITIONER CONTROLLER (UNIT)
A/T
Functions of Full Automatic Air Conditioner Controller ( )
1 2 11 6 4
M / T
T/C
CLUTCH
AXLE
SP
3 10 5 8 7 9
ST’NG
1. TEMP switch 4. AMB switch 7. AQS switch 10. A/C switch
2. AUTO switch 5. Mode switch 8. FRE switch 11. VFD (Display)
BRAKE
3. OFF switch 6. Blower switch 9. Defroster switch
A / BAG
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
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Functions of Full Automatic Air Conditioner Controller (ll)
Temperature Control Switch and AUTO Button
When pressing the air conditioner AUTO mode and temperature control dial
switch, the system operates in AUTO mode and can set the desired tem-
perature (18 ~ 32°C) by rotating. To get the desired temperature, the air
conditioner controls compressor, door mode, air source door, air mix door
and blower motor automatically.
Active Incar/Humidity Sensor (AIH Sensor)
The AIH sensor is installed on the air conditioner controller unit. It is a sensor that detects interior
temperature and humidity.
Display Window (VFD)
Each switch mode appears as a symbol on the fluorescent display and malfunction of each sensor
in air conditioner control system is also displayed.
AQS mode
Auto mode
Temperature (ambient Defroster
air temperature, interior A/C operation Air flow direction
set temperature)
Fan speed
Air recirculation
Indicates the ambient
temperature is displayed Fresh air
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Fan Speed Control Switch and AMP Switch
A/T
• When controlling the fan speed by rotating
this switch in AUTO mode, the mode is
changed from AUTO to manual and the fan
M / T
speed can be changed in 8 stages.
• When pressing this switch, the outside
temperature measured by ambient
temperature sensor comes on for 5
T/C
seconds and then returns back to preset
temperature.
CLUTCH
Mode Switch
• By depressing this switch, the airflow mode is changed.
AXLE
A/C Switch:
SP
When pressing this switch, the air The air flows The air flows The air flows The air flows towards
conditioner operates in manual towards face. towards face towards floor. front windshield and
mode and A/C ON indicator (Vent mode) and floor. (Foot mode) floor.
ST’NG
(Bi-level mode) (Defrost and foot mode)
comes on.
BRAKE
A / BAG
Air Source Selection Switch
A/C [OFF] Switch
When pressing this switch, the air recirculates in the
AQS System
A / CON
vehicle inside and indicator comes on. When pressing it
again, the indicator goes off and the fresh air comes in.
Air Quality System (AQS) changes the
air source selection to recirculation (However, under defroster mode or defroster/foot mode,
mode when polluted air is detected it stays in the fresh air mode.)
through AQS sensor. The air source se-
lection returns back to fresh air intake
mode after a specified period or the pol-
luted air disappears (refer to AQS and
ambient temperature sensor).
Defroster Switch
When pressing this switch, the airflow direction will be changed to windshield and door glasses, the air conditioner
operates automatically and outside air comes in. At this moment, the defroster indicator, air conditioner indicator and
fresh air mode indicator come on. When pressing the switch again, the air conditioner returns back to normal operations.
When pressing the AUTO switch, the defroster mode appears on the VFD
until the coolant temperature reaches at a certain level.
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Full Automatic Air Conditioner Controller
Interior temperature and humidity sensor
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Full Automatic Air Conditioner Controller Operation Table
A/T
1 2 17 4 5 18 14 13
12
M / T
11
10
9
8 If the TEMP DIAL is set under 18.0°C, this
T/C
7 shows Lo. If it is set over 32.0°C, this shows Hi.
CLUTCH
19 20 15 16 3 6
AXLE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
REC - - - - - - - - - - - - - -
FRE - - - - - - - - - - - - - -
SP
FR/DEF - - - - - - - - -
FAN speed 0 - - - - - - -
ST’NG
FAN speed 1 - - - - - - -
FAN speed 2 - - - - - - -
BRAKE
FAN speed 3 - - - - - - -
FAN speed 4 - - - - - - -
FAN speed 5 - - - - - - -
A / BAG
FAN speed 6 - - - - - - -
FAN speed 7 - - - - - - -
A / CON
FAN speed 8 - - - - - - -
MODE VENT - - - - - - - - - - - -
MODE B/L - - - - - - - - - - - -
MODE FOOT - - - - - - - - - - - -
MODE D/F - - - - - - - - - - - -
AUTO (AUTO A/C) - - - - - - - - - - - - - - -
A/C - - - - - - - -
AQS - - - - - - - - - - - - - - - - - -
AMB
OFF (IGN ON) - -
OFF (IGN OFF)
TEMPDIAL - - - - - - - - - - - - - - - - -
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Full Automatic Air Conditioner Operations
This section describes the main operations of full automatic air conditioner.
Blower Motor Control
In AUTO mode, the blower motor automatically controls the fan in 33 levels according to the sensing conditions (e.
g., ambient temperature and room temperature). In MANUAL mode, the blower motor controls the fan in 8 levels by
the fan switch operation.
Fan control in AUTO mode (33 levels)
Control Control Control Control
Level Level Level Level
voltage voltage voltage voltage
OFF 0V 9 6V 18 8.25 V 27 10.5 V
1 4V 10 6.25 V 19 8.5 V 28 10.75 V
2 4.25 V 11 6.5 V 20 8.75 V 29 11 V
3 4.5 V 12 6.75 V 21 9V 30 11.25 V
4 4.75 V 13 7V 22 9.25 V 31 11.5 V
5 5V 14 7.25 V 23 9.5 V 32 11.75 V
6 5.25 V 15 7.5 V 24 9.75 V 33 VACC
7 5.5 V 16 7.75 V 25 10 V
8 5.75 V 17 8V 26 10.25 V
Fan control in MANUAL mode (8 levels)
8th level
1st level
Level 1 2 3 4 5 6 7 8
Control 4~ 5~ 6~ 7~ 8~ 9~ 10 ~ 11 ~ Battery
voltage 4.75 V 5.75 V 6.75 V 7.75 V 8.75 V 9.75 V 10.75 V voltage
Heating Start Control
In winter, when the engine coolant temperature is low or the hot wind has not been sufficiently generated, the airflow
from the vent is not hot and so, not helpful to heating. The heating control is to restrain this airflow from releasing.
Thus, before the coolant temperature reaches at 55°C, the blower motor is set to first stage in Auto mode and the
blower operating voltage increases by 0.075V/sec, following the increase of duct temperature.
The air flow direction is in DEF mode (below 20°C), D/F mode (20°C~55°C) and AUTO mode (55°C).
When the coolant temperature sensor is defective, the heating control function is cancelled after 500 seconds.
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A/T
Cooling Start Airflow Control Ambient Air Temperature Display
M / T
When the intake temperature sensor indicates over 35°C, When the AMB button is pressed, the ambient tempera-
the voltage value increases by 1 V/sec with delay from ture is displayed for 5 seconds. When the vehicle stops
3 seconds after the compressor starts its operation. while driving, the ambient temperature before stop is
T/C
In the initial operation stage, the hot air is discharged to displayed.
the windshield (DEF mode) for a specific period of time
(approx. 5 seconds). This prevents the hot air from sud-
CLUTCH
denly discharging to the front passengers.
Amount of Sunload Compensation Control Recirculation Control
AXLE
The air flow is directed to “VENT” according to the A. AUTO control: Fresh air, 20% of fresh air, Recircu-
amount of sunload. In “VENT” and “B/L” modes, the lated air
blower voltage increases within 2.5 V. B. MANUAL control: Fresh air, Recirculated air
C. COMP OFF control: Fresh air (AUTO mode)
SP
DEF Mode Compensation Control D. PTC linked control: When PTC is activated, the recir-
culation door is fixed at 30% of fresh air position.
In “DEF” mode, the voltage increases 2 V compared to When PTC is deactivated, it returns to previous mode.
ST’NG
that in “AUTO” mode. The voltage after compensation
E. AQS control: In initial stage, the recirculation mode is
should not exceed 7 V.
activated for 35 seconds. After then AQS sensor con-
verts the mode between recirculation and fresh air.
BRAKE
Maximum Cooling/Heating Control High Intake Air Temperature Delay Control
A / BAG
17.5°C (Max.) 32.5°C (Min.) When the intake temperature sensor indicates over 35°C,
the voltage value increases by 1 V/sec with delay from
Mode Foot VENT
3 seconds after the compressor starts its operation.
A / CON
Inside air/Ambient air Ambient air Inside air
Air mix 100% 0% COMP Control
Air conditioner OFF ON
- Intake air temperature control: COMP OFF when the
Blower motor Hi Hi
thermo AMP temperature is below 2°C, COMP ON
when it is over 4°C.
CHANGED BY AIR CONDITIONING SYSTEM
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Manual Air Conditioner Controller
Manual air conditioner controller controls the fan speed, air distribution direction, air source selection and temperature
control with motor actuators according to soft button and dial switch operations.
Fan Speed Control Switch
The fan speed can be adjusted in 4 stages.
A/C Switch
When the A/C switch is pressed, the in-
dicator comes on and the air conditioner
starts to operate. When the switch is
pressed again, the air conditioner stops
its operation and indicator goes out. A/C operation indicator
Bi-level Mode
The air flows towards front windshield and floor
and the indicator comes on.
Vent Mode
The air flows towards face and the indicator
comes on.
Foot Mode
The air flows towards floor and the indicator
comes on.
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A/T
Temperature Control Switch
The temperature can be adjusted by rotating the switch.
Clockwise direction (red): Higher temperature
M / T
Counterclockwise direction (blue): Lower temperature
T/C
CLUTCH
Lower Higher
temperature temperature
AXLE
SP
Air Source Selection Switch
When pressing this switch, the air recirculates in the
vehicle inside and indicator comes on. When pressing it
ST’NG
again, the indicator goes off and the fresh air comes in.
BRAKE
Recirculation indicator
A / BAG
Defroster Switch
When pressing this switch, the airflow direction will be changed
A / CON
to windshield and door glasses, the air conditioner operates
automatically and outside air comes in.
At this moment, the indicator comes on. When the defrost-
ing is completed, press the switch to return to normal
operations.
Defroster & Foot Mode
The air flows towards face and floor and the
indicator comes on.
CHANGED BY AIR CONDITIONING SYSTEM
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5. SELF DIAGNOSIS (ONLY FOR FATC AIR CONDITIONER)
Self Diagnosis
1. Starting Self Diagnosis
Turn the ignition switch to OFF position and press OFF switch for more than 5 seconds within 10 seconds.
1. ÀÚ±â Áø´ÜÁøÀÔ
2) Check LED segments on the vacuum fluorescent display (VFD).
1) Press OFF switch more than 5 seconds.
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A/T
2. Set in Trouble Diagnosis Step 2
In this step, check the air mix door and sensors for defect.
M / T
Once the system starts diagnosis step 2, the digit “2” is displayed, implying step 2, on the display window and
the trouble diagnosis for sensors is executed. If no failure exists, “20” is displayed. If any failure exists, the
appropriate trouble code is displayed as below.
T/C
1) Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 2
CLUTCH
10 ~ 20
seconds
2 21
AXLE
SP
2) Indication of Step 2. 3) Sensor failure
Starting self diagnosis code blinking
ST’NG
When two sensors are
BRAKE
defective
NOTICE
• The symbol "-" in front of step number "2" means
a short circuit of the blinking sensor.
21 25
A / BAG
- 21
A / CON
Short-circuit in the ambi-
ent air temperature sensor First sensor failure Second sensor failure
code blinks twice code blinks twice
Trouble Code
Code Malfunction Remark Code Malfunction Remark
0 VDF segments are OK 5 Defective sun sensor
1 Defective ambient temperature sensor 6 Check Air mix door
2 Defective interior temperature sensor 7 Defective humidity sensor
3 Defective duct temperature sensor 8 -
4 Defective intake sensor 9 -
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3. Set in Trouble Diagnosis Step 3
In this step, check the position and conditions of recirculation air door and mode door.
Slightly turn the TEMP switch until “3” is displayed on the display window.
If no failure exists, "30" is displayed. If any failure exists, the appropriate trouble code is displayed.
1) Slightly turn the TEMP dial to the right to set in the trouble diagnosis
step 3
21 3 30
2) Indication of Step 2. 3) Sensor failure code
Starting self diagnosis blinking (30: no failure)
Trouble Code
Code Malfunction Remark Code Malfunction Remark
1 Defective VENT 6 DEF
2 Defective B/L 7 FRE
3 - 8 20% FRE
4 FOOT 9 REC
5 D/F 0 All door OK
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4. Set in Trouble Diagnosis Step 4
A/T
In this step, check the position of actuator door, check the fan speed, and check the compressor operation.
Slightly turn the TEMP switch in step 3 until “41” is displayed on the display window. When pressing DEF switch
,mode changes as shown below in turns to check each function.
M / T
1) Slightly turn the TEMP dial to the right 2) Press Press
to set in the trouble diagnosis step 4
T/C
41 42 43
CLUTCH
30 Press Press Press Press
46 45 44
AXLE
Function Check
SP
Displayed Number 41 42 43 44 45 46
Mode door VENT B/L B/L FOOT D/F DEF
ST’NG
Interior/Ambient door REC REC 20%FRE FRE FRE FRE
Air mix door F/COOL F/COOL F/HOT F/HOT F/HOT F/HOT
Blower
BRAKE
4.5 V 10.5 V 8.5 V 8.5 V 8.5 V MAX
Compressor ON ON OFF OFF ON ON
A / BAG
5. Set in Trouble Diagnosis Step 5
A / CON
In this step, check the conditions of temperature related sensors.
Slightly turn the TEMP switch in step 4 until “51” is displayed on the display window. When pressing DEF switch ,
displayed temperature changes as shown below in turns.
1) Slightly turn to right to set in
trouble diagnosis step 5.
2) Press Press Press
51 20 oC 18.5 oC 43oC
18
Ambient air Interior air Intake air
temperature temperature temperature
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6. Set in Trouble Diagnosis Step 6
In this step, the temperature can be compensated within the range of -3°C to 3°C in the control process according
to the temperature to air conditioner controller. The step 6 initiates when slightly rotating the fan speed switch (other
than TEMP switch) in step 5.
2) C o m p e n s a t e s
the temperature
61 1) Starts the trouble
diagnosis step 6 by
by turning TEMP turning fan speed
dial. dial.
61 - 3 oC 3 oC
Step 6 Min. temperature
43
Max. temperature
compensation value compensation value
7. Canceling the Trouble Diagnosis
Turn the AUTO switch ON or turn the ignition key OFF.
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6. SYSTEM DIAGRAM
A/T
This figures shows the input and output system between A/C components and A/C controller.
M / T
User Setting Power Fan speed control
Control temperature transistor (Blower motor
control)
T/C
Ambient
temperature
CLUTCH
Water temp.
sensor
Incar
AXLE
Air mix motor Temperature control
temperature Air
Environ-
ments conditioner
Sun loads controller Mode motor Air flow control
SP
Interior Interior/Ambient
AQS sensor
/Ambient motor control
Intake temp.
ST’NG
sensor
BRAKE
Vehicle Vehicle Compressor
Engine ECM
information speed control
A / BAG
A / CON
Air Conditioner Compressor Control by Engine ECU
In case of current vehicle models, the system turns ON/OFF the compressor switch according to refrigerant pressure,
ambient temperature and condenser temperature to protect air conditioner circuits. However, for the vehicle equipped
with DI engine, the engine ECU turns off air conditioner compressor as below in addition to above conditions.
1. Coolant temperature: below -20°C
2. Coolant temperature: over 115°C
3. For approx. 4 seconds after starting the engine
4. When engine speed is below 650 rpm
5. When engine speed is over 4,500 rpm
6. During abrupt acceleration for the vehicle equipped with manual transmission
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7. SENSORS AND ACTUATORS
Sun Sensor
It is installed on the upper left end of instrument panel. It is using characteristics that the amount of current changes
according to amount of light on the photosensitive surface. Photo diode, converts the changes in light intensity into
electrical changes, detects the amount of light coming through windshield and changes it into current and then sends
the signal to FATC controller.
Inspection
1. Remove the sun sensor and measure the current between terminals under sunlight.
2. Measure the current again under shade. It is in normal conditions if the measured value is less than the measured
value under sunlight.
3. Turn the ignition switch to “ON” position.
4. Measure the voltage to the sun sensor from FATC connector. (approx. 2.5 V under sunlight and 4.8 V under
shade.)
5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
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A/T
Active Incar/Humidity Sensor: AIH Sensor
The AIH sensor is installed at the driver side instrument panel undercover. It is a sensor that detects interior tem-
perature and humidity.
M / T
Location
T/C
CLUTCH
AXLE
SP
ST’NG
Humidity
BRAKE
sensor
A / BAG
A / CON
Active incar sensor
(interior temperature sensor)
Functions
Incar temperature sensor
This sensor is a negative temperature coefficient (NTC) thermistor and detects the interior temperature with air
coming from senor hole and then sends the voltage value according to the changed resistance to FATC controller.
Humidity sensor
This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the
changed humidity to FATC controller.
CHANGED BY AIR CONDITIONING SYSTEM
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8. AIR QUALITY SYSTEM (AQS)
Components of AQS
AQS sensor and ambient
temperature sensor
AQS sensor
Ambient temperature
sensor
Connector
AQS Operation
1. Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected
through AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the
polluted air disappears.
Press the
AUTO switch
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2. When pressing the AQS switch, the AQS indicator on display window comes on, and the air source selection is
automatically changed to recirculation mode (REC). At this moment, the self diagnosis and preheating mode of
A/T
AQS is performed for 35 seconds.
AQS indicator comes on
M / T
Changed to recirculation mode
from fresh air mode
T/C
CLUTCH
AXLE
AQS switch
SP
NOTICE
• When pressing DEF switch during in this process, the AQS indicator goes out and the air source selection is
ST’NG
changed to fresh air mode from recirculation mode.
• When pressing the AQS switch again, the self diagnosis and preheating mode of AQS operates only for the
remaining time.
BRAKE
3. After the self diagnosis and preheating mode of AQS is completed, the AQS system operates according to the air
pollution.
A / BAG
If the air pollution is not serious, the AQS system changes the air source selection to fresh air mode.
4. Although turning off the air conditioner while the AQS is in operation, the AQS stays ON (indicator on). However,
if the air conditioner is turned on by turning the ignition switch ON from OFF, the AQS stops its operation and the
indicator goes out and the display window shows the initial screen.
A / CON
NOTE
• If the AQS switch is pressed in, the AQS function
works regardless of air conditioner controller
operation.
CHANGED BY AIR CONDITIONING SYSTEM
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5. The modes available AQS function:
1) AUTO mode
2) Fan speed control dial operation mode
3) A/C switch operation. At this mode, the AQS system operates according to the AQS switch operation.
NOTICE
• If the ignition switch is turned off with AQS ON, the AQS
is turned on when turning the ignition switch on again.
Pressing AQS
AUTO A/C ON (TEMP switch ON) switch AUTO A/C ON (TEMP switch ON)
AQS ON
Adjusting fan speed control dial Memory return
Adjusting fan speed control dial
Pressing AQS (when system OFF)
Mode change (MODE switch) switch Mode change (MODE switch)
AQS OFF
6. The AQS is turned off,
1) When pressing the defroster switch
2) When pressing the recirculation mode switch
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Removal and Installation
A/T
1. Disconnect the negative battery cable and remove headlamps.
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
2. Disconnect the AQS sensor connector, unscrew two bolts
(10 mm) and remove the AQS sensor assembly. (Install
A / BAG
in the reverse order of removal.)
AQS sensor
A / CON
Connector
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9. AIR CONDITIONER MODULE SENSORS AND ACTUATORS
Water Temperature Sensor
Water temperature Sensor
Inspection
If the water temperature sensor defect code (DTC 3) is set, check as below.
1. Remove the water temperature sensor and measure the resistance between terminals on the sensor connector.
(standard: approx. 25°C, 2.2 kΩ)
In addition, if the resistance is extremely high or low, replace the sensor.
2. If the measured value is out of the specified range, replace the water temperature sensor. If the measured value is
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure the voltage to water temperature sensor from the FATC
controller connector. (standard: approx. 2 V at 25°C)
4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
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AFFECTED VIN
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6810 31
A/T
Removal and Installation
Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.
M / T
The water temperature sensor should be removed after removing the air conditioner module assembly.
T/C
1. Disconnect the connector from the removed A/C module assembly and then remove the bracket screw on heater pipe.
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
2. Remove the heater pipe bracket and separate the water temperature sensor from bracket.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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32 6810
Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing
the current value to the base of power transistor when receiving the fan control signal from FATC.
Air conditioner power transistor
Inspection
If the power transistor defect code (DTC 6) appears, check as below.
1. Turn the ignition switch to ON position.
2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6.
3. The specified voltage value in each stage:
Stage Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6
Blower (V) 4.5 6.0 7.5 9.0 11 Max HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the
power transistor.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 33
A/T
Removal and Installation
Preceding Work: Disconnect the negative battery cable.
M / T
The power transistor should be removed after removing the lower instrument panel in front of passen-
ger seat. (For removal and installation of the lower instrument panel, refer to the "Body" section.)
T/C
1. Remove the lower instrument panel in front of passenger seat and disconnect the power transistor connector.
CLUTCH
AXLE
SP
ST’NG
BRAKE
2. Unscrew the mounting screws and remove the power transistor.
A / BAG
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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34 6810
Mode Door Actuator
The mode door actuator is an actuator that closes, opens and adjusts the mode door for VENT, FOOT and DEF
mode to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays
on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as
below when the MODE switch is pressed.
The air flows The air flows The air flows The air flows towards
towards face. towards face towards foot. front windshield and foot.
(Vent mode) and foot. (Foot mode) (Defroster and foot
(Bi-level mode) mode)
Mode door actuator
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 35
A/T
Removal and Installation
Preceding Work: Disconnect the negative battery cable.
M / T
First remove the driver side instrument lower panel in order to remove and install mode door actuator.
For removal and installation of the panel, refer to “BODY” section.
T/C
1. Remove the lower instrument panel in front of driver seat. Disconnect the mode door actuator connector and
remove two mounting screws.
CLUTCH
AXLE
SP
ST’NG
2. Separate the mode door actuator and remove the mode door link assembly.
BRAKE
A / BAG
Face mode door lever
A / CON
Bi-level
Windshield mode
door lever
Vent
Defroster and foot
Foot
Foot mode door lever
NOTE
• Make sure that the mode door link mounted on the air conditioner module assembly. When
installing, if the location of the mode door link is not correct, may not operate properly.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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36 6810
IN/EX - Air Door Actuator
The air source door actuator sets the intake door mode according to the control signal from FATC.
In/ex air actuator component
In/ex air door actuator location
Removal and Installation
Preceding Work: Disconnect the negative battery cable and then remove the instrument panel assembly.
Remove the driver’s instrument lower panel and then disconnect the connection connector of the mode door actuator
and the mounting screws (2EA). Remove the in/ex air door actuator.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 37
Air Mix Door Actuator
A/T
The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according
to the control signals from FATC.
M / T
T/C
Air mix door actuator component
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
Air mix door actuator location
Removal and Installation
A / CON
Preceding Work: Disconnect the battery negative cable and remove the instrument panel assembly.
With the instrument panel assembly removed as shown in the above figure, disconnect the air mix door actuator and
unscrew two mounting screws to remove the air mix door actuator.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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38 6810
Intake Temperature Sensor
The Intake Sensor outputs the compressor ON or OFF signal to ECU to prevent evaporator from freezing. The
sensing part of the thermistor is the evaporator fin contact type.
Intake Sensor location Intake Sensor
If the air conditioner does not turn on, check as below.
1. Remove the Intake Sensor and measure the voltage between terminal No. 1 and 2 on the connector.
2. Check whether the output voltages (ON: approx. 12 V, off: 0 V).
3. If the voltage value is out of the specified value, replace the Intake Sensor. If the circuit is in normal condition,
check as below.
4. Turn the ignition switch to ON position and turn on the air conditioner by pressing the A/C button. And measure the
voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V)
5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 39
A/T
Removal and Installation
Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.
M / T
1. Unscrew three mounting bolts (10 mm) on air conditioner module assembly and remove the sensor wire of air
conditioner module. Separate the blower unit from the heater unit.
T/C
Blower unit
CLUTCH
Heater unit side
AXLE
Mounting Bolt at Bottom of
A/C Module
SP
ST’NG
BRAKE
A / BAG
2. Separate the upper case and lower case of blower unit and remove the Intake Sensor from the evaporator.
A / CON
Intake Sensor
Evaporator
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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40 6810
10. REMOVAL AND INSTALLATION
Air Conditioner Module Assembly
Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.
1. Collect the air conditioner refrigerant before removing the air conditioner module. (dispose the
wasted refrigerant to designated place)
2. Drain radiator coolant.
1. Disconnect the heater hose (A) from the engine compartment and remove the A/C high/low pressure pipe mount-
ing nuts.
A. Inner/outer heater hose and clamp
* Remove the mounting nut and loosen the
coolant reservoir.
B. A/C joint pipe mounting nut
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 41
A/T
2. Unscrew four mounting screws on A/C module assembly (in engine compartment).
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
Behind FFH pump: 3
BRAKE
Behind vaccum pump: 1
A / BAG
A / CON
3. Carefully remove the A/C module assembly.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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42 6810
A/C Module Mounting Location
Mounting locations inside of vehicle
Mounting locations on backide
of A/C module
Front View
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 43
Air Controller Switch And Active Incar/Humidity Sensor
A/T
Preceding Work: Disconnect the negative battery cable and remove the center fascia panel assembly.
Air Controller Switch Assembly
M / T
1. With the center fascia panel removed, unscrew two
mounting screws from the A/C controller switch assembly.
T/C
CLUTCH
AXLE
SP
2. Disconnect the connectors from the A/C controller switch
assembly.
ST’NG
BRAKE
A / BAG
A / CON
3. Remove the A/C controller switch assembly.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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44 6810
Active In-Car/humidity Sensor
Disconnect the sensor connector, unscrew two mounting screws, and remove the sensor from the air conditioner
controller switch.
Disconnect Connector
Active in-car sensor/ Remove Mounting Screw
humidity sensor
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 45
Air Duct Assembly
A/T
Air Duct (On Instrument Panel)
Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
1. Unscrew the mounting screws (one at each side and four in center area) and remove the front air duct.
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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46 6810
2. Unscrew the mounting screws (one at each side) and remove the left and right air ducts.
3. Unscrew the mounting screws (one at each side) and remove the upper air duct.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 47
Floor Air Duct
A/T
Preceding Work: 1. Disconnect the negative battery cable and remove the center fascia panel and center lower
panel.
2. Remove the center console assembly.
M / T
Floor Air Duct
1. Unscrew two center mounting screws in floor air duct.
T/C
2. Unscrew the mounting bolts and remove the air duct.
CLUTCH
Vehicle with Foot Parking Brake Mounting Screws
AXLE
SP
Lower Air Duct Assembly
ST’NG
BRAKE
A / BAG
Vehicle with Hand Parking Brake
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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48 6810
Front Floor Air Duct
1. Driver side lower air duct is installed behind the lower instrument panel. Remove it according to the procedures for
removal of lower panel.
Air conditioner
module assembly
Floor air duct (LH) Floor air duct (RH)
Floor air duct
2. Passenger side floor air duct is located under the
air conditioner module.
Mounting screw
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 49
MEMO
A/T
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
M / T
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T/C
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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CLUTCH
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
AXLE
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
SP
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
ST’NG
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
BRAKE
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
A / BAG
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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A / CON
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CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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50 6810
Vent Grille Assembly
Preceding Work: Disconnect the negative battery cable.
The vent center grille and the vent side grille should be removed after removing the relevant panel.
Side Vent Grille
The driver side vent grille is located on the
outside mirror switch bezel assembly.
Removal/Installation
Unscrew four mounting screws and remove the vent grille assembly.
Left side vent grille
Front Vent Grille
Front vent grille is mounted on the instrumetn panel with one screw. Unscrew
the mounting screw and pull the vent grille out of the instrument panel.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 51
Center Vent Grille
A/T
Center vent grille is mounted on the center facia panel with four screws (two at each side).
M / T
T/C
CLUTCH
AXLE
Side Vent Grille
SP
Center vent grille
1. Unscrew the mounting screws with the front air
duct removed.
ST’NG
Right side vent grille
BRAKE
A / BAG
A / CON
Right side vent grille
2. Pull the vent grille out of instrument panel.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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52 6810
Condenser Assembly
Preceding Work:
1. Collect the A/C refrigerant.
2. Remove the front bumper assembly.
3. Drain the coolant
(Store the collected A/C refrigerant and coolant
into the designated container.)
Removal and Installation
1. Remove the air cleaner duct. (Unscrew two mount-
ing screws, release the cleaner hose clamp and
remove the duct.)
2. Remove the pipes from the radiator oil cooler for automatic transmission.
Installation Notice
Tightening torque 25 ~ 35 Nm
AIR CONDITIONING SYSTEM CHANGED BY
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6810 53
A/T
3. Remove the right and left hoses from the inter cooler.
LH RH
M / T
T/C
CLUTCH
AXLE
4. Remove the inlet/outlet hoses and return hose from the radiator.
Radiator Inlet Hose Return Hose
SP
ST’NG
BRAKE
A / BAG
A / CON
5. Remove the air conditioner hose and pipe at condenser side.
High-pressure Pipe: Compressor Side Low-pressure Pipe: Receiver Dryer Side
Tightening
torque:
16 ~ 23 Nm
Plug the pipe openings with a seal caps after disconnecting the high/ low pressure pipes.
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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54 6810
6. Disconnect the ambient temperature switch con-
nector and the AQS sensor connector and remove
the ambient temperature switch.
7. Unscrew three mounting bolts (10 mm) and re- 8. Unscrew the mounting bolt (10 mm) and remove
move the hood latch mounted on the front end the front support panel.
panel and support panel.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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6810 55
9. Unscrew four bolts and remove the radiator mount- 10. Unscrew three mounting bolts (10 mm) and then
ing bracket. remove the front end panel.
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
11. Remove the mounting clips and remove the radiator assembly.
BRAKE
A / BAG
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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56 6810
12. Remove the outlet pipe from the inter cooler.
Remove Two Mounting Bolts (10 mm).
13. Unscrew the upper and lower mounting bolts (10 mm) and remove the inter cooler from the radiator.
Inter Cooler Assembly
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 57
14. Remove the oil cooler pipes for automatic transmission from the radiator assembly.
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
15. Unscrew five mounting bolts (10 mm) and remove the air conditioner condenser assembly.
A / BAG
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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58 6810
Receiver Dryer Assembly
Preceding Work: 1. Disconnect the negative battery cable.
2. Collect the air conditioner refrigerant.
1. Disconnect the connector from the receiver dryer.
2. Unscrew the mounting nuts on the receiver dryer and remove the high/low pressure pipes.
Tightening torque: The oil rings on the pressure pipes should
20 ~ 30 Nm be replaced with new ones once removed.
3. Unscrew the mounting bolt and remove the receiver dryer.
AIR CONDITIONING SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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6810 59
Compressor Assembly
A/T
Preceding Work: Disconnect the negative battery cable and collect the air conditioner refrigerant.
1. Remove the cooling fan belt from the engine.
M / T
T/C
CLUTCH
AXLE
2. Disconnect the connector from the compressor.
SP
ST’NG
BRAKE
3. Unscrew the flange nuts
A / BAG
Tightening
of pressure pipes and
torque:
compressor mounting 16 ~ 23 Nm
bolts and remove the com- Tightening
pressor assembly. torque:
A / CON
16 ~ 23 Nm
Tightening
torque:
18 ~ 27 Nm
Tightening torque: 18 ~ 27 Nm
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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60 6810
Piping Layout of Air Conditioner and Heater
Joint pipe assembly
Liquid pipe
Heater inlet
hose
Suction hose
Heater
outlet hose
Receiver drier
Compressor
Liquid hose
Discharging hose
A/C condenser assembly
Joint pipe assembly
Liquid pipe
Suction hose
Receiver drier
Liquid hose
AIR CONDITIONING SYSTEM CHANGED BY
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6910 61
FFH (FUEL FIRED HEATER) SYSTEM
A/T
1. OVERVIEW
M / T
The system is to increase the coolant temperature quickly by firing diesel fuel in the burner that is installed in
engine cooling system when in winter time the ambient temperature and engine coolant temperature is low.
(Option) The DI engine equipped vehicle has the Positive Temperature Coefficient (PTC) system as a basic
equipment. FFH is operated by the coolant temperature and ambient temperature while PTC is operated by the
T/C
coolant temperature intake air temperature.
FFH system consists of independent fuel lines and fuel pump, coolant circuit and coolant circulation pump,
electrical glow plug and exhaust system. It also provides the diagnostic function. FFH system cannot be oper-
CLUTCH
ated or stopped by driver’s intention. The FFH system is automatically operated by the coolant temperature and
the ambient temperature. The FFH system operates up to more 2 minutes to burn the residual fuel inside the
system when stopping the engine during its operation. Therefore, a certain period of FFH operation after stop-
ping the engine is not a malfunction.
AXLE
Components Locator
SP
ST’NG
BRAKE
Diagnostic connector Ambient temperature switch
FFH Fuel pump FFH A / BAG
A / CON
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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62 6910
2. FFH LAYOUT
Components
1. FFH assembly 7. FFH pipe assembly & silencer 13. Fuel pipe NO.3
2. Water pump and bracket assembly 8. Ambient temperature switch 14. Tube clip mounting
3. FFH bracket assembly 9. FFH fuel pump 15. Tube clip mounting
4. FFH water pump bracket 10. Fuel pump bracket 16. Intake hose
5. FFH NO.3 inlet hose 11. Fuel pipe NO.1 17. Clamp
6. FFH NO.2 inlet hose 12. Fuel pipe NO.2 18. FFH NO.1 inlet hose
AIR CONDITIONING SYSTEM CHANGED BY
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6910 63
Exploded View
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
1. Jacket 18. Surface sensor with cable
2. Jacket cover 19. Controller connector
3. Combustion air fan - 14-pin connector (waterproof)
4. Combustion chamber 20. Pressure spring for surface sensor
5. Combustion chamber with flame tube 21. Pressure spring for control and overheating sensor
6. Heat exchanger 22. O-ring
7. Controller 23. Coolant hose (inlet)
8. Seal (between combustion chamber and 24. Coolant hose (outlet)
combustion air fan) 25. Tooth ring (2x)
9. O-ring 26. Cable harness cover
10. Glow plug with cable 27. Rubber seal
11. Seal (between combustion chamber and heat 28. O-ring
exchanger) 29. Screw (M4 x 55 TORX / 2x)
12. Upper bush for fuel pipe 30. Screw (M4 x 16 TORX / 2x)
13. Lower bush for fuel pipe 31. Screw (M4 x 12 TORX / 2x)
14. Flame sensor 32. Screw (M4 x 16 TORX / 4x)
15. Bush for flame sensor (graphite) 33. Screw (M4 x 44 TORX / 4x)
16. Control and overheating sensor with cable 34. Controller cable harness
17. O-ring 35. Insulation washer
CHANGED BY AIR CONDITIONING SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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64 6910
3. SPECIFICATIONS
Heater D5S-H
Heating medium Coolant
Control of the heat flow Large (full load) Small
Heat flow 5,000 W 2,300 W
Fuel consumption per hour approx. 0.63 Liter approx. 0.28 Liter
Mean electric power consumption In operation 35 W 11 W
At start 100 W
After-running 12 W
Rated voltage 12 V
* Lower voltage limit: An undervoltage protection device in the
controller switches the heaters off at approx. 10 volt. 10 V
* Upper voltage limit: An overvoltage protection device in the
controller switches the heaters off at approx. 15 volt. 15 V
Tolerable operating pressure up to 2.5 bar overpressure
Minimum water flow through the heater 300 L/H
Fuel In the main fuel tank (fuel)
Tolerable ambient temperature Operation - 40°C ~ 80°C
Storage -40°C ~ 125°C
Weight
(without coolant and water pump & bracket) approx. 2.3 kg
AIR CONDITIONING SYSTEM CHANGED BY
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4. FFH OPERATING PROCESS
A/T
Operating Condition
FFH is operated according to the ambient temperature and coolant tempreature.
M / T
Initial Operating Conditions of FFH
T/C
Initial Operating Conditions of FFH: Ambient temperature: below 5°C
Coolant temperature: below 75°C
Repeated Operating Conditions of FFH: Coolant temperature: below 75°C
CLUTCH
When the difference between the ambient temperature at initial opera-
tion and current ambient temperature is over 3°C (to reduce the hyster-
esis with the temperature difference when operating FFH), FFH is oper-
AXLE
ated again.
For example, if the initial operating temperature was 4°C, the ambient temperature at repeat operation should
be below 1°C and the coolant temperature should be below 75°C.
SP
FFH Operations According To the Changes of Coolant Temperature
ST’NG
BRAKE
A / BAG
A / CON
75
Water temp. outlet
Above graph shows the FFH control process while the FFH is operating.
The control element is coolant temperature as shown in the graph.
The FFH is operated in HI mode (high output: approx. 5,000 W) until the coolant temperature reaches at 80°C
and starts to be operated in LO mode (low output: approx. 2,300 W) from 81°C.
When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions
will be met again.
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Coolant Circulating Route
Water pump
Fan Engine
Front
Heater
Blower fan
Heater module
Heating system
Connecting the Coolant Circuit
The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the
heat exchanger.
NOTICE
• Parts conveying coolant must be routed and fastened in such a way that they pose no temperature risk to
person or material sensitive to temperature from radiation and direct contact.
• Before working on the coolant circuit, disconnect the negative battery cable and wait until all compo-
nents have cooled down completely.
• When installing the heater and the water pump, note the direction of flow of the coolant circuit.
• Fill the heater and water hoses with coolant before connecting to the coolant circuit.
• When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts.
• Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures.
• Secure all hose connections with hose clamps.
AIR CONDITIONING SYSTEM CHANGED BY
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Circuit Diagram
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation
pump and the ambient temperature sensor (switch) that provides important signals for the initial and repeat
operations.
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Control and Safety Mode
Heater Operations and Safety Mode
1. If the fuel pump fails to ignite within 90 seconds 5. The fuel pump does not start when the glow plug is
after fuel pumping starts, the start procedure is defect or electrical lead to the dosing pump is
repeated as described. If after a further 90 sec- interrupted.
onds fuel pumping the fuel pump still fails to ignite, 6. The fan motor speed is monitored continuously. If
the heater is switched off in fault mode. The con- the fan motor does not start up, is blocked or if the
troller is locked after a certain number of failed speed falls below 40% of the nominal speed, the
starts. heater is switched off in fault mode after 120
2. If the flame does out by itself during operation, seconds.
firstly a new start is activated. If the fuel pump fails 7. It is possible to diagnose the system by connect-
to ignite within 90 seconds after fuel pumping has ing the diagnostic device to controller. For details,
started again, the heater is switched off. refer to the “Diagnosis Procedures” section.
3. If the heater is overheated (lack of water, poorly
vented cooling circuit), the overheating sensor [EMERGENCY SHUTDOWN]
triggers, the fuel supply is interrupted and the heater If an emergency shutdown -EMERGENCY OFF- is
is switched off. necessary during operation, proceed as follows;
4. The heater is switched off if the lower or upper • Pull the fuse (Ef6: 20A) out.
voltage limit is reached. • Disconnect the heater from the battery.
Specification - Water Pump
Rated voltage 12 V
Operating voltage 9 V ~ 15 V
Power consumption 16 W
Pumping capacity (0.1 bar) 800 l/h
Operating temperature - 40°C ~ 135°C
Weight 0.28 kg
Characteristic Curve of Water
Pump (12 V)
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Function Diagram
A/T
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
Switching Diagram According to Temperature Changes
BRAKE
A / BAG
A / CON
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5. COMPONENTS AND FUNCTIONS
NOTICE
• There is no need to disassemble the FFH unit for repair. This section is to show the internal components
of the FFH unit.
Jacket cover
1. The O-rings are installed between jacket cover and
two coolant hoses.
2. The coolant hoses should be connected to right side.
1) Jacket
2) Jacket cover
3) Cable harness cover
Control and overheating sensor
1. The Control and overheating sensor and cable har-
ness make up one component.
1) Control and overheating sensor
2) Mounting spring
Check controller and overheating sensor
Check the control and overheating sensor with a digital
multimeter. If the resistance according to the changes of
flame.
Resistance [Ω]
sensor temperature is out of specified values, the flame
sensor is defective.
Temperature [°C]
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance [W] 32.54 19.87 12.48 8.06 5.33 3.60 2.48 1.75 1.25 0.91 0.67 0.50 0.38
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Surface Sensor
A/T
1. The surface sensor and cable harness make up one
component.
1) Surface sensor
M / T
2) Mounting spring
T/C
CLUTCH
AXLE
Check Surface Sensor
Check the surface sensor with a digital multimeter. If the
resistance of flame sensor is out of specified values, the
Resistance [Ω]
SP
flame sensor is defective.
ST’NG
BRAKE
Temperature [°C]
A / BAG
Specified value
Temperature [°C] 0 10 20 30 40 50 60 70 80 90 100 120
Resistance [W] 30.00 19.53 13.03 8.90 6.20 4.41 3.19 2.34 1.75 1.32 1.02 0.62
A / CON
Controller
The surface heater and cable harness make up one
component.
1) Controller
2) Jacket
3) Combustion chamber housing
4) Mounting screw
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Glow Plug
1) Glow plug
2) Combustion chamber with flame pipe
Combustion Chamber Housing
1) Jacket
2) Combustion chamber housing
3) Insulation washer
4) Seal - combustion chamber / combustion air fan
5) Seal - combustion chamber / heat exchanger
Flame Sensor
1) Flame sensor
2) Graphite bush
3) Bush
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Check Flame Sensor
A/T
Check the surface sensor with a digital multimeter. If the
resistance of flame sensor is out of specified values, the
Resistance [Ω]
flame sensor is defective.
M / T
1. Jacket
2. Combustion chamber
3. Combustion chamber housing
T/C
4. Insulation washer
5. Seal - combustion chamber / combustion air fan
6. Seal - combustion chamber / heat exchanger Temperature [°C]
CLUTCH
Specified value
AXLE
Temperature [°C] -50 0 10 20 30 50 80 90 100 130 150 200 250 300 350 400
Resistance [W] 803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
SP
Combustion Air Fan
ST’NG
1) Combustion chamber
2) O-ring
BRAKE
3) Rubber seal
4) Combustion air fan
5) Screw
A / BAG
A / CON
Combustion
air fan
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Combustion Chamber
1) Combustion chamber
2) Heat exchanger
3) Jacket
4) O-ring
5) Seal - combustion chamber / heat exchanger
Heat Exchanger
1) Jacket
2) Combustion chamber with flame tube
3) Heat exchanger
4) Seal - combustion chamber / heat exchanger
5) O-ring (for heat exchanger)
Heat Exchanger
1) Heat exchanger
2) Jacket
3) Stopper
4) Groove (bottom of heat exchanger)
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6. REMOVAL AND INSTALLATION
A/T
Preceding Work: Disconnect the negative battery cable.
NOTICE
M / T
• The FFH is an auxiliary device that automatically operates or stops according to the coolant temperature
and the ambient air temperature.
• In initial operating stage, the fuel pump generates the operating sound and the FFH heater produces
white smoke. These are normal states to fill the fuel into the FFH fuel line.
T/C
• After replacing the FFH related components, fill up the system with fuel.
CLUTCH
Fuel Pump
AXLE
SP
3. From Fuel Tank
4. FFH Fuel Pump
ST’NG
BRAKE
1. To FFH
A / BAG
A / CON
2. Wiring
Fuel tank FFH
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1. Disconnect the fuel pump connector with the vehicle
lifted.
2. Disconnect the fuel hose from fuel pump.
3. Unscrew the bracket mounting bolt (10 mm) and remove the fuel pump assembly.
NOTICE
• Plug the hose opening with a seal cap to
prevent oil leakage
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Ambient Temperature Switch
A/T
Preceding Work: Disconnect the negative battery cable and remove the right headlamp.
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
* The ambient temperature switch should be re-
moved after removing the headlamp.
BRAKE
A / BAG
1. Remove the ambient temperature sensor from
holder.
2. Disconnect sensor connector while pushing the
connector pin.
A / CON
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FFH Assembly
Preceding Work: Disconnect the negative battery cable.
FFH Coolant Circulation
FFH Assembly Pump Assembly
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1. Disconnect the FFH coolant circulation pump (A) connector and FFH connector (B).
A/T
M / T
T/C
CLUTCH
AXLE
2. Remove the hose and pipe from the fuel pump.
SP
NOTICE
• Plug the hose openings with seal caps to pre-
ST’NG
vent oil leakage.
BRAKE
A / BAG
A / CON
3. Unscrew the hose clamps on the FFH coolant circulation pump and remove the inlet and outlet hoses.
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4. Unscrew five bracket nuts (10 mm) and remove the FFH coolant circulation pump assembly.
1) Unscrew three mounting nuts at bottom of coolant reservoir.
FFH Assembly
2) Unscrew the mounting nuts from the FFH coolant circulation pump.
Front Mounting Nut FFH Exhaust Pipe Side
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5. Fuel feeding operation should be performed after replacing FFH assembly or fuel lines.
A/T
Fuel Feeding Operation
NOTICE Picture B
M / T
• Otherwise, FFH system could make white smoke
with abnormal noise.
T/C
1. Connect the ambient temperature switch connector
as shown in picture (A).
CLUTCH
2. Check if the fuel comes out after engine started as
the FFH fuel supply hose is disconnected. (Picture
B)
3. If the fuel is sprayed out, connect the fuel pipe to AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
FFH assembly and keep the engine running for Picture A
1 minute.
4. Connect the ambient temperature switch
connector.
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7. TROUBLE DIAGNOSIS
FFH Heater Trouble Diagnosis Precedure
Connect Scan-100 to the diagnostic connector located at the lower instrument panel.
1. Select [KYRON] in [VEHICLE SELECTION].
2. Select “FFH (FUEL FIRED HEATER)” in [CONTROL UNIT SELECTION].
3. Select the trouble code out of check items.
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Trouble
Trouble Description Remedies
A/T
Code
0 No faults -
10 Shutdown for overvoltage Measure battery voltage (must be < 15.9V).
Check alternator and overvoltage.
M / T
11 Shutdown for undervoltage Measure battery voltage (must be > 10.2V under load).
Check alternator, wiring and undervoltage.
12 Overheating (abnormal reference value) Temperature at overheating sensor > 125°C: check cooling system.
T/C
Check temperature sensor and overheating sensor, replace if necessary.
14 Overheating (difference evaluation-1) Difference in temperature values between surface sensor and con-
trol overheating sensor is too large. (Prerequisite for this trouble
CLUTCH
code display is that the heater is in operation and the water tem-
perature at the overheating sensor has reached min. 80°C): check
cooling system.
Check temperature sensor and overheating sensor, replace if nec-
AXLE
essary
15 Overheating (abnormal heater operation) Heater does not operate (The controller is locked.)
Delete trouble code to release controller lock: check cooling system.
Check temperature sensor and overheating sensor, replace if nec-
SP
essary
16 Overheating (difference evaluation-2) If the surface sensor has a far higher temperature value than the
control overheating sensor, then the system proceeds with a fault
ST’NG
shutdown.
17 Overheating (defective hardware-2) Temperature at control overheating sensor > 130°C: check cooling
system
Check temperature sensor and overheating sensor, replace if
BRAKE
necessary.
20 Open glow plug circuit Check plug cable for damage, replace if necessary
21 Overload or short circuit of glow plug Check plug cable for damage, replace if necessary
A / BAG
22 Short circuit of glow plug Check plug cable for damage, replace if necessary
23 - -
24 - -
A / CON
25 Short circuit of communication line Check the communication line.
30 Abnormal speed of combustion fan Defective fan wheel or combustion air fan motor
motor (frozen, contaminated, stiff, damaged cable)
31 Defective combustion fan motor Check cable harness for damage, replace if necessary.
32 Overload or short circuit of combustion Defective fan wheel or combustion air fan motor
fan motor0 (contaminated, stiff)
Check cable harness for damage, replace if necessary.
34 Abnormal output of combustion fan Check the ground and short of combustion air fan motor circuit,
motor replace if necessary.
36 - -
38 - -
39 - -
41 Abnormal water pump operation Check connector.
42 Overload or short circuit of water pump Check connector.
43 Abnormal output of water pump -
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Trouble
Trouble Description Remedies
Code
47 Overload or short circuit of fuel pump Check cable harness for damage, replace if necessary.
48 Abnormal fuel pump operation Check cable harness for damage, replace if necessary.
Check plug-in connection, replace if necessary.
49 Short circuit of fuel pump (B+) Check cable harness for open to battery voltage, replace if necessary.
50 Improper operation The controller is locked due to excessive starting problem.
51 Delayed heating time During start (no flame formed yet), the flame sensor reports
temperature value too high for too long, check exhaust gas,
combustion air and flame sensor.
52 Time exceeded for cold blowing Check exhaust gas and combustion air.
Check fuel quantity and fuel supply.
Clean or replace filter in fuel pump.
53 Flame aborted from “large” stage Fault (no more starting attempt allowed ). Check exhaust gas and
combustion air system.
Check fuel quantity and fuel supply.
Check flame sensor - see trouble code 64 and 65.
54 Flame aborted from “small” stage Fault (no more starting attempt allowed ). Check exhaust gas
and combustion air system.
Check fuel quantity and fuel supply.
Check flame sensor - see trouble code 64 and 65.
60 Abnormal overheating sensor opera- Check cable harness for damage, check plug-in connection,
tion replace if necessary.
Check sensor resistance value, replace if necessary.
61 Short circuit or ground of overheating Check cable harness, replace if necessary.
sensor Check sensor resistance value, replace if necessary.
64 Abnormal flame sensor operation Check cable harness for damage, check plug-in connection,
replace if necessary.
Check sensor resistance value, replace if necessary.
65 Short circuit of flame sensor Check cable harness, replace if necessary.
Check sensor resistance value, replace if necessary.
71 Defective surface sensor Check cable harness for damage, check plug-in connection,
replace if necessary.
Check sensor resistance value, replace if necessary.
72 Short circuit of surface sensor Check cable harness, replace if necessary.
Check sensor resistance value, replace if necessary.
74 Defective overheating prevention device -
87 - -
88 - -
89 - -
90 Watchdog reset Replace controller.
91 Abnormal reset function If too many resets occurs, replace controller
92 ROM error Replace controller.
93 RAM error Replace controller.
94 Defective transistor Replace controller.
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Trouble
Trouble Description Remedies
A/T
Code
95 Software error Check cable harness for open to battery voltage, replace if
necessary.
Replace controller.
M / T
96 Abnormal process operation Replace controller.
97 Wrong processor cycle Replace controller.
98 Defective main relay Replace controller.
T/C
99 EEPROM error Replace controller.
CLUTCH
Trouble Diagnosis
Causes Remedies
AXLE
Low coolant • Leakage in radiator • Change radiator.
level • Leakage in coolant auxiliary tank • Change coolant auxiliary tank
• Leakage in heater core • Change heater core.
SP
• Leakage in joint junction of coolant hose • Check hose or replace clamp.
• Leakage in defective coolant hose • Change hose.
• Leakage in water pump gasket • Change gasket.
ST’NG
• Leakage in water pump sealing • Change water pump.
• Leakage in water inlet cap • Change water inlet cap gasket.
• Leakage in thermostat housing • Change thermostat sealing.
BRAKE
• Insufficient tightening torque of cylinder head bolt • Tighten bolt to specified torque.
• Damaged cylinder head gasket • Change cylinder head gasket.
Abnormally • The coolant leakage (Check the coolant level) • Add coolant
A / BAG
high coolant • Excessive anti-freezer • Check density of coolant (Anti-freezer).
temperature • Poor coolant hose condition • Check bent of hose, replace if necessary.
• Defective thermostat • Change thermostat
A / CON
• Defective water pump • Change water pump.
• Defective radiator • Change radiator.
• Defective coolant auxiliary tank or tank cap • Change coolant auxiliary tank or tank cap.
• Crack in cylinder head or in cylinder block • Change cylinder head or cylinder block.
• Clogged water flow in cylinder head or block • Clean coolant flow line.
• Clogged water flow in radiator core • Clean radiator core.
• Defective cooling fan • Change or check cooling fan.
• Defective temp. sensor, wiring, and lamp cluster • Change sensor or check relevant wiring.
Abnormally • Defective thermostat • Change thermostat.
low coolant • Defective cooling fan • Change or check cooling fan.
temperature • Change sensor or check relevant wiring.
• Defective temp. sensor, wiring, and lamp cluster
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PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM
1. 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.
Because PTC system is heated by electrical power, high capacity alternator is required. (Alternator of 12V 75A/
90A has changed to 12V 140A)
Non-operational Condition - During engine cranking
- When too low battery voltage (Below 11V)
- During preheating process of glow plugs
PTC Assembly Engine ECU
PTC Ground
* The ground ring terminal should be
secured as shown in below figure.
Mounting bolt PTC earthling
Earth plate terminal
Tightening torque: 6 ~ 10 Nm
PTC Relay and Fuse
PTC (Relay 1)
PTC Heater 2 (40A)
PTC Heater 1 (40A)
PTC (Relay 2)
PTC Heater 3 (40A)
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A/T
2. COMPONENTS
M / T
T/C
Radiator Element Frame
CLUTCH
AXLE
SP
ST’NG
Connector Spring clip
BRAKE
PTC-Ceramic
A / BAG
A / CON
Characteristics of PTC
P.T.C Heater
Heating type Air heating type
Element Ceramic PTC (BaTio3)
Advantages 1. Stable output regardless of voltage changes
2. Block the overcurrent with switch effect of PTC element
3. High heating capacity in a moment
4. Excellent durability of heating element against high current
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3. PTC OPERATING PROCESS
PTC Operating (ON) Condition
The operating condition of PTC is controlled by two step.
Generally, ECU control the power relay for PTC depending on the coolant temperature and ambient tempera-
ture sensor.
1st step (Initial PTC operating condition)
1. When coolant temperature < 15°C, PTC is operating (ON).
2. When coolant temperature 15°C, tow conditions described below must be satisfied.
2nd step (Coolant temperature: 15°C)
1. When coolant temperature 65°C and ambient temperature -10°C PTC operates (ON)
2. When coolant temperature 65 ~ 60°C and ambient temperature -10°C ~ 0°C PTC operates (ON)
3. When coolant temperature 60°C and ambient temperature 0°C ~ 5°C, PTC operates (ON)
PTC “OFF” Condition
1. Air conditioner blower switch OFF
2. Ambient temperature sensor error (wiring short or open)
3. When engine cranking
4. Battery voltage is lower than 11V
5. When preheating the engine (Glow indicator “ON”)
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A/T
Electrical Wiring
M / T
T/C
CLUTCH
AXLE
SP
ST’NG
BRAKE
A / BAG
A / CON
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4. REMOVAL AND INSTALLATION
Preceding Work: Disconnect the negative battery cable and the instrument panel.
1. Disconnect the PTC connector while pulling out it (A).
2. Unscrew two mounting bolts and remove the PTC assembly from the A/C module assembly.
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ELECTRIC SYSTEM
8000
TABLE OF CONTENTS
ELECTRIC SYSTEM LAYOUT ................................ 2
1. Locations of interior units and sensors ..................................2
2. Switches, units and sensors in engine compartment ............4
3. Interior switches .................................................................... 6
4. Audio & video system ........................................................... 8
5. Electric components and layout .......................................... 10
6. Fuses and relays ................................................................ 12
7. Interior fuse box .................................................................. 15
8. Diagnostic connector .......................................................... 18
9. Electrical wiring diagrams ................................................... 20
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2 8000
ELECTRIC SYSTEM LAYOUT
1. LOCATIONS OF INTERIOR UNITS AND SENSORS
Under Instrument Panel Steering Wheel Angular Sensor / Immobilizer
Steering wheel angular sensor Immobilizer
Door lock relay
Chime
bell
Curtain air bag
module
Buzzer Sun sensor
for PAS TV antenna amplifier
RK STICS
PAS Unit
TCCU and TCU
Driver Seat Memory Switch
TCCU TCU
ELECTRIC SYSTEM CHANGED BY
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STICS
Rain Sensing Unit (Including
Auto Lignt) and ECM Sensor Cluster Sun Roof Unit and Motor
IMMO
SPWM
Sun roof unit Sun roof motor
CLUSTER
Air Bag ECU
S/W
Curtain air bag
module
AV
TV antenna
amplifier
DVD changer
WIPER
Curtain Air Bag Sensor
R / SENSOR
DSP amp
PAS
Sub woofer
TV tuner
LAMP
Engine ECU and SSPS Unit Interior Temperature and
S / ROOF
Humidity Sensor
S E AT
A / CRUISE
SSPS unit
(under the engine ECU)
CHANGED BY ELECTRIC SYSTEM
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2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT
FFH Assembly
Receiver Drier and Triple Pressure Switch
Horn (RH)
AQS Sensor and FFH Ambient Temperature Sensor
FFH ambient temperature sensor
AQS sensor (ambient temperature
sensor integrated type)
ELECTRIC SYSTEM CHANGED BY
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EL
ESP Pressure Sensor / Primary, Secondary ABS (ESP) HECU
STICS
IMMO
SPWM
CLUSTER
S/W
IWE Vacuum Solenoid Valve (4WD)
Hood Contact Switch
AV
WIPER
R / SENSOR
Horn (LH)
(on battery tray)
PAS
LAMP
Theft Deterrent Horn (Under the Battery) Fuse and Relay Box
S / ROOF
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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3. INTERIOR SWITCHES
Remote Control Switch on the Steering Wheel
Audio remote
control switch Audio remote
control switch
Bezel Assembly on Outside Rearview Mirror Adjusting Switch
Outside rearview mirror folding switch
ESP OFF switch
Outside rearview mirror
adjusting switch
Seat Position Memory Switch (Driver’s Door)
Driver’s Power Window Main Switch
ELECTRIC SYSTEM CHANGED BY
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EL
Sun Roof Switch
Room lamp
STICS
main switch
Sun roof switch
IMMO
SPWM
CLUSTER
Bezel Assembly on Hazard Switch
S/W
Outside rearview
mirror and rear glass
HDC switch heated switch
AV
TRIP switch
Front defogger
switch
WIPER
Hazard switch
R / SENSOR
Center Fascia Switch
PAS
4WD
switch
Driver seat LAMP
warmer switch
Passenger’s Power Window Switch
S / ROOF
Passenger seat
warmer switch
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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4. AUDIO & VIDEO SYSTEM
AV System
Audio remote
control switches Center speaker
DVD changer
AV Head Unit
Front speaker (RH)
Tweeter speaker
Sub woofer
(amplifier integrated type)
DVD changer
DVD+tape
Center speaker
AV head unit
Sub Woofer
Tweeter speaker (LH)
Front speaker (LH)
Other Audio Head Unit
1. 6-INDASH CD+TAPE+RADIO 2. CD+RADIO
6-Indash CD slot
changer
Tape
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8000 9
EL
Location: Inside of panel above glove box
STICS
IMMO
6 DVD changer
SPWM
TV antenna amplifier (RH)
CLUSTER
Rear speaker (RH)
Tuner/Amp
Tweeter
S/W
speaker
Radio antenna amplifier
AV
WIPER
R / SENSOR
AV System
PAS
DSP integrated amplifier
Tweeter TV antenna amplifier (LH)
LAMP
speaker (LH)
Rear speaker (LH) S / ROOF
Tuner
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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AFFECTED VIN
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5. ELECTRIC COMPONENTS AND LAYOUT
Wiring Harness Arrangement
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8000 11
EL
Components Locator
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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6. FUSES AND RELAYS
There are three fuse and relay boxes in this vehicle (one at each side of instrument panel and one in engine
compartment). The designation and capacity of relays and fuses is shown on the fuse and relay box cover.
Fuse and Relay Box in Engine Compartment
Fuses and Relays Connector Arrangement
ELECTRIC SYSTEM CHANGED BY
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8000 13
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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Removal and Installation
1. Disconnect the negative battery cable, open the fuse and relay box cover in engine compartment, and unscrew
the mounting nuts.
2. Lift the fuse and relay box assembly and disconnect connectors behind the assembly.
3. Remove the fuse and relay
box assembly.
ELECTRIC SYSTEM CHANGED BY
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7. INTERIOR FUSE BOX
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Fuse and Relay Box (LH) Fuse and Relay Box (RH)
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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Designation and Capacity
Driver Side
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EL
Passenger Side
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY ELECTRIC SYSTEM
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AFFECTED VIN
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8. DIAGNOSTIC CONNECTOR
Connection Between Scan-100 and Diagnostic Connector
Scan-100
Diagnostic connector
Additional cable for CAN module
CAN module
Additional Devices of Scan-100 Connection of Scan-100
(Diagnosis: EAS, EPB Only) (Including CAN Module and Additional Cable)
CAN module
CAN module
connecting cable
ELECTRIC SYSTEM CHANGED BY
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8000 19
EL
Pin Arrangement of Diagnostic Connector
It is installed under the instrument panel and consists of 16 pins.
STICS
The REKES key coding should be performed with Scan-100.
IMMO
SPWM
CLUSTER
S/W
Functions of Terminal
AV
Pin no. 1 FFH diagnosis
WIPER
Pin no. 2 FFH forced driving
Pin no. 3 -
R / SENSOR
Pin no. 4 Ground
Pin no. 5 Signal ground
Pin no. 6 CAN - HIGH
PAS
Pin no. 7 Engine ECU
Pin no. 8 ABS / ESP
LAMP
Pin no. 9 Air bag
Pin no. 10 TGS lever position unit
Pin no. 11 TCU
S / ROOF
Pin no. 12 SSPS
Pin no. 13 TCCU
S E AT
Pin no. 14 CAN - LOW
Pin no. 15 REKES coding
A / CRUISE
Pin no. 16 Battery +
CHANGED BY ELECTRIC SYSTEM
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9. ELECTRICAL WIRING DIAGRAMS
ELECTRIC SYSTEM CHANGED BY
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8710
TABLE OF CONTENTS
RKSTICS (REKES+STICS) / STICS ....................... 3
1. Overview ................................................................................ 3
2. Specifications ....................................................................... 4
3. Functions and specifications ................................................8
4. Trouble shooting ................................................................. 18
5. Diagnosis trouble code and help tips .................................. 47
6. Electrical wiring diagrams ................................................... 49
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8710 3
RKSTICS (REKES+STICS) / STICS
EL
1. OVERVIEW
STICS
The RKSTICS (REKES + STICS (Super Time & Integrated Control System)) communicates with the transmitter
(remote controller) and other electronic systems to transmit and receive the data.
The STICS also includes a diagnosis function that can inspect the error for related devices.
IMMO
Door Lock Relay
SPWM
CLUSTER
PAS Buzzer
RK STICS
S/W
AV
WIPER
Door Lock Relay
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
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2. SPECIFICATIONS
Electrical Performance
Electrical Performance
Item Requirement Remark
Rated voltage DC 12.0 V
Operating voltage DC 9.0 V ~ 16.0 V Should operate normally within this range.
(9.5 V ~ 16.0 V only for auto hazard lamp function)
Operating temperature -30°C ~ +80°C Should operate normally within this range.
Reserved temperature -40°C ~ +85°C
Max. operating humidity 95%
Resistible voltage 24 V
Insulating resistance No heat and fire due to the Confined with PCB, waterproof and coating that
current leaks. requires the insulation.
Parasitic current below 7.0 mA When initiating the sleep mode after removing
ignition key and locking the doors
Voltage drop below 1.5 V Pin no. 72 and 2, 4, 7, 8, 9, 10, 11, 12, 19, 24, 27,
28, 29, 30, 31, 32, 33, 36, 56, 57, 58, 59, 60, 61,
70, 71
below 1.8 V Pin no. 72 and 5, 6, 16, 17, 18, 20, 21, 23, 35, 37,
39, 41, 42, 43, 44, 45, 62, 64, 65, 66, 67, 68, 69
Characteristics of Radio Wave
1. Transmitting frequency: 447.800 ± 0.0125 MHz
2. Channel width: below 12.5 KHz
3. Frequency bandwidth: below 8.5 KHz
4. Modulation method: FSK (Frequency Shift Keying)
5 Receiving distance: Approx. 10 ~ 15 m (In case there
are not obstacles around the system)
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8710 5
EL
STICS
Rated Load
NO. Description Rated Load
IMMO
1 Chime bell / Buzzer DC 12 V 350 mA (Inducted load)
2 Front Room lamp DC 12 V 16 W (Lamp load)
SPWM
3 Rear Room lamp DC 12 V 8 W (Lamp load)
CLUSTER
4 Key hole illumination DC 12 V 1.2 W (Lamp load)
5 Seatbelt warning lamp DC 12 V 1.2 W (Lamp load)
S/W
6 Parking brake warning lamp DC 12 V 1.2 W (Lamp load)
7 Door ajar warning lamp DC 12 V 1.2 W (Lamp load)
AV
8 Door lock relay DC 12 V 200 mA (Inducted load)
WIPER
9 Door unlock relay DC 12 V 200 mA (Inducted load)
10 Horn relay DC 12 V 200 mA (Inducted load)
R / SENSOR
11 Tail lamp relay DC 12 V 200 mA (Inducted load)
12 Hazard warning relay DC 12 V 200 mA (Inducted load)
PAS
13 Power window relay DC 12 V 200 mA (Inducted load)
14 Rear defogger relay DC 12 V 200 mA (Inducted load)
15 Wiper LOW relay DC 12 V 250 mA (Inducted load) LAMP
S / ROOF
16 Wiper HIGH relay DC 12 V 250 mA (Inducted load)
17 Front washer motor DC 12 V 1.5 A
S E AT
18 Rear washer motor relay DC 12 V 500 mA (Inducted load)
19 Headlamp relay DC 12 V 750 mA (Inducted load)
A / CRUISE
20 Front defogger relay DC 12 V 200 mA (Inducted load)
CHANGED BY RKSTICS (REKES + STICS) / STICS
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Input Signals
NO. Input Signal Name Logic Status
1 IGN1 ON = BAT (IGN “ON” or “START”)
2 IGN2 ON = BAT (IGN “ON”)
3 ALT_D ON = BAT equivalent (engine running)
4 Key reminder (door ajar warning switch) IGN = BAT (Key in)
5 Driver’s door switch OPEN = GND, CLOSE = OPEN
6 Passenger’s door switch OPEN = GND, CLOSE = OPEN
7 Rear door switch – OPEN (one of rear seat) = GND
– CLOSE (all rear seats) = OPEN
8 Tailgate switch OPEN = GND, CLOSE = OPEN
9 Hood switch OPEN = GND, CLOSE = OPEN
10 Driver’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
11 Passenger’s door lock/unlock switch LOCK = OPEN, UNLOCK = GND
12 Rear door lock/unlock switch – UNLOCK (one of rear seat) = GND
– LOCK (all rear seats) = OPEN
13 Tailgate lock/unlock switch LOCK = OPEN, UNLOCK = GND
14 Rear defogger switch ON = GND, OFF = OPEN
15 Seatbelt switch Unfastened = GND, Fastened = OPEN
16 Hazard warning flasher selection switch ON = GND, OFF = OPEN
17 Parking brake switch ON = GND, OFF = OPEN
18 Air bag collision sensor ON = 200 ms output (LOW), OFF = OPEN
19 Wiper motor (parking) switch STOP = BAT VOLTAGE, ROTATING = GND
20 Washer switch ON = BAT, OFF = OPEN
21 Intermittent auto switch ON = BAT, OFF = OPEN
22 Auto washer switch ON = BAT, OFF = OPEN
23 Intermittent resistance 0W ~ 51 KW (for intermittent wiper)
24 Speed sensor ON = GND (PWM), OFF = OPEN
25 IDR (Coding) ON = BAT, OFF = OPEN
26 Front defogger switch ON = GND, OFF = OPEN
27 Central door lock switch ON = GND, OFF = OPEN
28 Rear washer switch ON = BAT, OFF = OPEN
29 Multifunction auto light switch ON = GND, OFF = OPEN
30 Indicator lamp switch ON = BAT/GND, OFF = OPEN (Approx. 5.1 V ~ 9.2 V)
31 Seat adjustment and switch memory unit ON = GND (PWM), OFF = OPEN
32 Rain sensor ON = GND (DATA), OFF = BAT
33 Diagnosis (SCAN-100) ON = GND (DATA), OFF = BAT (KWP2000)
34 Immobilizer ON = GND (DATA), OFF = BAT (KWP2000)
RKSTICS (REKES + STICS) / STICS CHANGED BY
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8710 7
Chattering of Input Signals
EL
1. Vehicle speed input:
The vehicle speed is the average value of 4 pulses among 6 pulse inputs regardless of the input for 1.0 second
STICS
after IGI 1 ON. The time indicated in each function does not include the vehicle speed calculating time.
2. 20 ms target input:
Wiper motor A/S (parking) terminal
IMMO
3. 100 ms target input switch
All switches except wiper motor A/S (parking) terminal
SPWM
CLUSTER
Time Tolerance
1. If not indicated, time tolerance will be ± 10%.
However, if less than 500 ms, time tolerance will be ± 100 ms.
S/W
2. The time indicated in each function does not include chattering processing time from switch input changing point.
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
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3. FUNCTIONS AND SPECIFICATIONS
Wiper and Washer Operations
Front wiper operation Front Automatic Wiping Speed Control Switch
The interval of wiper swings can be adjusted by
twisting the control knob upward or downward when
MIST the windshield wiper switch is in the AUTO position.
Fast: Fast interval
When pulling up the lever, the Slow: Slow interval
wiper operates once and the
wiper lever returns to the “OFF”
position.
OFF
Stop the operation.
AUTO
Operates automatically
according to the vehicle
speed or the amount of rain.
LO HI
Continuous wipe, Continuous wipe, fast operation
slow operation.
Front Auto Washer and Wiper Switch
When pressing the auto washer switch with the wiper switch
“OFF”, the washer fluid is sprayed on the windshield and
the wiper sweeps off 4 times, after then the washer fluid is
sprayed and the wiper sweeps off 3 times again.
Rear Washer and Wiper
The rear washer and the wiper operate
only while holding the switch. When re-
leasing the switch, it returns to the rear
wiper operate position.
Rear Wiper Operation
Wiper and Washer Coupled Operation
Pull the lever briefly (below 0.6 seconds): One
wiping cycle
Pull and hold the lever for more than 0.6 seconds:
Rear Wiper Stops Three wiping cycles with washer spray
Rear Washer and Wiper
The rear washer and the wiper operate only while holding the
switch. When releasing the switch, it returns to “OFF” position.
RKSTICS (REKES + STICS) / STICS CHANGED BY
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8710 9
EL
Wiper MIST and Front Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds after turning “ON” the washer switch for 0.1 ~ 0.59 seconds with the
STICS
ignition key “ON”, and it is turned off when the parking terminal is turned off.
IMMO
ON
KEY IN
& IGN2 SW
OFF
SPWM
T2
ON
WASHER SW
CLUSTER
OFF
ON
WIPER MOTOR
PARKING
OFF
S/W
ON T1
WIPER
LOW RELAY
OFF
AV
T1: 0.3 T2: 0.1 ~ 0.59 sec
WIPER
R / SENSOR
2. The wiper relay is turned on 0.3 seconds after turning “ON” the washer switch over 0.6 seconds with the ignition
key “ON”, and it is turned on three times immediately after turning off the washer switch.
PAS
ON
KEY IN
& IGN2 SW
OFF
T2
LAMP
ON
WASHER SW
OFF
S / ROOF
T3
ON
WIPER MOTOR
PARKING
OFF
S E AT
T1
ON
WIPER
LOW RELAY
OFF
A / CRUISE
T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
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3. When the washer switch is ON for more than 0.6 seconds during the wiper operation by the INT switch, the
operation in step (2) is performed. When it is ON for a certain period of time (0.1 to 0.59 seconds), the operation
in step (1) is performed.
ON
KEY IN
& IGN2 SW
OFF
ON
INT SW
OFF
T2 T3
ON
WASHER SW
OFF
T4
ON
WIPER MOTOR
PARKING
OFF
ON T1 T1
WIPER
LOW RELAY
OFF T5
T5
T1: within 0.3 sec T2: 0.1 ~ 0.59 sec T3: over 0.6 sec T4: 3 cycles T5: pause
Rear Washer Motor Control
1. When the rear washer switch is turn on with the ignition switch “ON”, the rear washer motor relay output is
activated from the time when the rear washer switch is turned on, and it is deactivated when the rear washer
switch is turned off.
2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer)
is in operation.
ON
KEY IN
& IGN2 SW
OFF
ON
REAR
WASHER SW
OFF
ON
REAR WASHER
MOTOR RELAY
OFF
RKSTICS (REKES + STICS) / STICS CHANGED BY
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8710 11
Auto Washer and Wiper Switch (AFW)
EL
1. When the auto washer switch is turned on with the ignition switch “ON” and the INT switch “OFF”, the washer
motor output is activated for 1 second. If the system recognizes this output, the wiper relay output is activated
STICS
during 4 cycles and the washer motor output is activated for 1 second. Then, the wiper relay output is deactivated
after 3 cycles.
IMMO
ON
KEY IN
& IGN2 SW
OFF
SPWM
AUTO
INT SW AUTO
OFF
T1
ON
CLUSTER
AUTO WASHER
SWITH ON
OFF
T6
S/W
ON
WASHER MOTOR T2 T2
OPERATING
OFF
AV
ON
WASHER MOTOR
PARKING
WIPER
OFF
T4 T5
ON T3
WIPER
R / SENSOR
LOW RELAY
OFF
T1: over 100 ms T2: 1.0 ± 0.1 sec T3: within 0.3 sec T4: 4 cycles T5: 3 cycles T6: 0.5 ± 0.1 sec
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
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2. The auto washer switch output is overridden during the washer coupled wiper operation.
3. The auto washer switch input is overridden during the auto washer coupled wiper operation.
4. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT
wiper operation.
5. When the auto INT switch input is received during the auto washer operation, the auto washer operation stops
and the auto INT operation is activated.
ON
KEY IN & IGN2
SW
OFF
INT AUTO ON
WITCH
OFF
ON
FRONT
WASHER SW T1
OFF
ON
AUTO T2
WASHER SW
OFF
ON
WASHER MOTOR
OUTPUT OFF
ON
WIPER MOTOR
PARKING
OFF
T4
ON
WIPER LOW T3 T3
RELAY
OFF
T1: over 0.6 sec T2: over 100 ms T3: within 0.3 sec T4: 3 cycles
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 13
Rain Sensor Coupled Wiper and Auto Light Control
EL
If equipped with RKSTICS rain sensor, it has following operation system.
STICS
System layout
IMMO
Multi-function (wiper)
Switch
SPWM
CLUSTER
INT Auto SW
S/W
Auto washer SW IGN 1 (15)
Washer SW
AV
Volume (Resistance) 4
Rain
LIN (Local Interconnect Network) communication 1 Sensor
WIPER
RKSTICS &
N.C. 2
Auto
(Numerical Control)
Light
R / SENSOR
Wiper parking 3 Sensor
Wiper LO
PAS
Wiper HI
LAMP
S / ROOF
Wiper Motor
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 8710
INT Switch Auto Position Reminder (Power-Up Reminder Wiper)
1. When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of
communication with rain sensor.
2. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the wiper switch to
“AUTO” position from any other positions (while the ignition key is in the “ON” position).
When the wiper switch is turned to the “ON” position again from other positions, the system drives the wiper
motor through LOW relay one cycle only when the rain sensor detects the “Rain Detected” signal.
ON
KEY IN
& IGN2 SW
OFF
ON
INT AUTO SW
OFF
Rain Detected
RAIN SENSOR
to RKSTICS
OFF
T1 T1 T1
ON
WIPER
LOW RELAY
OFF
T1: 1 cycle
Rain sensing unit (auto light integrated type) Multifunction wiper switch: AUTO and sensitiv-
ity control
A sensor that emits infrared rays through LED and then AUTO: Wiper operates automatically by rain sensor
detects the amount of rain drops by receiving reflected FAST ↔ SLOW: Auto delay/Auto speed control. A po-
rays against sensing section (rain sensor mounting sec- sition that can control sensitivity against rains in the
tion on the windshield) with photodiode (auto light sen- windshield and transmits wiping demand signal accord-
sor integrated type) ingly
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 15
Washer Coupled Wiper in Rain Sensing Mode
EL
1. The washer coupled wiper is operated when receiving the washer switch input with the ignition switch “ON” and
the auto INT switch “ON” in the rain sensing mode. At this moment, the communication with the rain sensor is
STICS
overridden. However, the washer switch input is overridden during the continuous operation.
2. The operation data is sent to the rain sensor even during the washer coupled wiper’s operation.
ON
IMMO
KEY IN &
IGN2
OFF
AUTO
INT AUTO SW
SPWM
OFF
ON
WASHER SW
OFF
CLUSTER
ON
WIPER P-POS
OFF
S/W
ON
WIPER
LOW RELAY
OFF
Override Rain
RAIN
AV
SENSOR
Sensing
WIPER
Rain Sensing Sensitivity Control
1. The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (while
R / SENSOR
the ignition key is in the “ON” position, the wiper switch is in the “ON” position, and the wiper motor is in “Parked”
position). However, the wiper motor can be operated only when the rain sensor detects the “Rain Detected” signal.
* If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
PAS
SENSITIVITY
LAMP
Rain Detected
RAIN
S / ROOF
SENSOR to
RKSTICS OFF
S E AT
T1 T1 T1
ON
WIPER LOW
A / CRUISE
RELAY
OFF
T1: 1 cycle
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 8710
Wiper Operation When the Wiper Parking Terminal Is Grounded
1. 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 “ON” position).
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
WIPER
PARKING
GND (Stop)
SENSITIVITY
SEN. 2
RKSTICS to
RAIN SENSOR
2. When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current
sensitivity for 2 seconds, then continuously outputs the parking signal of current sensitivity.
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
WIPER
PARKING
GND (Stop)
SENSITIVITY SEN. 2
RKSTICS to
RAIN SENSOR
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 17
Defective Rain Sensor
EL
1. The wiper relay (LOW) 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 from the rain sensor (while the ignition key is in “ON” position and
STICS
the wiper switch is in “ON” position).
IMMO
SENSITIVITY
SPWM
Malfunction
RAIN SENSOR signal: Yes
to RKSTICS
CLUSTER
Malfunction
signal: No
T1
S/W
ON
WIPER
LOW RELAY
OFF
AV
T1: 1 cycle
WIPER
2. The wiper relay (LOW) 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 from the rain sensor (while the ignition key is in “ON” position and
the wiper switch is in “ON” position).
R / SENSOR
SENSITIVITY
PAS
LAMP
S_COMMFAULT
RAIN SENSOR
to RKSTICS
S / ROOF
OFF
T1
ON
S E AT
WIPER
LOW RELAY
OFF
A / CRUISE
T1: 1 cycle
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 8710
4. TROUBLE SHOOTING
Symptom 1. The wiper does not operate one cycle when turning the multifunction wiper switch to
the “AUTO” from the “OFF” position or starting the engine while the wiper switch is in
the “AUTO” position.
1. When starting the engine with the multifunction wiper switch in the “AUTO” position, the wiper operates one cycle
to remind a driver that the wiper switch is in the “AUTO” position.
2. When the wiper switch is turned to “AUTO” from “OFF”, the wiper operates one cycle. It always operates one
cycle for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if
not raining when turning the wiper switch to “AUTO” from “OFF”. However, the wiper operates up to 5 minutes
after rain stops. If this function does not occur, check No. 8 pin. If the pin is normal, check the wiper relay related
terminals in the ICM box.
Symptom 2. It rains but the system does not work in the “AUTO” position.
1. Check whether the multifunction wiper switch is in the “AUTO” position.
2. Check the power to the sensor. Check the conditions of the pin 3 (Ground) and the pin 4 (IGN).
3. Check the wiper relay for defective.
Symptom 3. The wiper operates 3 or 4 times at high speed abruptly.
Check whether the variable resistance knob on the multifunction wiper switch is set in “FAST”. The “FAST” is the
highest stage of the sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the
low sensitivity.
Symptom 4. The wiper operates continuously even on the dry glass.
1. Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could
be occurred. In this case, replace the wiper blade with a new one.
2. Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the
highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the
low sensitivity.
Symptom 5. The wiper does not operate at high speed even in heavy rain.
Check if the wiper operates at high speed when grounding pin 1 and pin 2.
Symptom 6. The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in “FAST" or "SLOW”.
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 19
EL
Auto Light Control
1. The tail lamps and headlamps can be controlled with the communication with the rain sensor only when the auto
STICS
light switch is in the “AUTO” position with the ignition switch “ON”.
IMMO
ON
IGN KEY IGN2
OFF
AUTO
SPWM
AUTO
LIGHT SW
OFF
RAIN SENSOR Headlight
CLUSTER
DATA
Taillamp
ON
TAILLAMP
RELAY
OFF
S/W
ON
HEADLAMP
RELAY
OFF
AV
2. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on
automatically.
WIPER
3. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain,
the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level, but
R / SENSOR
the wiper operates at the 4th level.)
Emitter lense
PAS
LAMP
S / ROOF
Auto light sensor
Auto light sensor
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 8710
Speed Sensitive INT (Intermittent) Wiper
For RKSTICS without the rain sensor, perform the following operation:
1. Controls the wiper intermittent operation by the values from the vehicle speed and the volume.
1) Calculates and converts the Intermittent interval automatically by using the INT VOLUME when the ignition
switch is in the “ON” position and the INT switch is in the “ON” position.
2) The wipers are operated in vehicle speed sensitive mode when turning the INT switch to the “ON” position with
the engine running or starting the engine with the INT switch positioned to “ON”.
3) Intermittent interval (at 0 km/h): 3 ± 0.5 ~ 19 ± 2 seconds
2. Vehicle speed calculation
[Input the vehicle speed]
It is calculated by the numbers of input pulses for one second.
60 [km/h] X 60 [sec]
1 [PULSE/SEC] = 1.41 [km/h]
637 X 4 PULSE
3. VOLUME calculation
The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume (input voltage). Each level
has the hysteresis.
4. Pause time calculation
1) Pause time: the duration that wipers are stopped at parking position
2) Elapsed time: the duration after the wiper motor started to operate from parking position
3) The pause time is calculated by the vehicle speed and the VOLUME.
• If the pause time is below 1.0 second, the wipers operate without pause.
• If the pause time is over 1.5 seconds, the wipers operate intermittently.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 21
EL
Pause time of vehicle speed sensitive INT wiper
STICS
Vehicle
Speed
Resistance
IMMO
SPWM
CLUSTER
S/W
AV
Pause
time
(sec.)
WIPER
R / SENSOR
PAS
LAMP
Vehicle speed (km/h)
CAUTION
S / ROOF
• Speed sensitive INT (intermittent) wiper
1) The wiper relay continues to output for remaining “ON” time even when the INT switch is turned off.
2) IGN 2 switch “ON”, INT switch “OFF”: Resume the intermittent time when turning “ON”
S E AT
3) IGN 2 switch “OFF”, INT switch “ON”: Resume the intermittent time when turning “ON”
• Controls when the wiper motor parking is defective
1) The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper
A / CRUISE
relay is “ON” (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the
switch) (The output stops immediately after turning OFF the switch.)
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 8710
(The ignition key reminder warning has priority over
Ignition Key Reminder Warning
the “TAILLAMP ON WARNING”.)
1. The chime buzzer output in the ICM box continues when opening the driver’s door while the ignition key is
inserted the into ignition switch.
2. When removing the ignition key or closing the driver’s door during chime buzzer output, the output turns off.
3. This function is not available when the ignition switch is “ON”.
ON
IGN1
OFF
IN
IGN KEY SW
OUT
OPEN
Dr DOOR
CLOSE
ON
CHIME BUZZER
OFF
Chime buzzer
Ignition Key Reminder
1. The system outputs “UNLOCK” for 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).
2. The system outputs “UNLOCK” for 5 seconds (T2) when the door lock switch is changed to “LOCK” from “UN-
LOCK” and the driver’s door is closed within 0.5 seconds (while the ignition key is in the ignition switch).
3. If the UNLOCK conditions are met, the UNLOCK output should be unconditionally activated. However, if the ignition
key is removed after the door lock switch is changed from UNLOCK to LOCK, the UNLOCK output is not activated.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 23
ON
EL
IGN KEY
IN
REMINDER
OUT
STICS
LOCK
DOOR LOCK
SW(*1)
UNLOCK
IMMO
T1
OPEN
DOOR SW (*2)
CLOSE
SPWM
ON
UNLOCK RELAY
OFF T2 T3 T3 T3 T2
CLUSTER
T1: within 0.5 sec T2: 5.0 sec T3: OFF during T2 output
(*1): Driver’s door is opened and driver’s door lock switch is turned to LOCK,
(*2): Driver’s door is opened and passenger’s door lock switch is turned to LOCK
S/W
All Door Lock Prevention Function when a Door is Opened
AV
1. All doors, except the tailgate and hood, output “UNLOCK” for 5 seconds when the “LOCK” signal is inputted
(while the ignition key is removed and one of doors is opened).
WIPER
2. When the door is closed during the unlock output for 5 seconds, the unlock output stops.
3. When the ignition key is inserted during the output, the output continues for approx. 5 seconds.
4. If the ignition switch is in the “ON” position or the ignition switch is removed, the above steps are performed. If the
R / SENSOR
key is in the key cylinder, the ignition key reminder function is activated.
5. This function does not work if the vehicle speed is over 10 km/h.
KEY ON
PAS
IGN KEY IN
OUT
LAMP
LOCK
ALL Door
LOCK SW (*1)
UNLOCK S / ROOF
OPEN
Door SW (*2)
CLOSE
ON
S E AT
T1 T1
Door UNLOCK
OFF
A / CRUISE
T1: 5 sec ± 0.5 sec
(*1) DR & PS & RR DOOR LOCK SW & T/GATE LOCK SW, (*2) DR or PS or RR DOOR SW
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 8710
Mark Lamp Left on Warning
1. 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.
2. The chime/buzzer output stops when turning off the tail lamp and closing the driver’s door.
3. The system outputs “UNLOCK” for 5 seconds when the driver’s and passenger’s door lock switch is locked (while
the tail lamp is turned on and the driver’s door is open).
4. This function is not available when the ignition key is in the “ON” position.
ON
IGN1
OFF
ON
TAIL LAMP RELAY
OFF
OPEN
Dr DOOR
CLOSE
UN-
Dr DOR LOCK LOCK
SW
LOCK
T2 T2
ON
UNLOCK RELAY
OFF
T1 T1
ON
C/BUZZER
OFF
T1: 0.8 sec ± 0.1 sec T2: 5 sec ± 0.5 sec
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 25
Door Ajar Warning
EL
1. The warning light in indicator display comes on when opening any of the driver’s door, the passenger’s door, the
rear doors or the tailgate while the vehicle speed is below 10 km/h.
STICS
2. The warning light goes off when closing the door under step 1.
3. The warning light blinks when the vehicle speed is over 10 km/h while the warning light is turned on.
4. The warning light blinks when a door is open while the vehicle speed is over 10 km/h.
IMMO
5. The warning light goes off when closing the door under step 3.
6. The warning light comes on when the vehicle speed is below 10 km/h under step 3.
SPWM
ON
IGN1
CLUSTER
OFF
OPEN
DOOR SW (*1)
S/W
CLOSE
OVER V1
VEHICLE SPEED
BELOW V1
AV
T2
ON
WIPER
DOOR AJAR
WARN LAMP
OFF
T3
R / SENSOR
T2: 0.6 sec T3: 0.3 sec V1 = 10 Km/h
(*1) DOOR OPEN: Dr or Ps or Rr or T/GATE = OPEN
CLOSE: Dr & Ps &r Rr & T/GATE = CLOSE
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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26 8710
Seat Belt Warning
1. 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 the the “ON” position, the warning light in the indicator
display blinks, however, the chime buzzer does not sound.
2. The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch
to the “OFF” position.
3. The chime buzzer stops and the seat belt warning light stays on for the specified duration when fastening the
seat belt during the warning operation.
4. The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the
seat belt during fastening operation while the ignition key is the “ON” position.
ON
IGN1 SW
OFF
FASTEN
S/BELT SW
UNFASTEN
T3 T2
ON
S/BELT WARN
LAMP
OFF
T1
T2
ON
C/BUZZER
OFF
T1: 0.6 sec T2: 6.0 sec T3: 0.3 sec
Seat Belt Warning Lamp Chime Buzzer
Chime buzzer
The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the
ignition key to “ON” from “OFF”. After fastening the seat belt, the chime buzzer stops.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 27
Parking Brake Warning
EL
1. The parking brake warning light comes on for approx. 4 seconds when turning the ignition key from the “OFF” to
the “ON” position regardless of the vehicle speed and the parking brake switch position. After this 4 seconds, the
STICS
warning lamp comes on, goes off or blinks according to the vehicle speed and the parking brake switch position.
2. The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km/h.
3. The warning light goes off when turning off the parking brake switch under step 2.
4. The warning light blinks and the chime buzzer in the ICM box sounds for 2.85 seconds and stops for 1.5 seconds
IMMO
when the vehicle speed is over 10 km/h for more than 2 seconds while the parking brake switch is turned on.
5. The warning light goes off and the chime buzzer stops when turning off the parking brake switch under step 4.
6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 10 km/h under step 4.
7. This function is not available when the ignition key is turned to the “OFF” position.
SPWM
ON
IGN1 SW
OFF
CLUSTER
ON
P/BRAKE
S/W
OFF
Over V1
VEHICLE SPEED
AV
Below V1
WIPER
T4 T1 T4
T2
ON
P/BREAK WARN
LAMP
R / SENSOR
OFF
T3
ON
C/BUZZER
PAS
OFF
T5 T6
LAMP
T1: 2.0 sec ± 0.5 sec T2: 0.6 sec T3: 0.3 sec T4: 4.0 sec V1: 10 Km/h T5: 2.5 sec ± 0.1 sec T6: 1.5s ± 0.1 sec
Parking Brake: Hand operated type (manual transmission equipped vehicle), Foot operated type (automatic trans-
mission equipped vehicle)
S / ROOF
S E AT
A / CRUISE
Hand Operated Type Foot Operated Type
(Manual Transmission Equipped Vehicle) (Automatic Transmission Equipped Vehicle)
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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28 8710
Center/Luggage Room Lamp Control
The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the
center/luggage room lamp switch is at the coupled operating position and the key reminder switch is “OFF”.
1. When the door (Driver’s/Passenger’s/Rear) is opened, the front and center room lamps come on and automati-
cally go off after 30 seconds.
2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the driver’s door,
passenger’s door or rear doors.
3. The decaying operation must have greater than 32 steps per one second.
4. The room lamp output should stop immediately after turning on the ignition key during the decaying operation.
5. The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the
remote control key while the door is closed.
6. The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal
from the remote control key again during output. (The lamp stays on when unlocked by the remote control key.)
7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
8. The room lamp output stops immediately after receiving the lock signal from driver’s door, passenger’s door and
rear doors lock switch while the driver’s door, passenger's door and rear doors are closed.
9. The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch
is pressed.
OPEN
Dr or Ps DOOR SW
CLOSE
ON
IGN KEY
REMINDER SW OFF
REMOTE RECEIVE
CONTROL
UNLOCK NO SIGNAL
ON
UNLOCK OUTPUT
OFF
ON
FRONT ROOM T1
LAMP OFF
T4
T2 T3
T1: 30 sec T2: 2 sec T3: 3 sec T4 : 30 sec
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 29
EL
Front Room Lamp Center and Luggage Room Lamp
Tailgate Driver’s seat
STICS
Center Room
Lamp
(Lamp : ON)
IMMO
Luggage Room
Lamp
(Tailgate coupled
Center Room type)
Lamp
SPWM
(Door coupled type)
Luggage Room
Lamp 12V / 10W - 1EA
12V / 10W - 2EA (Lamp : OFF)
CLUSTER
Front room lamp (driver’s or passenger’s) is Center Room Lamp Luggage Room Lamp
turned on and off when pressing in this switch
The center room lamp comes The luggage room lamp
(1 or 2). However, it comes on when the door is
on while the switch is at the comes only when the tail-
open and goes off when the door is closed. The
door coupled position when gate is open while the
S/W
front and center room lamps come on when
the door is open. The lamp switch is at the tailgate
pressing the room lamp main switch (3).
always comes on while the coupled position.
switch is at the other position.
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 8710
Ignition Key Hole Illumination
1. The ignition key hole illumination comes on when opening the driver’s door or passenger's door while the ignition
key is removed.
2. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1.
3. The output stops when the ignition key is turned to the “ON” position.
4. The output stops when receiving the lock signal from the remote control key (under armed mode).
ON
IGN KEY (*1)
OFF
OPEN
DOOR SW (*2)
CLOSE
ON
KEY ILLUMI LAMP
OFF
T1 T1 T1
T1 : 10 sec
(*1) ON : IGN KEY = ON (*2) OPEN : Dr or Ps DOOR = OPEN
OFF : IGN KEY = OFF CLOSE : Dr & Ps DOOR = CLOSE
Key cylinder with key hole illumination
For diesel and gasoline For diesel engine equipped
engine equipped vehicle vehicle
Without immobilizer With immobilizer
→ With key hole illumination → With key hole illumination
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 31
Battery Saver (Tail Lamp Auto Cut)
EL
1. The tail lamp is turned on or off according to the operations of the tail lamp switch.
2. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door after removing the ignition
STICS
key without turning off the tail lamp.
3. The tail lamp relay is turned on when inserting the ignition key into the ignition switch.
4. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door while the ignition key is
removed and the tail lamp is turned on.
IMMO
IN AUTO AUTO
IGN KEY CUT CUT
SPWM
OUT
ON
CLUSTER
TAIL LAMP
OFF
OPEN
Dr DOOR
S/W
CLOSE
ON
TAIL LAMP RELAY
AV
OFF
WIPER
Front Defogger Timer
1. The front defogger output is “ON” when turning “ON” the front defogger switch while the ignition switch is “ON”
R / SENSOR
(with engine running).
2. The output stops when turning on the defogger switch again during its operation.
3. The output is “ON” only for 6 minutes when turning “ON” the front defogger switch within 10 minutes after
completion of output for 12 minutes. This can be done only once.
4. The output is “OFF” when the ignition switch is “OFF”.
PAS
ON
IGN2
LAMP
OFF
HIGH
ALT
S / ROOF
LOW
FR DEFOGGER ON
SW
OFF
S E AT
ON
FR DEFOGGER
RELAY
OFF
T1 T1 T1 T2 T3 T1
A / CRUISE
ALT LOW = 9V ± 1V T1: 12 minutes T2: within 10 minutes T3: 6 minutes ON: IGN2 & ALT = ON
OFF: IGN2 OR ALT = OFF
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
32 8710
Rear Defogger Timer
1. The rear defogger output is “ON” when turning “ON” the rear defogger switch while the IGN 2 switch is “ON” (with
engine running).
2. The output is “OFF” when turning “ON” the rear defogger switch again during output.
3. The output is “ON” only for 6 minutes when turning “ON” the rear defogger switch within 10 minutes after comple-
tion of output for 12 minutes. This can be done only once.
4. The output is “OFF” when the IGN 2 switch is “OFF”.
ON
IGN2
OFF
HIGH
ALT
LOW
ON
RR DEFOGGER
SW
OFF
ON
RR DEFOGGER
RELAY
OFF
T1 T1 T1 T2 T3 T1
ALT LOW = 9V ± 1V T1: 12 minutes T2: within 10 minutes T3: 6 minutes ON: IGN 2 & ALT = ON
OFF: IGN 2 or ALT = OFF
Tailgate and outside rearview mirror
heated glass switch
Press this switch to turn on the tailgate and
the outside rearview mirror heated glass. It
will operate for about 12 minutes.
Windshield heated glass switch
Press this switch to turn on the windshield
heated glass. It will operate for about 12
minutes.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 33
Headlamp Control
EL
1. When the system receives the remote control key after receiving the LOCK signal (theft deterrent mode) with the
ignition switch “OFF”, it supplies the power to the headlamp relay to turn on the headlamp (turned off after 20
STICS
seconds).
2. The output is “OFF” when receiving the “LOCK” signal from the remote control key while outputting the headlamp
relay.
However, other signals other than “LOCK” are overridden.
IMMO
3. The output is “OFF” when inserting the ignition key and turning it to the “ON” position while outputting the headlamp
relay.
SPWM
ON
REMOTE NO SIGNAL
CLUSTER
CONTROL
ARMED
THEFT
S/W
MODE
DETERRENT
OPERATION OTHERS
ON
AV
HEADLAMP
RELAY PWR
OFF
WIPER
ON
HEADLAMP
RELAY OUTPUT
OFF
T1
R / SENSOR
T1 : 20 sec
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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34 8710
Door Lock/Unlock Control by Door Lock Switch
1. The door lock system outputs “LOCK” for 0.5 seconds when positioning the driver's or passenger’s door lock
switch to the lock position.
2. The door lock system outputs “UNLOCK” for 0.5 seconds when positioning the driver's or passenger's door lock
switch to the unlock position.
3. “LOCK” or “UNLOCK” by the door lock switch is ignored when outputting the “LOCK” or “UNLOCK” by other functions.
4. All door lock signals are “UNLOCK” for 0.5 seconds just for once when receiving the “LOCK” signal within 0.5
seconds after closing the driver’s or passenger's door while the ignition key is removed.
LOCK
DR DOOR
LOCK SW
UNLOCK
LOCK
PS DOOR
LOCK SW
UNLOCK
OPEN
DR/PS DOOR
SW
CLOSE
T1 T3
ON
DOOR LOCK
RELAY
OFF
T2 T4
ON
DOOR UNLOCK
RELAY
OFF
T1: 0.5 sec T2: 0.5 sec T3: within 0.5 sec T4: 0.5 sec
Door Lock/Unlock by Central Door Lock Switch
1. The door lock system outputs “LOCK/UNLOCK” for 0.5 seconds when operating the central door lock switch.
(However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice
versa.)
2. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored.
ON
CENTRAL
LOCK SW
OFF
LOCK
MONITORING
UNLOCK
T1
ON
DOOR LOCK
RELAY
OFF
T2
ON
DOOR UNLOCK
RELAY
OFF
T1: 0.5 sec T2: 0.5 sec
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 35
Door LOCK/UNLOCK by Remote Control Key
EL
1. The door lock relay output is “ON” for 0.5 seconds when receiving the remote control lock signal.
2. The door unlock relay output is “ON” for 0.5 seconds when receiving the remote control unlock signal.
STICS
LOCK
IMMO
TX SIGNAL NO SIGNAL
T2
SPWM
ON
DOOR LOCK
RELAY
OFF
CLUSTER
ON
DOOR UNLOCK
RELAY
OFF
S/W
T4
ON
AV
HORN RELAY
OFF
WIPER
T6
ON
T5 T5 T5
HAZARD RELAY
R / SENSOR
OFF
T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec
Door button PAS
LAMP
S / ROOF
S E AT
A / CRUISE
Panic button
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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36 8710
Auto Door Lock
1. 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.
2. 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.
3. If any of doors is unlocked after 5 times of "LOCK" outputs, the door is regarded as “FAIL”.
4. If the door that was regarded as fail changes (UNLOCK to LOCK) to unlock, only one “LOCK” output will be done.
5. If any door is regarded as FAIL, the auto door lock function does not work (if it is occurred when the vehicle speed
is over 50 km/h, the auto door lock output does not occur even if the vehicle speed falls below 50 km/h and
accelerates again to over 50 km/h.). Nonetheless, the central door lock function works properly.
6. When the system receives “UNLOCK” signal from a door switch, it outputs “LOCK” signals 5 times. If additional
“LOCK” signal from another door switch is detected during the period, the system outputs five “LOCK” signals 5
times for the door.
7. The door lock system outputs “UNLOCK” automatically if the “LOCK” output conditions are established by this
function or the key is cycled (IGN1=OFF) (even when there is no “LOCK” output while the vehicle speed main-
tains over 50 km/h under lock condition).
(If the LOCK condition is established with the ignition switch ON, the system outputs UNLOCK signal uncondi-
tionally when turning the ignition switch to OFF position.)
However, when the ignition key is turned to “OFF” position, the lock output conditions will be cancelled.
8. The “FAIL” condition of the door will be erased when the ignition key is turned to “OFF” position.
ON
IGN1 SW
OFF
OVER
VEHICLE 50 km/h
SPEED BELOW
50 km/h
UNLOCK
DOOR
LOCK SW (*1)
LOCK
T1
T2
ON
DOOR LOCK
OUTPUT
OFF
5 times
T2 T2 T2 T2
T2: 0.5 sec
(*1) LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK
UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 37
Auto Door Unlock (Crash Unlock)
EL
1. The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to “ON”
position.
STICS
2. After this period, the door lock system outputs “UNLOCK” for all doors for 5 seconds from 0.4 seconds
after receiving the air bag collision signal.
3. Even though the key is turned to “OFF” position during the output of “UNLOCK”, the output continues on for
remaining period.
IMMO
4. The function is erased when turning “off” the IGN switch.
SPWM
ON
IGN SW
OFF
CLUSTER
T1
ON
AIR BAG
SIG
S/W
OFF
T2
ON
UNLOCK
AV
RELAY
OFF T3
WIPER
T1: 200 ms T2: 40 ms T3: 5 sec
R / SENSOR
CAUTION
• The “Unlock” control by air bag signal prevails over any “LOCK” or “UNLOCK” control by other functions.
PAS
• The “LOCK/UNLOCK” request by other functions will be ignored after/during the output of “UNLOCK” by the air
bag.
However, the door lock is controlled by other functions when the ignition switch is “OFF”.
LAMP
• “LOCK” (or “UNLOCK”) output is ignored if “LOCK” (or “UNLOCK”) output is required while performing the
output of “LOCK” (or “UNLOCK”).
• If the door lock system outputs “LOCK” and “UNLOCK” simultaneously, only the “LOCK” output can be
activated.
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
38 8710
Time Lag Power Window Control
1. The power window relay output is “ON” when turning on the ignition switch.
2. The power window relay output is “ON” for 30 seconds when turning off the ignition switch.
The power window relay output is “OFF” when opening the driver’s door or the passenger’s door.
3. The power window relay is turned “OFF” when receiving the remote control key lock signal (armed mode) during
its extended operation period of 30 seconds.
ON
IGN1
OFF
OPEN
Dr, Ps DOOR
SWITCH
CLOSE
T1 T2
ON
P/WINDOW
SWITCH
OFF
T1: 30 sec T2: OFF during T1 output
PANIC Warning (With ignition key in)
1. The PANIC warning output is “ON” (theft deterrent horn) when receiving the PANIC signal from the remote control
key (pressing PANIC button).
2. The PANIC warning output is “OFF” when receiving any signal from the remote control key during PANIC warning.
3. Followings are theft deterrent warnings:
1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft
deterrent.
2) The theft deterrent warning output is “ON” when the theft deterrent conditions are established during PANIC
warning (PANIC output is “OFF”).
3) The PANIC warning output is “ON” when receiving the PANIC signal from the remote control key in Armed
Ready / Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode).
4. This function operates only in armed mode.
Tx SIGNAL ON
(REMOTE CON-
TROL SIGNAL) OFF
WARNING
THEFT
DETERRENT OFF
MODE
T1 T1
T2
ON
HORN
OFF
T3
T1: 27 sec T2: 0.5 sec T3: 1.0 sec
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 39
Description of Burglar Alarm Function
EL
1. Definitions of Door Open and Close
1) Definitions in theft deterrent mode
STICS
Door OPEN: Any of door switches (engine hood, front doors, rear doors, tailgate) output “OPEN” signal.
Door CLOSE: All door switches (engine hood, front doors, rear doors, tailgate) output “CLOSE” signal.
2) Door LOCK: Any of door lock switches (front doors, rear doors, tailgate) output “LOCK” signal.
IMMO
Door UNLOCK: All lock switches (front doors, rear doors, tailgate) output “UNLOCK” signal.
SPWM
CLUSTER
S/W
Engine hood open warning lamp
The warning lamp comes on when the engine hood
is open.
AV
WIPER
2. Armed mode activation requirements
1) The “LOCK” output is “ON” when receiving the “LOCK” signal from transmitter while the ignition key is re-
moved and all doors are closed. The armed mode is activated when the door lock switch is locked (theft
R / SENSOR
deterrent horn output: once, hazard relay output: twice).
2) The theft deterrent horn and hazard relay outputs are “ON” when receiving the “LOCK” signal from the remote
control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice).
3) When receiving “LOCK” signal from the remote control key while any of doors is not closed, only the “LOCK”
PAS
output can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning
flasher). At this moment, if the ignition key is in the ignition switch, the door unlock switch is turned “ON” or
the door lock switch is unlocked, it cancels the armed mode and activates the normal mode.
LAMP
4) When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after
receiving “UNLOCK” signal, it outputs “LOCK” and then activates armed mode (RELOCK operation). Also, at
this moment, the system outputs hazard warning flasher twice.
5) The armed mode will not be activated except above conditions.
S / ROOF
Ex) The armed mode will not be activated when the door is locked by the ignition key.
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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40 8710
LOCK
Tx SIGNAL NO SIGNAL
UNLOCK
ENTRANCE OPEN T5
DOOR SW
CLOSE
ENTRANCE LOCK
DOOR LOCK
SW UNLOCK
ON
DOOR LOCK
RELAY
OFF
ON
(Dr) DOOR
UNLOCK RELAY
OFF
T2 T4
T1
ON
HAZARD RELAY
OFF
ON
HORN
OFF
T3
ARMED
OPERATION MODE
OTHERS
T1: 0.5 sec T2: 1.0 sec T3: 50 ms T4: 1.0 sec T5: 30 sec
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 41
3. Armed mode cancellation requirements
1) Unlocking by remote control key or engine starting.
EL
4. Warning operation requirements
1) When opening the door in armed mode
STICS
2) When unlocking the door lock switch in armed mode by other than the remote control key
3) When closing and then opening the door after completion of warning (27 seconds)
IMMO
5. Warning operation
1) The theft deterrent horn and hazard warning flasher output is “ON” for 27 seconds with the interval of 1 second.
6. Warning cancellation requirements
SPWM
1) Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, PANIC) during warning
operation.
2) Cancels warning after 27 seconds (remaining period) while the ignition key is turned to “ON” position.
CLUSTER
3) If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is
canceled immediately and the warning buzzer stops after 27 seconds (remaining time).
7. Operation when warning is cancelled
S/W
1) The theft deterrent horn and hazard warning flasher outputs are “OFF”.
ESTABLISHED
WARNING
AV
REQUIRE- NO ESTAB-
MENTS LISHED
ESTABLISHED
WARNING
WIPER
CANCELLA-
TION NO ESTAB-
LISHED
WARNING
THEFT DETER- ARMED
R / SENSOR
RENT STATE
NORMAL
T2
ON
HAZARD RELAY
PAS
OFF
T1
ON
LAMP
HORN
OFF
T3 T3
S / ROOF
WARNING
OPERATION
STATUS
OTHERS
S E AT
T1: 0.5 sec T2: 1.0 sec T3: 27 sec
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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42 8710
8. Operations when removing and installing the battery
Installed
Normal Armed Warning Remark
Removed
Normal Armed
Armed Ready
Armed
Warning
Warning Completion
RELOCK Ready
If the system is in armed mode while installing a battery, the horn sounds and the emergency warning lamp blinks
(Same operations with warning in armed mode).
RELOCK Operation
It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the
door with remote control key, the system outputs “LOCK” signal and activates the armed mode.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 43
Specifications of Remote Control Key
EL
When any of switches on remote control key is pressed, the integrated CPU in remote control key sends the coded
control message to the CPU in receiver to control the vehicle.
STICS
Switch Functions on Remote Control Key
Function Switch Operation
IMMO
Door lock Briefly press the switch briefly
Function Door unlock Press and hold the door switch
PANIC Briefly press the panic button
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Panic button Door button
1. Panic function 1. Door lock (short press)
1) The theft deterrent horn sounds approx. 27 sec- 1) The door is locked and it goes into the armed
onds when pressing this button for 0.1 ~ 0.5 mode when pressing this button for 0.1 ~ 0.5
PAS
seconds. seconds.
2) It stops when pressing any of the buttons on the
2. Door unlock (long press)
remote control key.
LAMP
1) The door is unlocked and it gets out of the armed
mode when pressing this button for 0.5 ~ 1.0
seconds.
2) The front room lamp comes on for 30 seconds
S / ROOF
when receiving door unlock signal by the remote
control key while the front room lamp coupled
switch is pressed.
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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44 8710
Receiver
1. Operating requirements
IGN Key = OUT (removed)
2. Code registration requirement
Codes can be registered only through SCAN-100.
3. Transmitter Code Registration
1) Up to two transmitter codes can be registered.
2) The received code cannot be output during the registration.
3) Both single REKES and dual REKES must be encoded through the SCAN-100.
Remote Door Lock
1. All doors are locked when briefly pressing the door LOCK switch on remote control key (less than 0.5 seconds).
2. The system outputs LOCK signal immediately after receiving the door lock message from the remote control
key. The system activates the theft deterrent mode when all doors are locked while they are fully closed (the
hazard warning lamps blink twice.).
REMOTE
CONTROL KEY Door Lock
PRESS THE DOOR
LOCK BUTTON
0.5 ± 0.1 seconds
OFF
DOOR LOCK
OUTPUT Chattering time
ON
UNLOCK
DOOR LOCK
SWITCH
LOCK
ON
SENSING Door Close, Hood Close,
Door Lock, T/Gate Close
OFF
0.5 ± 0.1 0.5 ± 0.1 0.5 ± 0.1
seconds seconds seconds
ON
HAZARD LAMP
OFF
ON
HORN 50 ms
OFF
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 45
Door Unlock
EL
1. The door unlock operates when pressing the door switch on the remote control key for longer than 0.5 seconds.
2. The door unlock relay is “ON” for 0.5 seconds when receiving the door unlock message from the remote control
STICS
key.
3. The hazard warning lamps blink once only when all the doors unlocked.
IMMO
RECEIVING
MESSAGE
OFF
SPWM
DOOR UNLOCK Chattering
OUTPUT time
ON
DOOR UNLOCK DOOR UNLOCK
UNLOCK
DOOR LOCK
CLUSTER
SWITCH
LOCK
ON
SENSING
S/W
OFF
0.1 seconds ± 0.1
ON
HAZARD LAMP
AV
OFF
WIPER
PANIC
R / SENSOR
1. This function operates when pressing the PANIC switch on the remote control key for less than 0.5 seconds.
2. The horn sounds for 27 seconds when receiving the PANIC message from the remote control key.
PAS
Pressing PANIC
button
LAMP
UNLOCK
DOOR LOCK
SWITCH
LOCK
S / ROOF
0.5 sec
ON
HORN
OFF
0.1 sec
S E AT
A / CRUISE
T1
27 sec
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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46 8710
Auto Door Lock
1. It the door is not opened within 30 seconds after unlocking the door with remote control key, the system outputs
“LOCK” signal and activates the armed mode (Relock function).
OFF
DOOR UNLOCK
SIGNAL
ON
0.5 seconds ± 0.1 second
Max 30 seconds ± 0.3 seconds
UNLOCK
DOOR LOCK Auto Door
SWITCH Door Unlock Unlock
LOCK
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 47
5. DIAGNOSIS TROUBLE CODE AND HELP TIPS
EL
Fault Code Malfunction Descriptions
01 Dr Door Lock Knob Driver’s door lock knob is not operated when locking/unlocking doors.
STICS
02 Ps Door Lock Knob Passenger’s door lock knob is not operated when locking/unlocking
doors.
IMMO
03 Rr Door Lock Knob Rear door lock knob is not operated when locking/unlocking doors.
04 T/Gate Lock Knob Tailgate lock knob is not operated when locking/unlocking doors.
05 Door Lock Output All door lock knob are not moved to lock position even when the door
lock relay is activated.
SPWM
06 Door Unlock Output All door lock knob are not moved to unlock position even when the
door unlock relay is activated.
07 C/DR Lock Output Doors are locked by central door lock switch while the engine is
CLUSTER
running.
08 DR Lock Output Doors are locked by driver’s door lock switch while the engine is running.
09 PS Lock Output Doors are locked by passenger’s door lock switch while the engine is
S/W
running.
10 Auto Door Lock Output Door lock knob is not moved to lock position when the system out-
puts auto door lock signal while the ignition switch is in ON position
and the vehicle speed is over 50 km/h.
AV
11 Auto Door Unlock Output Door lock knob is not moved to unlock position after receiving the
output from collision sensor.
WIPER
12 Wiper Output The WIPER P-POS signal is not detected when the wiper relay is
activated.
13 SPEED SIGNAL The vehicle speed over 3 km/h is detected at the speed signal area
while the ignition switch is in ON position and the alternator signal is
R / SENSOR
“D” LOW.
14 INT WIPER Volume The circuit is open (over 4.5 V) when changing the INT volume in the
speed sensitive INT wiper (saved as history error).
15 SPEED SENSOR The vehicle speed over 200 km/h is detected (saved as history error).
PAS
16 A/BAG COLLISION A signal is sent to the collision sensor input area while the ignition
SENSOR INPUT switch is in OFF position (saved as history error unconditionally).
17 A/BAG COLLISION The RKSTICS outputs UNLOCK signal after receiving collision sensor
LAMP
SENSOR OUTPUT input while the ignition switch is in ON position (saved as history
error).
18 A/BAG COLLISION The STICS outputs the Door Unlock signal due to the collision sensor
S / ROOF
MONITOR and the feedback value is in proper range (saved as history error).
19 Door Ajar Warning IND The door warning indicator blinks when the vehicle speed is over
10 km/h (saved as history error).
20 PARKING BRAKE IND The parking brake indicator blinks when the vehicle speed is over
S E AT
10 km/h (saved as history error).
21 Auto Washer Out The auto washer output is not sent to the front washer (saved as
history error).
A / CRUISE
22 WASHER RELAY The front washer switch receives the input signal for more than
10 seconds (saved as history error).
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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48 8710
Fault Code Malfunction Descriptions
23 REMOCON VOLTAGE The voltage from remote control key is saved as history error.
CHECK
24 SBR S/BELT SW When the seat belt switch circuit is OPEN (HIGH) in KEY OUT &
(Only EU) ARMED MODE, the system recognizes it as FAIL and saves it as
History error (Normal Close (GND)).
25 SBR SENSOR (Only EU) When the sensor value is recognized in KEY OUT & ARMED MODE,
the system saves it as History error.
26 SBR CONNECTION When the seat belt switch circuit maintains OPEN (HIGH) in KEY
(Only EU) OUT & ARMED MODE while the vehicle speed is over 50 km/h, the
system saves it as History error.
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 49
6. ELECTRIC WIRING DIAGRAMS
EL
Power/Ground, Chime Bell, Buzzer, Warning Lamp (Brake, Seat Belt,
DR Open)
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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50 8710
Central Door Lock Circuit
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8710 51
Tail Lamp, Hazard, Power Window
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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52 8710
Windshield Heated Glass (Defogger)
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 53
Panic, Auto Light & Rain Sensing, Room Lamp
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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54 8710
FRT Wiper/Washer & RR Washer
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8710 55
Removal and Installation
EL
Preceding Works:
1. Disconnect the negative battery cable.
STICS
2. Remove the lower panel in front of driver’s seat.
(For details, refer to BODY section.)
IMMO
SPWM
CLUSTER
S/W
1. Disconnect the connectors from STICS unit and remove the RKSTICS antenna.
AV
WIPER
R / SENSOR
PAS
LAMP
1. STICS connector 4. PAS buzzer connector
S / ROOF
2. STICS antenna 5. Door lock/unlock relay connector
3. Chime/buzzer connector
S E AT
A / CRUISE
CHANGED BY RKSTICS (REKES + STICS) / STICS
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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56 8710
2. Unscrew two mounting bolts (10 mm - 2EA) and remove the STICS unit.
RK-STICS antenna
Chime bell
Door lock relay
PAS buzzer
RK-STICS
3. Separate the STICS unit.
STICS Unit
RKSTICS (REKES + STICS) / STICS CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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IMMOBILIZER SYSTEM
7010
TABLE OF CONTENTS
IMMOBILIZER SYSTEM .......................................... 2
1. Overview ...............................................................................2
2. Basic functions of immobilizer key (REKES function) .......3
3. Other functions in system ...................................................4
4. Replacement of electronic head part (excluding key plate) ...6
5. REKES operation logic ........................................................ 7
6. Dual REKES coding .......................................................... 10
7. Immobilizer coding and removal of immobilizer unit ......... 12
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2 7010
IMMOBILIZER SYSTEM
1. OVERVIEW
The immobilizer unit communicates with the engine
control unit to enable the engine starting.
Immobilizer
What is the immobilizer system?
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 im-
mobilizer installed in the key box, and the system per-
mits the engine to start after confirming the encrypted
coding from the engine ECU. Refer to the information
that follows for specific functions and their descriptions.
Transponder
Battery
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 3
2. BASIC FUNCTIONS OF IMMOBILIZER KEY (REKES FUNCTION)
EL
1. Door and tailgate lock (briefly press) 2. Door and tailgate unlock (press and hold)
All doors and tailgate are locked and the vehicle All doors and tailgate are unlocked and the theft
STICS
the theft deterrent mode is activated. deterrent mode is deactivated. The front room lamp
and the center room lamp come on for 30 seconds.
The lamps go off immediately when the LOCK sig-
nal is sent from the remote control key (room lamp
IMMO
coupled function).
SPWM
Door button
CLUSTER
Key plate
1. Engine start
2. Door lock/unlock
S/W
PANIC button
AV
WIPER
PANIC function (with ignition key in)
NOTICE
Theft deterrent horn sounds approx. 27 seconds.
R / SENSOR
• The doors cannot be locked by remote control
if they are not closed. The PANIC function oper-
ates only in theft deterrent mode.
PAS
The PANIC function operates only in theft deterrent mode. Specification CR 2032
Quantity one
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 7010
3. OTHER FUNCTIONS IN SYSTEM
Immobilizer Function
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.
2
The immobilizer unit Immobilizer Unit
Transponder transmits the encrypted
code to the transponder.
The transponder sends an The transmitted code is
3 encrypted signal to the unit as 4 changed to an encrypted signal
a response. in the unit.
The system compares the signal
5 from transponder and the
encrypted signal in immobilizer
unit.
NOTICE
In the following cases, a driver may be unable to start the vehicle with the immobilizer.
• When two or more immobilizer keys come into contact with (each) other(s).
• When the key is close to any device sending or receiving electromagnetic fields or waves.
• When the key is close to any electronic or electric devices such as lightening equipment, security keys or
security cards.
• When the key is close to a magnetic or metal object or a battery.
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 5
ELECTRIC
Immobilizer and Warning Lamp
STICS
This indicator comes on when the ignition key is com-
municating with the engine control unit (during engine
IMMO
starting) and goes out after starting the engine.
Lamp ON: in communication
SPWM
Blinking twice for one second:
immobilizer system failure
Blinking once for two seconds:
immobilizer unit is not coded
CLUSTER
SWITCH
When turning the ignition key to ON position, the
1 ECU transmits the challenge message to the
immobilizer unit. (to verify whether the key is valid)
AV
Engine Control Unit 7 The ECU starts the engine.
WIPER
(ECU)
RAINSENSOR
Only when the two signals are identical, it recog-
6 nizes the key as the authorized one and transmits
the positive message to the ECU.
PAS
NOTICE
• Do not drop or shock to the transponder in the key as it may be damaged.
• With a damaged transponder, the engine cannot be started.
LAMP
• When you erase the code or register an extra key, let the owner attend on the site.
SUNROOF
NOTICE
• In any case, the immobilizer system can not be removed from the vehicle. If you attempt to remove it and
damage the system, starting will be impossible, so never attempt to remove, damage or modify it.
• The remote engine starter cannot be installed on the vehicle equipped with the immobilizer system.
S E AT
AUTO CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 7010
4. REPLACEMENT OF ELECTRONIC HEAD PART (EXCLUDING KEY
PLATE)
Replace the Electronic Head Part of the Immobilizer When:
1. The transponder (immobilizer key) is broken or damaged.
2. The immobilizer system is not properly functioning.
Rubber cover
Key plate
Screws (2EA) Key electronic head
assembly
Remove the rubber cover on the back of the key assembly. Remove two screws to uncover the key plate. Install the
new electronic head assembly on the key plate.
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 7
5. REKES OPERATION LOGIC
EL
Remote Door Lock
1. When briefly pressing the door lock switch on the remote control key for less than 0.5 seconds, all doors are
STICS
locked.
2. The system outputs the “LOCK” signal immediately after receiving the door lock message from the remote control
key. If the vehicle is locked while all doors including tailgate and engine hood are closed, the theft deterrent mode
IMMO
is activated (hazard warning lamps are blinking twice).
SPWM
PRESS DOOR Door Lock
LOCK
0.5 sec
± 0.1
CLUSTER
DOOR LOCK OFF
OUTPUT Chattering
DOOR LOCK time
SWITCH ON
UNLOCK
S/W
SENSOR
LOCK
AV
Door Close, Hood Close,
HAZARD LAMP Door Lock, T/Gate Close
0.5 sec 0.5 sec 0.5 sec
WIPER
± 0.1 ± 0.1 ± 0.1
ON
HORN
OFF
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 7010
Door Unlock
1. When pressing and holding the door unlock switch on the remote control key for more than 0.5 seconds, all doors
are unlocked.
2. When receiving the DOOR UNLOCK message from the remote control key, the door unlock relay is turned on for
0.5 seconds.
3. The hazard warning lamps blink once only when the doors are successfully unlocked.
PRESS DOOR
UNLOCK
SWITCH
OFF
DOOR UNLOCK Chattering
OUTPUT time
ON
Door Unlock
UNLOCK
DOOR LOCK
SWITCH LOCK
ON
SENSING
OFF
ON
0.1 sec
HAZARD LAMP
± 0.1
OFF
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 9
Remote PANIC (With ignition key in)
EL
1. When briefly pressing the PANIC switch on the remote control key for less than 0.5 seconds, the PANIC function
is activated.
2. When receiving the PANIC message from the remote control key, the horn sounds for 27 seconds.
STICS
PRESS PANIC
SWITCH
IMMO
UNLOCK
DOOR
LOCK
LOCK
SPWM
SIWTCH
0.5 sec
ON
HORN
CLUSTER
OFF
0.1 sec
S/W
T1 27 sec
T1: 27 sec
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7010
6. DUAL REKES CODING
The new coding is required by using the scanner when lost the transmitter. Vehicles with REKES function only have
one REKES remote control key and vehicles with immobilizer system have two keys with remote control function.
Therefore, there is a need to code two immobilizer keys.
1. After connecting the scanner and selecting 2. To start to code, press YES in the below
KYRON, then select DUAL REKES. screen. This results in clearing the key
codings of the old REKES.
REKES REMOCON CODING
KYRON DUAL REKES
DO YOU START REKES CODING?
[Yes / No]
4. The below screen is displayed when the first 3. Press one button of a remote control key once
key coding is completed. for 0.5 - 1.5 sec. You can hear a beep sound.
To start the second coding, press YES.
REKES REMOCON CODING REKES REMOCON CODING
KYRON DUAL REKES KYRON DUAL REKES
>>>> FIRST KEY CODING OK. <<<<
REMOCON ID. CODE : 0X AX FX XX PROCESSING THE CODING.
KEY CODE NUMBER : 01
Press the remocon button.
DO YOU START 2nd KEY CODING? (About 0.5-1.5 second)
[ Yes / No ]
Continued
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 11
EL
STICS
5. Press one button of a second remote control 6. The below screen is displayed when the sec-
key once for 0.5 - 1.5 sec. You can hear a ond key coding is completed.
IMMO
beep sound. To exit REKES key coding, press ENTER.
REKES REMOCON CODING REKES REMOCON CODING
SPWM
KYRON DUAL REKES KYRON DUAL REKES
>>>> SECOND KEY CODING OK. <<<<
CLUSTER
PROCESSING THE CODING. REMOCON ID. CODE : 0X AX FX XX
KEY CODE NUMBER : 01
Press the remocon button.
S/W
(About 0.5-1.5 second)
[ENTER] : EXIT
AV
WIPER
8. After exiting the SCAN-100 and disconnecting 7. Back to return the main screen when you have
R / SENSOR
it from the diagnostic connector, perform the finished coding.
function tests for the remote control keys. If they
do not work, repeat the above dual REKES key
coding procedures.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7010
7. IMMOBILIZER CODING AND REMOVAL OF IMMOBILIZER UNIT
When Replacing the ECU
After replacing the ECU with new one, perform the variant coding. Then, insert the ignition key and perform the
immobilizer coding.
When Replacing the Immobilizer Unit or Key Head Part
When inserting an ignition key after replacing the immobilizer unit, the ECU transmits the challenge message and
waits for the response message. The immobilizer unit indicator blinks with 0.5 Hz of interval to inform that the
immobilizer unit is not programmed (i.e. newly replaced). In this case, the immobilizer coding should be performed.
Removal of Immobilizer Unit
Preceding Works: Remove the battery negative cable.
1. Remove the lower panel from the driver’s seat.
(For details, refer to BODY section.)
2. Remove the steering column shaft assembly.
(For details, refer to STEERING section.)
3. Remove the connector from the key switch and
disconnect the immobilizer unit.
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 13
EL
Immobilizer Coding
STICS
CONTROL UNIT SELECTION FUNCTION SELECTION
KYRON IMMOBILIZER KYRON IMMOBILIZER
IMMO
1] ECU 1] READ FINGERPRINT
2] TCU “6” 2] IDENTIFICATION
3] ABS / ESP 3] CODING
SPWM
4] AIR-BAG
5] TCCU
CLUSTER
6] IMMOBILIZER
S/W
“3”
TEST PASSWORD IMMOBILIZER CODING
AV
KYRON IMMOBILIZER KYRON IMMOBILIZER
WIPER
ENTER TESTER PASSWORD >>>> WARNING <<<<
YES
1 1 4 3 4
R / SENSOR
If you start immobilizer coding procedure,
value of coded key is cleared.
Are you sure? [Yes/No]
PAS
LAMP
11434
S / ROOF
Continued
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7010
11434
INPUT USER ID. IMMOBILIZER CODING
KYRON IMMOBILIZER KYRON IMMOBILIZER
ENTER USER ID. ENTER TESTER PASSWORD
114
1 1 4 Turn “OFF” ignition key.
Press “ENTER”
Range : 0 ~ 255
FAIL
OK
IMMOBILIZER CODING IMMOBILIZER CODING
KYRON IMMOBILIZER KYRON IMMOBILIZER
CODING FAIL. Wait for 30 Seconds.
and then Turn “ON” ignition key.
Turn “OFF” ignition key. After Check the
IMMO. System, Retry Coding Procedure. Rest time: 27 seconds
Turn “ON” ignition key
Press “ENTER”
Press “ENTER”
ENTER
Continued
IMMOBILIZER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7010 15
EL
ENTER
STICS
IMMOBILIZER CODING IMMOBILIZER CODING
IMMO
KYRON IMMOBILIZER KYRON IMMOBILIZER
1st Key
Turn “OFF” ignition key. Input code to first key.
SPWM
Coding OK
Remove key and insert 2nd key,
and then Turn “ON” ignition key.
Please wait.
CLUSTER
Press “ENTER”
05 Seconds
S/W
All Key Coding OK
ESC
AV
IMMOBILIZER CODING IMMOBILIZER CODING
WIPER
KYRON IMMOBILIZER KYRON IMMOBILIZER
R / SENSOR
Are you sure exit ? CODING END.
[ Yes / No ] Turn “OFF” ignition key, and then
Turn “ON” ignition key.
Press “ENTER”
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY IMMOBILIZER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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SEAT POSITION WITH MEMORY
7410
TABLE OF CONTENTS
SPWM (Seat Position With Memory) UNIT ............ 3
1. Overview ...............................................................................3
2. Components .........................................................................4
3. Operations ...........................................................................5
4. Input/output of SPWM unit .................................................. 8
5. Control and operating conditions ......................................... 9
6. Removal and installation of seat ....................................... 15
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7410 3
SPWM (Seat Position With Memory) UNIT
EL
1. OVERVIEW
STICS
The memory setting of seat position is available availabe for up to 3 different drivers. Each driver can set his/her own
driver’s seat and outside rearview mirrors positions and they will be stored in the computer. Even if someone have
moved your seat and outside rearview mirrors, the memory positions will be recalled automatically by pressing the
IMMO
position button.
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Location SPWM
(Bottom of diver’s seat)
PAS
Functions of SPWM
Seat Position With Memory Power seat control
LAMP
Outside rearview mirror control
S / ROOF
Driver’s seat and outside mirror position memory
S E AT
1. Adjusting the power seat’s position with the seat adjusting switch
2. Adjusting the angle of the outside rearview mirrors (OSRVM)
A / CRUISE
3. Seat memory positions: for 3 persons
4. Folding/Unfolding the outside rearview mirrors
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 7410
2. COMPONENTS
SPWM Unit
LH outside rearview
mirror
RH outside rearview
mirror
Front
cushion
motor/
sensor
Reclining
motor/
sensor
Rear
Seat memory switch
cushion
motor/
sensor
Sliding
motor/
sensor
Outside rearview
mirror folding switch
Seat adjusting switch
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 5
3. OPERATIONS
EL
Outside Rearview Mirror Control
STICS
Outside Rearview Mirror Folding Switch
To fold the outside rearview mirrors, press the
switch. To unfold the mirrors, press again.
IMMO
Mirror Selection Switch
• “L”: Driver side mirror
• “R”: Passenger side mirror
SPWM
CLUSTER
Aiming Switch
Select the driver side mirror (L) or pas-
senger side mirror (R) with the mirror
selection switch. And then adjust the
S/W
selected mirror up, down, left, or right
by pressing the corresponding edges
of the switch to get the direct rearview.
AV
WIPER
Seat Position Control Seatback Reclining
Adjustment
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
Seat Slide Adjustment Seat Height Adjustment Seat Tilt Adjustment
A / CRUISE
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 7410
Driver’s Seat Position Memory Function
The position memory is available for up to three drivers. Each driver can set his/her own driver's seat outside rearview
mirrors and interior rearview mirror positions and they will be separately stored in the integrated computer. If some-
body has moved the seat, the memory positions can be recalled automatically by pressing the position button.
STOP button
Position SET button
buttons
(1, 2, 3)
Storing Memory Settings
1. Position the transmission shift lever to “P” with the ignition switch “ON” (for your safety, do not start the engine).
Apply the parking brake if the vehicle is equipped with M/T.
2. Adjust the driver’s seat and outside rearview mirrors to the desired positions.
3. Press the “SET” button. The indicator on the button will come on.
4. Within 5 seconds, press the buttons ( ), ( ) or ( ) you want to set. The indicator on the set button
blinks 3 times.
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 7
EL
Operating Memory Settings
STICS
1. Press and hold the desired buttons ( , or ) for more than 1.5 seconds.
2. Driver’s seat and outside rearview mirrors start to move. The position memory recall is canceled if moving the
vehicle during its operation.
3. Wait until they stop moving.
IMMO
4. When the position memory recall is completed, the buzzer sounds twice. (If failed, the buzzer sounds three
times.)
SPWM
CAUTION
• The position memory recall is canceled if operating the seat or the outside rearview mirrors during its
operation.
CLUSTER
• In the vehicle equipped with automatic transmission, the position memory recall is not available if the parking
brake is released and the gear shift lever is not in “P” position.
• In the vehicle equipped with manual transmission, the position memory recall is not available if the parking
brake is released.
• If the position memory recall is successfully completed the buzzer sounds twice. If it failed, the buzzer sounds
S/W
three times.
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 7410
4. INPUT/OUTPUT OF SPWM UNIT
Seat memory power Sliding motor
Seat sliding, rear lift power Cushion front motor
Seat reclining, front lift power Cushion rear motor
Instrument panel:
gear shift lever at “P” position RH outside rearview
In the vehicle equipped with automatic mirror folding/unfolding
transmission, the position memory recall motor
is not available if the gear shift lever is not
in “P” position.
LH outside rearview
mirror folding/unfolding
motor
Parking brake operation RH outside mirror Up/
SPWM UNIT
In the vehicle equipped with manual Down adjustment motor
transmission, the position memory recall
is not available if the parking brake is
released.
RH outside mirror Left/
Right adjustment motor
Vehicle speed signal
If vehicle speed is over 3 km/h, the position
memory recall is not available.
LH outside mirror Up/
Down adjustment motor
Outside rearview
mirror folding switch
LH outside mirror Left/
Right adjustment motor
Outside rearview mirror
adjusting switch
Power seat control switch The changes of each motor are always
monitored by the sensor in the motor.
Seat memory
switch
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 9
5. CONTROL AND OPERATING CONDITIONS
EL
Seat Position Memory
STICS
Seat Position Memory Operation
1. To store the seat position and the outside rearview mirror position, press the SET button and, within 5 seconds,
press one of position switches. The memory setting is available for up to 3 different drivers.
IMMO
2. The memory set mode is only available within 5 seconds after pressing the SET button.
over 100 ms
SPWM
ON
MEMORY
SW OFF
Memory set Cannot memorize
mode
CLUSTER
over 100 ms
POSITION ON
SW OFF
S/W
5 sec 5 sec
AV
3. If any of the following conditions is met, the memory set mode is canceled.
1) No switch inputs within 5 seconds after pressing SET button.
WIPER
2) When adjusting the seat or outside rearview mirror positions during the memory recall operation.
3) When turning off the ignition switch.
R / SENSOR
4) When pressing the STOP button
5) When the memory setting is completed.
4. The memory recall is not available when the vehicle speed is over 3 km/h or the gear shift lever is not in “P”
position with the parking brake released.
PAS
5. The memory set can be unlimitedly renewed.
6. The stored positions are erased when disconnecting the battery cables.
7. The buzzer sounds once if the memory set mode is activated.
LAMP
8. The buzzer sounds twice if the memory setting/recalling is completed.
9. The buzzer sounds three times if an error is found in the sensor during the memory recall operation.
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7410
Seat Memory Recall Operation
1. When pressing the position switch with the ignition switch ON, the seat and outside rearview mirrors move to the
memorized positions.
2. When pressing another position switch during previously activated memory recall operation, the newly pressed
position switch takes priority and recalls its stored position.
3. The buzzer sounds once if a position switch is pressed.
4. If any of the following conditions is met, the memory recall function is deactivated.
1) When turning off the ignition switch.
2) When the gear shift lever is not in “P” position with the parking brake released.
3) When the parking brake is released (only for the vehicle equipped with manual transmission)
4) When the vehicle speed is over 3 km/h.
5) When pressing the STOP button during the memory recall operation.
6) When adjusting the seat or outside rearview mirrors during the memory recall operation.
5. The seat will not move unless a position switch has a memory setting.
6. Timing Chart
ON
IGN SW
OFF
1.5 ± 0.2 sec
ON
POSITION SWITCH
OFF
Once Twice
ON
BUZZER
OFF
MANUAL OPERA-
ON
TION SWITCH
(SEAT, OUTSIDE
OFF
REARVIEW MIR-
ROR ADJUSTING
SWITCH)
Over 3 km/h
VEHICLE SPEED Below 3 km/h
ON
OFF
STOP BUTTON
ON
RECALL OPERA-
OFF
TION
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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7410 11
POWER SEAT
EL
Seat Position Control
1. The position sensor senses the changes of motor in the seat.
STICS
2. The seat position is stored by the memory order of position switch.
3. The stored seat position is recalled by the recall order of position switch.
4. The manual adjustment of seat positions takes priority over the memory and recall orders.
IMMO
SPWM
Motor Drive Control
1. In the case of the automatic control, each motor drive is delayed for 100 msec to prevent the irruptive current from
CLUSTER
being overlapped. The priorities are as follows.
Seat sliding →Seatback reclining →Seat cushion height adjusting (front) →Seat cushion height adjusting (rear)
S/W
Seat sliding ON
relay Min 100 ms
OFF
AV
ON
Seatback
WIPER
reclining relay
OFF
Min 100 ms
R / SENSOR
Seat cushion ON
(front) adjusting
relay OFF Min 100 ms
PAS
Seat cushion
(rear) adjusting
relay OFF
LAMP
2. Continuous motor driving time
S / ROOF
Seat sliding: 16 seconds, Seatback reclining: 50 seconds, Cushion height adjusting: 6 seconds
3. Reverse control
When reversing the control motor, the motor starts to rotate in the opposite direction 100 msec after the forward
driving is completed.
S E AT
4. The motor doesn’t operate if the difference between the stored position and the current position is out of the
specified range.
A / CRUISE
1) Sliding: 12 edges (6 pulses)
2) Cushion height: 6 edges (3 pulses)
3) Reclining: 100 mV
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7410
Error Detection
After the motor starts to drive, if the position sensor value doesn’t change for about 3 seconds during the seat sliding
or seatback reclining adjustment and for 1.6 seconds during the seat cushion height adjustment, it is determined
that the harness circuit is open or the sensor failure occurred.
If an error is detected,
The memory recall operation stops. However, the seat can be adjusted by manual switches.
The memory recall operation can be activated after the failure is corrected. This is determined when the system
detects the value changes from the position sensor. This is called the Release of automatic control stop
Relay Protection
Once the relay is turned on, it will not be turned off within 60 ms.
Specifications
1. Rated voltage: DC 12 V
2. Operating voltage: DC 9 ~ 16 V
3. Current consumption: Max. 500 mA (not including the load)
4. Operating temperature range: -30°C ~ 75°C
5. Reserve temperature range: -40°C ~ 85°C
6. Parasitic current: Max. 2 mA
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
7410 13
Outside Rearview Mirror (OSRVM)
EL
Mirror Position Control
1. The position sensor senses the changes of motors in the mirrors.
STICS
2. The mirror position is stored by the memory order of position switch.
3. The mirror position is recalled by the recall order of position switch.
4. The manual adjustment of mirror positions takes priority over the memory and recall orders.
IMMO
Motor Drive Control
SPWM
1. Driving sequence
Horizontal → Vertical
CLUSTER
2. Control during memory recall Field of vision:
Specifications of the field of vision • The control range of mirror that is not
1) Horizontal direction: 1.5 ~ 3.7 V limited mechanically.
2) Vertical direction: 1.5 ~ 3.7 V • The control range of that doesn’t affect
S/W
the sensor characteristics
3. LOCK detection
Timer monitors the motor driving time to detect LOCK condition.
AV
1) Monitoring the memory recall time
If the memory recall operation cannot be finished within 40 seconds after activating it, the system stop the
motor output and terminate the control.
WIPER
Error Detection
R / SENSOR
Even though the motor runs, if the drive input change (for 5 seconds) from the position sensor doesn’t change, it is
determined that the harness circuit is open or the motor/sensor failure occurred.
When an error is detected, any memory set or recall operations are prohibited, but the manual operation is possible.
PAS
When the sensor input changes by a manual operation, this error is cleared.
LAMP
Specification
1. Rated voltage: DC 12 V
S / ROOF
2. Operating voltage: DC 9 ~ 16 V
3. Current consumption: Max. 300 mA (not including the load)
4. Operating temperature range: -30°C ~ 75°C
5. Reserve temperature range: -40°C ~ 85°C
S E AT
A / CRUISE
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7410
Folding/Unfolding of Outside Rearview Mirror
Operation Logic
1. When pressing the outside rearview mirror folding switch, the outside rearview mirrors are folded.
2. Normal operation mode
Mode changes between Folding and Unfolding
3. The outside rearview mirrors can be folded and unfolded within 30 ± 6 seconds even after turning off the ignition
switch.
4. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is extended
13 seconds when pressing the switch again.
Timing Chart
IGN ON
OFF
POWER RELAY ON T2
OFF
T3 T3
SIDE REAR-
VIEW MIRROR
FOLDING ON
SWITCH OFF
T1
FOLD/UNFOLD
T
T1
T : T < T1 , T1 : 13 ± 3 sec , T2 : 30 ± 6 sec , T3 : 1 sec ± 0.1 sec
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
7410 15
6. REMOVAL AND INSTALLATION OF SEAT
EL
Driver’s Seat (Power Seat)
1. Slide the seat all the way to the rear and remove the
STICS
seal rail mounting bolts (LH/RH: 14 mm - 1EA).
Installation Notice
IMMO
Tightening torque 35 ~ 55 Nm
SPWM
CLUSTER
2. Slide the seat to the front stop and remove the seat rear
mounting bolts (LH/RH: 14 mm - 1EA).
S/W
Installation Notice
Tightening torque 35 ~ 55 Nm
AV
WIPER
R / SENSOR
3. Pull up the seat and disconnect the harness connector. Remove the seat assembly.
PAS
LAMP
Release the hook to disconnect the connector.
S / ROOF
Connector
on seat
S E AT
A / CRUISE
Main connector
CHANGED BY SEAT POSITION WITH MEMORY
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 7410
4. Unscrew the screws (arrows) and remove the protective cover.
5. Disconnect the harness connector and remove the SPWM unit.
SPWM unit
SEAT POSITION WITH MEMORY CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
CLUSTER
8010
TABLE OF CONTENTS
INSTRUMENT CLUSTER ....................................... 2
1. Descriptions of indicator display ...........................................2
2. Warning & indicator panel ................................................... 10
3. Removal and installation of meter cluster ............................ 18
4. Electrical wiring diagrams ................................................... 21
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2 8010
INSTRUMENT CLUSTER
The instrument cluster sends and receives the data through CAN communication.
The HDC warning light and the engine hood open warning light are newly introduced.
1. DESCRIPTIONS OF INDICATOR DISPLAY
1. Tachometer 12. Brake warning light 23. 4WD LOW indicator
2. Speedometer 13. Low fuel level warning light 24. 4WD CHECK warning light
3. Left turn signal indicator 14. Winter mode indicator 25. Auto shift indicator (for automatic
4. Right turn signal indicator 15. ESP warning light transmission)
5. Engine coolant temperature gauge 16. 4WD HIGH indicator 26. ODOmeter/ Trip odometer
6. Fuel gauge 17. Battery charge warning light 27. ABS warning light
7. Engine overheat warning light 18. Air bag warning light 28. EBD warning light
8. Fog lamp indicator 19. HDC indicator 29. Engine hood open warning light
9. High beam indicator 20. Immobilizer indicator 30. Glow indicator
10. Door ajar warning light 21. Water separator warning light 31. Engine check warning light
11. Sea belt reminder (passenger’s 22. Seat belt reminder (driver’s 32. Engine oil pressure warning light
seat) seat) 33. Auto cruise indicator
CLUSTER CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8010 3
EL
Configuration
STICS
Front View
IMMO
SPWM
CLUSTER
S/W
Rear View
AV
WIPER
R / SENSOR
PAS
LAMP
Main Connector Sub Connector
No.1 No.10 No.1 No.10
S / ROOF
S E AT
A / CRUISE
No.11 No.20 No.11 No.20
CHANGED BY CLUSTER
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 8010
Connector Pin Arrangement
Main Connector - 20 pins Sub Connector - 20 pins
1. A/T N (Neutral) output 1. -
2. Hood open 2. -
3. Seat belt (passenger) 3. 4P output
4. SSPS 4. Buzzer output
5. - 5. Light (+)
6. Front fog lamp 6. PGND (signal -)
7. Hazard warning flasher 7. Engine check
8. - 8. Door open
9. Charge 9. -
10. IGN (alternator) 10. Battery
11. A/T P (Parking) output 11. Troubleshooting
12. Air bag 12. Fuel input signal
13. Seat blet (driver) 13. RESET / MODE switch
14. High beam (-) 14. M/T N (Neutral) input
15. RH indicator lamp (+) 15. M/T P (Parking) input
16. High beam (+) 16. CAN Low
17. LH indicator lamp (+) 17. CAN High
18. Oil pressure 18. AGND (Fuel -)
19. Parking brake signal input (STICS) 19. MGND (Micom -)
20. - 20. IGN
CLUSTER CHANGED BY
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AFFECTED VIN
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8010 5
Warning Lights and Indicators
EL
Engine Tachometer
STICS
Danger range
(red zone)
IMMO
SPWM
CLUSTER
S/W
AV
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will
be the current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700 ~ 800 rpm. The red zone (danger rpm
WIPER
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
R / SENSOR
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Description Specification (VIN=13 ± 0.1V, Temperature: 25°C)
PAS
Engine speed (rpm) 750 1000 2000 3000 4000 5000 6000
Tolerance (rpm) - +100 +100 +100 +100 +100 -
LAMP
- -100 -100 -100 -100 -100
Checking
S / ROOF
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives
in tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer,
connect a scanner and then compare the value on tachometer with the reading from scanner.
S E AT
A / CRUISE
CHANGED BY CLUSTER
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 8010
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear (right 8 LEFT) wheel speed
sensor through ABS or ESP unit. In this model, the wheel speed sensor is installed at the rear tire area even though
the ABS/ESP is not equipped. Its signal is used as a standard vehicle speed that is transmitted to instrument panel,
TCU, TCCU, and engine ECU via CAN communication.
1. ABS/ESP (equipped): ABS/ESP ECU (208h), RR RH wheel speed sensor
2. ABS/ESP (not equipped): ENG ECU (320h), RR RH wheel speed sensor
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives
in speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire
inflation pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field
due to lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
Description (VIN = 13 ± 0.1V, Temperature: 25°C)
Standard speed (Km/h) 20 40 (60) 80 100 120 140 (160) (180)
Tolerance (Km/h) +4 +4 +7 +9 +10.5 +12.5 +14.5 +16 +18
0 0 +2.5 +3.5 +4 +6 +7.5 +8.5 +10
NOTICE
• The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
CLUSTER CHANGED BY
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8010 7
Fuel Level Gauge
EL
STICS
IMMO
SPWM
CLUSTER
S/W
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer.
Note that this vehicle doesn't have a service hole for checking the fuel sender connector in the fuel tank.
AV
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power
supply and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
WIPER
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so,
replace the fuel sender.
R / SENSOR
Tolerance and resistance value by indicating angle
Tolerance and resistance value by indicating angle
(VIN = 13.5 ± 0.1 V, temperature: 25°C)
PAS
Scale Full Full (Gauge) (3/4) 1/2 (1/4) Empty (Gauge) Empty
Indicating angle (°) - 105 78.75 52.5 26.25 0 -
LAMP
Tolerance (°) - +4, 0 - ±5 - 0, -4 -
Resistance (Ω) 38 43 67 99.5 150 276.3 283 S / ROOF
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the
differences that can be occurred by the road conditions and fuel fluctuations are ignored.
S E AT
A / CRUISE
CHANGED BY CLUSTER
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8 8010
Coolant Temperature Gauge
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that
changes by coolant temperature is as shown below.
Tolerance and resistance value by indicating angle
Indicating angle (°) 0 52.5 102 105
Tolerance +0°C +0°C - +4°C
-4°C -4°C +0°C
Coolant temperature Less than 40°C 70 ~ 110°C 120°C Over 125°C
Measurement of coolant temperature sensor resistance
Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature: 20°C - 2449W ± 5 %
50°C - 826W ± 5 %
80°C - 321W ± 5 %
100°C - 12W ± 5%
When the resistance value by coolant temperature is within the specified range, check thermostat, water
pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors
for proper connection.
CLUSTER CHANGED BY
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AFFECTED VIN
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8010 9
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Odometer/Trip Odometer
When pressing the TRIP/RESET switch on the cen-
ter panel, the odometer/trip odometer is converted Displaying range:
PAS
and the meter resets to 0.0 km in Trip A and Trip B. TRIP A 0.0 ~ 999.9 km
Displaying range: LAMP
TRIP B 0.0 ~ 999.9 km
S / ROOF
Displaying range:
ODO 0 ~ 999999 km
S E AT
A / CRUISE
CHANGED BY CLUSTER
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 8010
2. WARNING & INDICATOR PANEL
ESP Warning Light Battery Charge Warning Light Air Bag Warning Light
This warning light comes on when This warning light comes on when When the ignition is switched on,
pressing the “ESP OFF” switch or the ignition switch is turned on and this warning light illuminates and
the ESP system is defective. If the go off when the engine is started. If then should go out, to confirm that
ESP function operates while driving, this light doesn’t go off after engine the air bag is operational. If it does
this warning light flickers and the starting or comes on while driving, not come on, or if it does not go out,
alarm sounds. it means there is a malfunction in or if it flashes or illuminates con-
the system. tinuously while driving, it means that
there is malfunction in the system.
HDC Warning Light
Green light on: HDC is ready for
use (by pressing the HDC switch).
Green light blinking: HDC is being
applied.
Red light on: the HDC system is
overheated or malfunctioning.
When HDC is applied, the green
HDC indicator blinks.
When the red HDC indicator is on,
the HDC system is overheated or
malfunctioning.
When the red HDC indicator is
on, the HDC function does not
work.
Immobilizer Indicator
This indicator comes on when the
ignition key is communicating with
the engine control unit (during en-
gine starting) for approx. 0.5 seconds.
Water Separator Warning Light
When the water level inside water sepa-
rator in fuel filter exceeds a certain level,
4WD Indicator this warning light comes on and buzzer
sounds. Also, the driving force of the
4WD HIGH indicator vehicle decreases. If these conditions
occur, immediately drain the water from
When shifting the driving mode from "4L" to "4H", this indicator
fuel filter and water separator.
blinks until the shifting operation is completed. After completion
of the mode change to 4H, the indicator comes on.
Seat Belt Reminder
4WD LOW Indicator
When shifting the driving mode between “4WD LOW” and “4WD The seat belt warning light comes on
HIGH”, this indicator blinks until the shifting operation is and the seat belt warning chime sound
completed. After completion of mode change, the indicator goes for 6 seconds when the ignition switch
out. is turned to “ON” position unless the
driver’s seat belt is securely fastened.
4WD CHECK Warning Light This reminding operation stops when
If “4WD CHECK” warning light stays on continuously, it may in- the driver fastens the seat belt even
dicate that there is something wrong in the transfer case system. during its operation period.
CLUSTER CHANGED BY
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AFFECTED VIN
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8010 11
Over Temp. Warning Light
EL
When the engine coolant temperate is ab-
normally hot (over 120ºC), the engine over-
heat warning light blinks and a warning SSPS Warning Light
STICS
buzzer sounds. (check the coolant system) This warning light comes on when the SSPS system
is defective. When this warning light comes one, the
steerability becomes heavy.
Fog Lamp Indicator
IMMO
Door Open Warning Light
When the tail or head lights are on, the fog
lights come on if the fog light switch is turned This light comes on when a door or tailgate is either
to the “ON” position. Then, the fog light indi- opened or not closed completely.
cator comes on the instrument panel.
SPWM
Brake Warning Light
High Beam Indicator
This warning light comes on and warning buzzer sounds
This indicator illuminates when the head- when the parking brake is applied and/or the brake
light high beam is switched on.
CLUSTER
fluid level is lower than specified level.
Low Fuel Level Warning Light
This warning light indicates that the fuel will soon be
S/W
exhausted. The time it takes to turn on, however, varies
according to the vehicle operating conditions or gradi-
ent of the road.
Winter Mode Indicator
AV
The indicator comes on when the Winter mode (W)
switch near the gear selector lever is pressed.
WIPER
Use this mode to drive off smoothly under icy and slip-
pery road.
R / SENSOR
Glow Indicator
This indicator comes on when the ignition switch is
turned on and stays on for a short time or may go off
right away. When the glow plugs are sufficiently heated
ABS Warning Light for cold starting, the light will go out. In the vehicle
PAS
equipped with direct injection type engine, this indica-
This warning light comes on when the ignition switch is tor may come on very shortly or may not come on.
turned to ON and should go out if the system is normal.
The vehicle equipped with ABS performs self-diagnosis
Engine Hood Open Warning Light
on the system when the engine is started and drives off.
LAMP
During the diagnosis, brake pedal vibration and noise When the engine hood is open, this light comes on to
may be apparent when the driving motors discharges inform the driver.
the hydraulic pressure from the internal hydraulic device.
This means the ABS is properly functioning. EBD Warning Light
S / ROOF
Engine Check Warning Light This warning light comes on when the ignition switch is
turned to ON and should go out if the system is normal. If the
If the light stays on or comes on while driving, some of EBD system is abnormal, EBD warning light comes on.
engine control components including sensors and de-
S E AT
vices are defective. Engine Oil Pressure Warning Light
When this warning light comes on, the vehicle oper-
ates in safety mode to maintain minimum driving con- This warning light comes on when the ignition is switched
ditions and to prevent the system from being damaged. on and should go out when the engine is started. If the
A / CRUISE
In this mode, the engine driving force may be decreased light comes on while driving, it indicates that the oil pres-
or the engine may stall. sure is dangerously low.
CHANGED BY CLUSTER
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12 8010
Operation of HDC Indicator Controller
This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF).
The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC
switch is a push & self return type switch – when you press it once, it starts to operate and when you press it again,
it stops the operation.
HDC indicator HDC warning lamp
Green Red
HDC Operation Mode
HDC HDC
Initial ignition ON (From hence, this signifies operation mode
after the engine starts. Even when HDC switch is ON, if the OFF ON
ignition is OFF, HDC operation stops automatically.)
Not available HDC switch OFF OFF OFF
HDC system error OFF ON
Stand-by HDC switch ON ON OFF
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating
requirements are not met.
In operation HDC system is operating. Blinking (0.5 seconds
OFF
of interval)
The HDC switch is turned ON, and the operating requirements are met. HDC is operating with
operating sound.
System High brake system HDC stand-by mode OFF Blinking
overheat temperature
HDC is operating Alternate blinking of green and red lamp
(over 350°C)
(0.5 seconds of interval)
Too high brake system temperature
OFF ON
(over 450°C)
There is no specific temperature sensor in the system, but a programmed logic inside the HECU
predicts the temperature based on the operating numbers and conditions of HDC (HDC cannot be
operated).
NOTICE
Basically, the brake system’s basic functions can work even when there are problems with the HDC system.
As given in the table above, the HDC warning lamp comes on when:
• Initial ignition ON
• HDC system error occurs
• Brake system overheat
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8010 13
ESP Warning Lamp
EL
ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds
STICS
to warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is
operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 500 milliseconds.
IMMO
ON
ESP operation
(including TCS)
OFF
SPWM
500 ms
ON
CLUSTER
ESP warning lamp
OFF
500 ms
S/W
Min. 4 times
1. When receiving CAN data
LAMP: (200h, 1.5) ESP - INFO - BL: when receiving data, 500 ms on/off
BUZZER: (200h, 1.4) ESP - INFO - BUZZ: when receiving data, 100 ms on/off
AV
WIPER
ESP System Cancellation Using the ESP OFF Switch
When the ESP switch is pressed (for over approximately 150 ms), the ESP system will be cancelled and the
vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP
R / SENSOR
warning lamp on the instrument panel comes on.
The detailed operation procedures are as follows:
1. The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
PAS
3. The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx.
150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately
LAMP
when the ESP warning lamp is turned on by pressing the ESP OFF switch.
When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the
basic ABS system will operate.
S / ROOF
Resuming the ESP System by Using the ESP OFF Switch
The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch
S E AT
at the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
A / CRUISE
1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
3. The ESP system will be resumed after approx. 150 ms.
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14 8010
PUSH RELEASE PUSH RELEASE
350 ms
HI
Disabled
ESP operation range
LO
150 ms 150 ms
ON
ESP operation
(including TCS)
OFF 150 ms
150 ms
ON
ESP warning lamp
OFF
NOTICE
• When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when
ignition switch is turned on again.
• When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
• The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the
ESP OFF mode and the ESP warning lamp will not be changed.
• When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system
will not be turned on.
ESP OFF Switch Monitoring
When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds, the ESP unit determines
it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 10
seconds. However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and
then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP
unit resets the ESP OFF switch for approx. 3.5 seconds.
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8010 15
EL
Push Release
HI Error detection
STICS
ESP operation
LO
10 sec 3.5
sec
IMMO
Return to Reset to normal
switch signal condition
ESP function ON
SPWM
(including TCS)
OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
CLUSTER
ON
ESP warning lamp
OFF
S/W
AV
ESP Warning Lamp Operation Depending on System Conditions
The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function)
WIPER
is working.
Warning Lamp Controls
R / SENSOR
ABS W/L ESP W/L ABS ASR ABD Vehicle yaw control
Initial start
ON ON NO NO NO NO
(for 1.8 sec)
BLINKS WHEN ESP
Normal mode OFF OK OK OK OK
PAS
OPERATION
ESP fault OFF ON OK NO NO NO
ABS fault ON ON NO NO NO NO
LAMP
System fault ON ON NO NO NO NO
Low batt. voltage ON ON NO NO NO NO
S / ROOF
High battery voltage ON ON NO NO NO NO
High brake pad temp. OFF ON OK NO NO NO
ESP-OFF mode OFF ON OK NO NO OK Note 1)
S E AT
Entering diag. mode ON ON NO NO NO NO
NOTICE
A / CRUISE
• When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen-
sate the vehicle stability (posture) during ESP operation.
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16 8010
Reasons why N Switch Signal is Transmitted to Instrument Panel *(1)
1. HDC operation signal
The HDC function operates when the HDC switch is turned on with gear shift lever is in forward/reverse driving
positions. Vehicles with the automatic transmission receive the signal from the gear shift lever unit and vehicles with
manual transmission receive the neutral signal from the N (neutral) switch.
1) Manual transmission: operates in the 1st gear or reverse gear position (does not operate in the neutral position).
2) Automatic transmission: operates in all hear positions except P (parking) and N (neutral) position.
The vehicle with the manual transmission doesn’t have a independent device or switch that detects the 1st
gear position. It detects only the forward/reverse direction through the rear light switch and the neutral switch,
and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, although the HDC also
operates at over the 2nd gear, is because the engine may be turned off during the HDC operation.
The HDC operates on the very steep road. Thus, it should be used only when the transmission is in the 1st gear
position.
2. Raising the RPM in vehicles with the manual transmission.
This switch detects whether the gear is in N position or in other positions. The instrument cluster sends the signal
to the engine ECU. The engine ECU receives the N switch signal, the vehicle speed, the clutch operating conditions,
and the engine coolant temperature and raises the engine speed by 100-200 rpm. This helps the vehicle start
smoothly during gear shifting.
N Switch
Outside Inside
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8010 17
Vehicle Speed Input to Non-ABS Equipped Vehicle
EL
The wheel speed sensor is installed on the rear right wheel regardless of the ABS/ESP installation.
This sensor is to signal the vehicle speed to the engine ECU, TCCU, transmission, and instrument panel. There is
STICS
no separate unit to process the wheel speed sensor signal. The wheel speed sensor is connected to the engine ECU
(terminal 36), where its signal is processed, and is connected to other related systems through CAN communication.
IMMO
36 Battery(+)
SPWM
Wheel speed sensor
DSL
CAN HI
Engine 54
CLUSTER
ECU
Cluster
CAN LO
73
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
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18 8010
3. REMOVAL AND INSTALLATION OF METER CLUSTER
Preceding Works: Disconnect the negative battery cable.
Location
Cluster
Center Fascia Panel
Assembly (LH/RH)
Cluster
Outside Mirror Switch
Bezel Assembly
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8010 19
Removal and Installation
EL
1. Remove the left center fascia panel and unscrew three
NOTE
mounting screws on the hazard switch bezel
• Remove the bottom of the center fascia panel first.
STICS
assembly.
• For details, refer to “Removal and Installation of
Instrument Panel”.
IMMO
SPWM
CLUSTER
S/W
2. Remove four instrument panel mounting screws.
AV
WIPER
R / SENSOR
PAS
3. Disconnect the outside mirror switch bezel connector and remove the meter cluster panel assembly.
LAMP
S / ROOF
S E AT
A / CRUISE
NOTICE
• Be careful not to damage the another components during removal procedures.
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20 8010
4. Unscrew four cluster mounting screws.
5. Disconnect the connectors from the back of meter cluster and remove the cluster from the instrument panel.
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8010 21
4. ELECTRICAL WIRING DIAGRAMS
EL
Gauge (speed, RPM, fuel, temp), Warning Lamp (fuel, fuel filter, ABS/
ESP, brake, HDC, 4WD)
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY CLUSTER
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22 8010
Warning Lamp (batt charge, oil, hood, door, eng check, air bag, ssps,
seat belt), Turn Signal, Fog Lamp, Hazard
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SWITCHES / ELECTRIC DEVICES
8510 / 7770 / 8610 / 7632 / 7610
TABLE OF CONTENTS
SWITCH ARRANGEMENT ........................ 2 SEAT POSITION MEMORY SWITCH ...... 72
1. Location and functions ....................................... 72
CENTER FASCIA & BEZEL SWITCH 2. Switch arrangement ........................................... 73
ASSEMBLY ............................................... 4 3. Exploded view .................................................... 74
1. Location ............................................................... 4 4. Output voltage in each switch position ............... 74
2. Switch arrangement ............................................. 5 5. Functions and operations ................................... 75
3. Functions ............................................................. 6 6. Removal and installation of seat position
memory switch .................................................. 77
4. Switches in hazard & bezel switch assembly ...... 8
7. Electrical diagram of power seat & outside
5. Center fascia switch bezel assembly ................. 19
rearview mirror .................................................... 79
6. Removal and installation of hazard &
bezel switch assembly ...................................... 21 AUDIO REMOTE CONTROL SWITCH
OUTSIDE REARVIEW MIRROR SWITCH ON STEERING WHEEL .......................... 81
BEZEL ASSEMBLY ................................. 27 1. Locations and functions ..................................... 81
2. Components ...................................................... 82
1. Location ............................................................. 27
3. Circuit diagram ................................................... 83
2. Switch arrangement ........................................... 28
4. Removal and installation .................................... 84
3. Switches in outside rearview mirror switch
bezel assembly ................................................. 29
MULTIFUNCTION SWITCH .................... 86
4. Removal and installation .................................... 36
1. Overview ............................................................. 86
OVERHEAD CONSOLE SWITCH ........... 41 2. Functions and operations ................................... 87
1. Location ............................................................. 41 3. Operating range ................................................. 90
2. Components ...................................................... 42 4. Connector pin arrangement ................................ 91
3. Switches in overhead console switch 5. Removal and installation .................................... 92
assembly ........................................................... 43
DIGITAL CLOCK ..................................... 96
4. Removal and installation of overhead console
switch ................................................................ 50
CIGARETTE LIGHTER ............................ 98
SWITCH ASSEMBLY ON DRIVER’S
DOOR ARMREST .................................... 53 POWER OUTLET .................................. 100
1. Locations and functions ..................................... 53
2. Switch arrangement and appearance ................. 54 HORN (INCLUDING THEFT WARNING
3. Power window operations ................................... 55 HORN) ................................................... 103
4. Circuit diagram of power window ........................ 56
1. Location ........................................................... 103
5. Central door lock/unlock switch ......................... 58
2. Electrical wiring diagram of horn ...................... 104
6. Removal and installation of power window
3. STICS control for theft deterrent mode ............. 105
switch ................................................................ 64
4. Removal and installation .................................. 110
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2 8510
SWITCH ARRANGEMENT
Outside Rearview Mirror Folding Switch HDC Switch
To fold the outside rearview mirrors, press When this button is pressed once, HDC is ready for use. The
the switch. To unfold the mirrors, press it green HDC indicator comes on the instrument panel. When
again. the button is pressed again, HDC is deactivated and the
indicator goes off. (Refer to ABS/ESP section.)
Tailgate Glass and Out
side Rearview Mirror
Heated Glass Switch
Press this switch to turn
on the tailgate and out-
side rearview mirror
defogger. It will operate
for about 12 minutes.
ESP OFF Switch
TRIP Switch Windshield Heated Glass
If you press the ESP OFF switch,
To choose a desired driving dis- Switch
the ESP function stops and the
tance display mode, press the Press this switch to turn on the
indicator lamp in instrument
switch: Changing sequence: windshield heated glass. It will
panel comes on. Press this
ODO - TRIP A - TRIP B - ODO operate for about 12 minutes.
switch again to resume the ESP
function. At this time, the indica-
tor lamp goes out.
Seat Position Memory Switch
The position memory is available
for up to three drivers. Each driver
can set his/ her own driver’s seat
and outside rearview mirrors’ posi-
tions and it will be separately stored
in the integrated computer. If some-
body has moved the seat, the
memory positions can be recalled
automatically by pressing the posi-
tion button.
Driver’s Power Window Switch
Driver can controls all door
windows (Open/Close/Lock/
Unlock) and doors (Lock/
Unlock) with this switch unit.
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8510 3
Additional Functions of Multifunction Switch
EL
Washer fluid will be sprayed Auto Washer Switch
onto the rear window glass once When the front wiper switch
during rear wiper operation. is off and this switch is
pressed, washer fluid will
STICS
Rear wiper operation be sprayed and the wiper
will automatically operate 4
Front wiper operation range times. Then, the fluid will
(move the wiper lever up/down) be sprayed again and the
IMMO
wiper will automatically
operate 3 times.
Front Wiper and Washer Coupled
SPWM
Operation
Pull the lever briefly (below 0.6
seconds): One wiping cycle
Auto light position Washer fluid will be sprayed onto Pull and hold the lever for more than
the rear window glass and the
CLUSTER
0.6 seconds: Three wiping cycles
wiper will also operate once. with washer spray
Sun roof switch
S/W
Main room lamp switch
AV
Room lamp Room lamp
WIPER
operating switch operating switch
R / SENSOR
PAS
LAMP
T/C Control Switch
Audio Remote Control Switch
S / ROOF
Driver’s Seat POWER
Warmer Switch
MODE MUTE
S E AT
Passenger’s Seat
Warmer Switch SEEK VOL
SEEK VOL
A / CRUISE
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CENTER FASCIA & BEZEL SWITCH ASSEMBLY
1. LOCATION
The center fascia switch consists of hazard switch bezel assembly, T/C control switch and seat warmer switch.
Center Fascia Assembly
[Front View] [Rear View]
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8510 5
2. SWITCH ARRANGEMENT
EL
Tailgate glass and out- HDC switch
side rearview mirror
STICS
heated glass switch
IMMO
SPWM
CLUSTER
Windshield heated glass TRIP switch
switch
S/W
Hazard switch
AV
WIPER
R / SENSOR
T/C Control Switch
PAS
Driver’s Seat Warmer
Switch
LAMP
Passenger’s Seat
S / ROOF
Warmer Switch
S E AT
A / CRUISE
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3. FUNCTIONS
HDC Switch
When you press the HDC switch, the green HDC indicator comes on,
and when the HDC operates, the green HDC indictor blinks with 0.5
second of interval.
NOTICE
The HDC system is an automatic descent control device that allows • The G sensor in sensor cluster
measures the actual road
the vehicle to automatically decelerate to about 7 km/h by 0.1G, on
steepness. However, it may
steep roads (slope level exceeding 10%) through a separately installed recognize a sharp turn or rough
switch operation. When the vehicle speed reaches below 7 km/h (refer road as a downhill road with a
to the information below), the HDC automatically terminates the slope level exceeding 10%, and
operation. the HDC may operate.
Tailgate Glass & Outside Rearview Mirror
Heated Glass Switch
1. Press this switch to turn on the tailgate
and outside rearview mirror heated glass.
It will operate for about 12 minutes.
2. Press the switch again to stop the
operation.
Hazard Switch 3. This switch is designed to defrost and defog
on tailgate glass and outside rearview
mirrors.
4. The heated glass will operate for about 6
minutes when the switch is pressed again
within 10 minutes after completion of its
first operation cycle.
5. The indicators in the switch come on when
in use.
TRIP Switch
To choose a desired driving distance display mode, press the Windshield Heated Glass Switch
switch: Changing sequence: ODO - TRIP A - TRIP B - ODO
This switch is designed to defrost and defog on
TRIP A/B display will be initialized to 0 km when the dis-
windshield.
tance of an individual trip exceeds 999.9 km. If you press
and hold the reset button for more than one second in TRIP 1. Press this switch to turn on the windshield
A or TRIP B mode, the trip ODO meter resets to zero. heated glass. It will operate for about 12 minutes.
2. Press the switch again to stop the operation.
TRIP A Unit: 0.0 ~ 999.9 km 3. The indicators in the switch come on when in
use.
TRIP B Unit: 0.0 ~ 999.9 km
ODO Unit: 0 ~ 999999 km
CHANGED BY
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8510 7
EL
STICS
IMMO
T/C Control Switch
Choose a proper mode according to the road conditions.
SPWM
4WD 4WD 4WD
HIGH LOW CHECK
This indicator blinks This indicator blinks This warning light
CLUSTER
during mode changes during mode changes comes on when
to 4 H mode, then goes to 4 L mode, then goes the 4WD system is
off after completion of off after completion of defective.
mode change. mode change.
S/W
Driver’s Seat Warmer Switch
AV
WIPER
Passenger’s Seat Warmer Switch
R / SENSOR
PAS
LAMP
Headlight Leveling Switch
S / ROOF
S E AT
A / CRUISE
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8 8510
4. SWITCHES IN HAZARD & BEZEL SWITCH ASSEMBLY
HDC Switch
Overview
HDC switch is a Push & Self Return type switch and connected to ABS/ESP HECU terminal. This switch has an
illumination lamp connected to the tail lamp circuit.
ABS/ESP HECU
9
4 1
HDC Switch
5 2
ON OFF
1(B)
2(GND)
3(IND)
4(ILL+)
5(ILL-)
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8510 9
EL
Operation of HDC Indicator Controller
This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/
STICS
OFF).
The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC
switch is a push & self return type switch – when you press it once, it starts to operate and when you press it again,
IMMO
it stops the operation.
HDC Indicator HDC Warning Lamp
Green Red
SPWM
HDC Operation Mode
HDC HDC
CLUSTER
Initial ignition ON (From hence, this signifies operation mode ON
after the engine starts. Even when HDC switch is ON, if the OFF (goes off after
ignition is OFF, HDC operation stops automatically.) 1.8 seconds)
S/W
Not available HDC switch OFF OFF OFF
HDC system error OFF ON
Stand-by HDC switch ON ON OFF
AV
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating
requirements are not met.
In operation HDC system is operating.
WIPER
Blinking (0.5 second of
OFF
interval)
The HDC switch is turned ON, and the operating requirements are met. HDC is operating with
R / SENSOR
operating sound.
System High brake system HDC stand-by mode OFF Blinking
overheat temperature
HDC is operating Alternate blinking of green and red lamp
(over 350°C)
(0.5 second of interval)
PAS
Too high brake system temperature
(over 450°C) OFF ON
LAMP
There is no specific temperature sensor in the system, but a programmed logic inside the HECU
predicts the temperature based on the operating numbers and conditions of HDC (HDC cannot be
operated).
S / ROOF
NOTICE
• Basically, the brake system’s basic functions can work even when there are problems with the HDC system.
As given in the table above, the HDC warning lamp comes on when:
S E AT
1) Initial ignition ON
2) HDC system error occurs
3) Brake system overheat
A / CRUISE
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HDC (Hill Descent Control) System Operating Conditions
1. When HDC switch is turned ON and
2. Gearshift lever position (Forward/Reverse) and
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in neutral position).
Automatic transmission: operates in any position except P (parking) or N (neutral) positions.
NOTICE
• The vehicles with manual transmission do not have a separate device or switch that detects the 1st gear. It
only detects the forward/reverse driving direction of the vehicle through backup lamp switch and neutral switch,
and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, though the HDC also
operates in 2nd gear position, is because the engine may turn off during the HDC operation process. You may
face a very dangerous situation if the engine turns off at a steep hill.
• The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. For manual
transmission equipped vehicle, HDC system should operated only in 1st gear.
3. When not depressing the accelerator pedal or brake pedal. and
4. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode). and
NOTE
• The vehicle speed given in step (3) varies according to the vehicle driving mode, and the speed ranges by the
vehicle driving mode and condition are as follows.
1) Speed available in HDC mode (slope)
2H/4H mode: vehicle speed below 50 km/h (operation slope level: 10%, termination slope
Forward level: when it reaches 8%)
driving 4L mode: vehicle speed below 25 km/h (operation slope level: 10%, termination slope
level: when it reaches 5%)
2H/4H mode: vehicle speed below 50 km/h (operation slope level: 8%, termination slope
Reverse level: when it reaches 5%)
driving 4L mode: vehicle speed below 25 km/h (operation slope level: 8%, termination slope level:
when it reaches 4%)
2) HDC target speed in 2H/4H mode
(The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches 7
km/h, but is converted to the stand-by mode. When the vehicle speed increases again as a result of the
increase of the road steepness, etc., the HDC goes into operation.)
Forward driving: 7 km/h
Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission)
3) HDC target speed in 4L mode
Forward and reverse driving: 3 km/h
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8510 11
EL
5. Vehicle position control function in ESP and HBA function are not in operation: and
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP
STICS
function is in operation, HDC operation is overridden.
IMMO
6. Slope level exceeds 10%.
When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed value given in step (4).
SPWM
When the slope level is between 10% and 20% during the HDC operation
When depressing the accelerator pedal or brake pedal, HDC system is changed to stand-by mode. When
depressing the accelerator pedal again, HDC starts its operation again. Therefore, drivers can control the vehicle
CLUSTER
speed to a desired level by operating the accelerator pedal.
When the slope level exceeds 20% during the HDC operation
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the brake
S/W
pedal, HDC continues its operation and the braking power is increased.
In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition
due to HDC operation.
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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12 8510
HDC (Hill Descent Control) System Non-Operation Conditions
1. When HDC switch is turned OFF or
2. Gearshift lever has passed neutral (N) position. or
NOTICE
• Vehicle with the manual transmission: Sensing at the neutral switch
• Vehicle with the automatic transmission: Sensing at the selector lever unit
3. When the vehicle speed is out of the specified values. or
4. When the ESP related functions, e.g. vehicle position control, or
HBA, ARP is activated during HDC operation.
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP
function is in operation, HDC operation is overridden.
5. When the internal temperature of HDC system goes over 350°C or
due to long downhill driving on a steep hill with HDC operated.
There is no specific temperature sensor in the system, but a programmed logic inside the HECU predicts the
temperature based on the operating numbers and conditions of HDC.
NOTICE
• The red HDC warning lamp blinks when the internal temperature goes over 350°C. When it reaches 450°C,
the HDC warning lamp comes on. The HDC can be operated in the range even where the HDC warning lamp
blinks.
6. When the slope level is below 10%
When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed condition given in step
(4).
When the slope level is between 10% and 20% during the HDC operation
When depressing the accelerator pedal or brake pedal, HDC system is changed to stand-by mode. When
depressing the accelerator pedal again, HDC starts its operation again. Therefore, drivers can control the vehicle
speed to a desired level by operating the accelerator pedal.
When the slope level exceeds 20% during the HDC operation
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the brake
pedal, HDC continues its operation and the braking power is increased.
In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition
due to HDC operation.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8510 13
Tailgate/Outside Rearview Mirror Heated Glass Switch
EL
Overview
Tailgate/Outside rearview mirror heated glass switch is a Push & Self Return type switch.
STICS
1. The outside rearview mirror & tailgate glass defogger operates for approx. 12 minutes when pressing this switch
while the ignition switch is turned on.
2. It stops when pressing the switch again during its operation.
IMMO
3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6
minutes.
4. It stops when the ignition switch is turned to “OFF”.
SPWM
CLUSTER
S/W
AV
WIPER
T/LP
REPLAY RR DEFOGGER SW
R / SENSOR
STICS GND
U
IND
ILL+ ILL-
PAS
ON OFF
1(U) LAMP
S / ROOF
2(GND)
3(IND)
4(ILL+)
S E AT
5(ILL-)
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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14 8510
Timing Chart
ON
IGN2 SW
OFF
HIGH
ALT “L”
LOW
Tailgate glass/
ON
Outside rearview
mirror heated
OFF
glass switch
ON
Defogger relay
OFF
T1 T1 T1 T2 T3 T1
ALT “L” = 9 V ± 1 V T1: 12 min. T2: within 10 min T3: 6 min ON: IGN2
(Key ON) & ALT = ON
OFF: IGN2 (Key ON) or ALT = OFF
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 15
Windshield Heated Glass Switch
EL
Overview
Windshield heated glass switch is a Push & Self Return type switch.
STICS
1. The windshield defogger operates for approx. 12 minutes when pressing this switch while the ignition switch is
turned on.
2. It stops when pressing the switch again during its operation.
IMMO
3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6
minutes.
4. It stops when the ignition switch is turned to “OFF”.
SPWM
CLUSTER
S/W
AV
WIPER
T/LP
RR DEFOGGER SW
R / SENSOR
REPLAY
STICS GND
U
IND
ILL+ ILL-
PAS
LAMP
ON OFF
1(U)
S / ROOF
2(GND)
3(IND)
S E AT
4(ILL+)
5(ILL-)
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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16 8510
Timing Chart
ON
IGN2 SW
OFF
HIGH
ALT “L”
LOW
ON
Windshield
defogger SW OFF
ON
Defogger Relay
OFF
T1 T1 T1 T2 T3 T1
ALT “L” = 9 V ± 1 V T1: 12 min. T2: within 10 min. T3: 6 min. ON: IGN2
(Key ON) & ALT = ON
OFF: IGN2 (Key ON) or ALT = OFF
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8510 17
TRIP Switch
EL
Overview
Trip switch is a Push & Self Return type switch.
STICS
To choose a desired driving distance display mode, Unit: 0.0 ~ 999.9 km
TRIP A
press the switch: Changing sequence: ODO - TRIP A
IMMO
- TRIP B - ODO
TRIP A/B display will be initialized to 0 km when the
distance of an individual trip exceeds 999.9 km. If you TRIP B Unit: 0.0 ~ 999.9 km
press and hold the reset button for more than one sec-
SPWM
ond in TRIP A or TRIP B mode, the trip ODO meter re-
sets to zero. ODO Unit: 0 ~ 999999 km
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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18 8510
Hazard Switch
Overview
Hazard switch is connected to the turn signal lamp circuit.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 19
5. CENTER FASCIA SWITCH BEZEL ASSEMBLY
EL
T/C Control Switch
STICS
Overview
T/C control switch is the rotary type switch with steps and the switch operation is recognized by TCCU. This switch
has an illumination lamp connected to the tail lamp circuit.
IMMO
TCCU
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
TAIL LAMP GND
CAUTIONS
• There could be mechanical noises and shocks during • To shift from “4L” into another mode or vice versa, stop LAMP
mode changes. However, these are normal conditions the vehicle and depress the brake pedal before any
S / ROOF
due to mode changing operations. shift.
• Use only the 2H mode on a normal paved surface. Do • If the “4WD CHECK” warning light stays on, have the
not drive your vehicle in the “4H” or “4L” position on 4WD system checked.
paved road surfaces. Doing so will result in damages • When cornering a curved road in 4WD LOW or 4WD
S E AT
to the drive train. HIGH drive mode, there could be some mechanical
• Driving in a 4 wheel mode on a normal paved surface shocks and resistances in vehicle’s drive train. These
will cause unwanted noises, premature wear of tires, are normal conditions due to internal resistance in drive
A / CRUISE
or increased fuel consumption. train when the 4WD LOW is properly working. To avoid
damages to the drive train, do not drive your vehicle
with excessively high speed in sharply curved road.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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20 8510
Seat Warmer Switch
Overview
Seat warmer switch is Push lock type switch. When the seat warmer switch is operated, the seat cushion and
seatback gets warm. If the temperature of seat surface gets 40 ± 5°C, the thermistor cuts or connects the power to
heated wire to maintain the temperature to the specified level. The is no control switch and unit to control the
temperature of the seat surface temperature.
NOTE
• The temperature of seat surface should be increased over 20°C within 3 minutes after turning on the switch
while a person (height: 175 ± 5 cm, weight: 75 ± 5 kg) occupies the seat.
CAUTIONS
• Do not place anything sharp on the seat.
• When cleaning the seats, do not use organic solvents such as benzene or thinner.
• Do not use this function when the engine is not running. The battery could be discharged.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 21
6. REMOVAL AND INSTALLATION OF HAZARD & BEZEL SWITCH
EL
ASSEMBLY
Preceding Works: Disconnect the negative battery cable.
STICS
Location
Tailgate glass & outside rearview
IMMO
mirror heated glass switch
SPWM
HDC switch
Hazard warning
switch
CLUSTER
Windshield heated
glass switch
TRIP switch
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
T/C control switch
S / ROOF
S E AT
Driver’s seat warmer switch
A / CRUISE
Passenger’s seat warmer switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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22 8510
Removal and Installation
1. Remove the RH panel from the center fascia panel and unscrew three screws from the center fascia panel.
2. Disconnect the switch connectors and remove the
center fascia panel assembly.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 23
3. Remove the hazard switch bezel assembly and miscellaneous switch assembly from the removed center fascia
panel.
EL
Front View Rear View
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
Remove Three Mounting Screws Remove Four Mounting Screws
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
24 8510
4. Remove each switch from the hazard switch bezel assembly.
Front View Side View Rear View
1) Remove the round cover and switches.
2) Remove the hazard switch mounting bracket and remove the hazard switch.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 25
5. Remove each switch from the miscellaneous switch assembly.
EL
Front View Rear View Side View
STICS
IMMO
SPWM
CLUSTER
S/W
Driver’s Seat
T/C Control Switch
Warmer Switch
AV
WIPER
R / SENSOR
PAS
LAMP
Passenger’s Seat
Warmer Switch
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
26 8510
Center Fascia Panel
Digital clock
Tailgate glass &
outside rearview mirror
heated glass switch
HDC switch
Windshield
TRIP switch heated glass
switch
Hazard warning
switch
T/C control
switch
Driver’s seat
warmer
switch
Passenger’s
seat warmer
switch
Headlight
leveling
switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8510 27
OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
EL
1. LOCATION
STICS
Outside rearview mirror switch bezel assembly consists of outside rearview mirror folding switch, ESP OFF switch
and rear fog lamp switch (regional option).
IMMO
Rear fog lamp
SPWM
switch
CLUSTER
S/W
Front View of Outside Rearview Mirror Bezel Panel
AV
WIPER
R / SENSOR
PAS
Rear View of Outside Rearview Mirror Bezel Panel
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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28 8510
2. SWITCH ARRANGEMENT
Outside Rearview Mirror Folding Switch
ESP OFF Switch
Outside Rearview Mirror Angle Adjusting Switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 29
3. SWITCHES IN OUTSIDE REARVIEW MIRROR SWITCH BEZEL AS-
EL
SEMBLY
Outside Rearview Mirror Folding and Adjusting Switch
STICS
Overview
Outside rearview mirror folding switch is Self return type switch and outside rearview mirror control switch is Seesaw
IMMO
& Self return type switch.
The outside rearview mirrors folding/unfolding function is not available when the vehicle speed is over 3 km/h. You
can fold and unfold the mirros for 30 seconds after ignition OFF. Do not fold or unfold the outside rearview mirrors
SPWM
manually. It may cause a malfunction of the mirror folding system.
To fold the outside rearview
CLUSTER
mirrors, press the switch. To
unfold the mirrors, press it
again.
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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30 8510
The outside rearview mirrors can be folded and unfolded within 30 ± 6 seconds even after turning off the ignition
switch. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is
extended 13 seconds when pressing the switch again.
Timing Chart
ON
IGN SW
OFF
P/W TIME ON
RELAY OFF T2
T3 T3
FOLDING ON
SW OFF
T1
FOLDING
UNFOLDING
T
T1
T: T < T1, T1: 13 ± 3 sec, T2: 30 ± 6 sec, T3: 1 Sec ± 0.1 sec
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 31
Electrical Wiring Diagrams
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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32 8510
ESP OFF switch
Overview
ESP OFF switch is Self return type switch.
ESP OFF Switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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ESP System Cancellation Using the ESP OFF Switch
EL
When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be
cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the
ESP warning lamp on the instrument panel comes on.
STICS
The detailed operation procedures are as follows:
1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
IMMO
3. The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx.
150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately
when the ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by
SPWM
pressing the ESP switch for over 150 ms, the TCS system (including ABD function) is turned off. And the ABS
system is still operated.
Resuming the ESP System by Using the ESP OFF Switch
CLUSTER
The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch
is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
S/W
1. The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms.
2. The switch returns to normal position when the OFF switch is released.
3. The ESP system will be resumed after approx. 150 ms.
AV
PUSH RELEASE PUSH
RELEASE
350 ms
WIPER
HI
ESP operation Disabled
LO range
R / SENSOR
150 ms 150 ms
ON
ESP function
PAS
(including TCS)
OFF
150 ms
150 ms
LAMP
ON
ESP warning lamp
OFF
S / ROOF
NOTICE
• When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when
S E AT
ignition switch is turned on again.
• When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
• The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the
A / CRUISE
ESP OFF mode and the ESP warning lamp will not be changed.
• When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system
will not be turned on.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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34 8510
ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds
to warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is
operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds.
ON
ESP operation
(including TCS)
OFF
175 ms
ON
ESP warning lamp
OFF
175 ms
Min. 4 times
ESP OFF Switch Monitoring
When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds, the ESP unit determines
it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 10
seconds. However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and
then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP
unit resets the ESP OFF switch for approx. 3.5 seconds.
Push Release
Detect
HI failure
ESP operation
LO
10 3.5
sec sec
Return to switch signal Reset to normal condition
ON
ESP function
(including TCS)
OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
ON
ESP warning lamp
OFF
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 35
EL
ESP Warning Lamp Operation Depending on System Conditions
STICS
The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function)
is working.
Warning Lamp Controls
IMMO
Vehicle yaw
ABS W/L ESP W/L ABS ASR ABD
control
Initial start (for 1.8 sec) ON ON NO NO NO NO
SPWM
BLINKS WHEN
Normal mode OFF OK OK OK OK
ESP OPERATION
ESP fault OFF ON OK NO NO NO
ABS fault
CLUSTER
ON ON NO NO NO NO
System fault ON ON NO NO NO NO
Low batt. voltage ON ON NO NO NO NO
High battery voltage ON ON NO NO NO NO
S/W
High brake pad temp. OFF ON OK NO NO NO
ESP-OFF mode OFF ON OK NO NO OK
Entering diag. mode ON ON NO NO NO NO
AV
NOTICE
WIPER
• When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compen-
sate the vehicle stability (posture) during ESP operation.
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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36 8510
4. REMOVAL AND INSTALLATION
Preceding Works: Disconnect the negative battery cable.
Location
Outside rearview mirror folding
switch
Outside rearview mirror angle
adjusting switch
ESP OFF switch
Rear fog lamp switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 37
Removal and Installation
EL
1. Remove the center fascia panel and unscrew four screws on the meter cluster fascia panel.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
2. Disconnect the connector from the outside rearview mirror switch bezel assembly and remove the meter cluster
fascia panel.
R / SENSOR
PAS
LAMP
S / ROOF
NOTE
S E AT
• To make the operation easier, move down the
steering wheel.
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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38 8510
3. Remove the switch assembly from the removed meter cluster fascia panel.
Front View
Rear View
4. Remove the round cover on the switch assembly.
Round cover
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 39
5. Remove each switch from the outside rearview mirror switch bezel assembly.
EL
Switch Assembly
STICS
Remove the switch bracket.
IMMO
SPWM
CLUSTER
S/W
ESP OFF Switch Outside Rearview Mirror Adjusting Switch
AV
WIPER
R / SENSOR
PAS
Outside Rearview Mirror Folding Switch
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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40 8510
Meter Cluster Fascia Panel
Round cover
Outside rearview Outside
mirror adjusting rearview mirror
switch bracket folding switch
Fog lamp switch
ESP switch
Outside rearview
mirror adjusting switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 41
OVERHEAD CONSOLE SWITCH
EL
1. LOCATION Main room lamp switch
STICS
Front/center room lamps are
turned on when pressing in this
switch. They are turned off when
pressing in this switch again.
IMMO
Sunroof switch
SPWM
Driver’s spot switch
The driver’s room lamp
comes on if you depress
CLUSTER
Passenger’s spot switch
the spot switch (A). The passenger’s room lamp
comes on if you depress the
spot switch (B).
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
Luggage Room Lamp Center Room Lamp
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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42 8510
2. COMPONENTS
Front Room Lamp (Overhead Console Lamp)
Sun roof switch Overhead console case
Main room lamp
switch
Interior light switch
Center Room Lamp and Luggage Room Lamp
Center Room Lamp Luggage Room Lamp
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 43
3. SWITCHES IN OVERHEAD CONSOLE SWITCH ASSEMBLY
EL
Overview
Front room lamp switches in overhead console: Push ON/OFF type
STICS
Sunroof switch: Rotary, self return type
Main room lamp switch
IMMO
(Push ON-OFF type)
SPWM
CLUSTER
S/W
AV
WIPER
Passenger’s spot lamp Driver’s spot lamp switch
switch (Push ON-OFF type) (Push ON-OFF type)
R / SENSOR
PAS
Front room lamp
Sunroof switch connector
LAMP
connector
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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44 8510
Sunroof Switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 45
Front Room Lamp
EL
STICS
Main room lamp switch
(Push ON-OFF type)
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Passenger’s spot lamp Driver’s spot lamp switch
R / SENSOR
switch (Push ON-OFF type) (Push ON-OFF type)
1 2 3 4
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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46 8510
Room Lamp Control
The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the
center/luggage room lamp switch is at coupled operating position and the key reminder switch is OFF.
1. The front room lamp comes on when opening the door (driver’s/passenger’s/rear) and goes off automatically in 30
seconds.
2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the door within 30
seconds.
3. The decaying operation must have greater than 32 steps per one second.
4. The room lamp output should stop immediately after turning on the ignition key during decaying operation.
5. The front room lamp comes on for 30 seconds when receiving the unlock signal from the remote control key while
the door is closed.
6. The front/rear room lamp output period is extended by 30 seconds when receiving the unlock signal from the
remote control key again during output.
7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
8. The room lamp output stops immediately after receiving the lock signal from driver’s door, passenger's door and
rear doors lock switch while the driver's door, passenger's door and rear doors are closed.
DR’S OR PS’S OPEN
DOOR SW CLOSE
IGN KEY ON
REMINDER SW
OFF
RECEIVE
Tx UNLOCK
NO SIGNAL
ON
UNLOCK
OUTPUT OFF
Fr ROOM ON T1
LAMP
OFF
T4
T2 T3
T1: 30 sec. T2: 2 sec. T3: 3 sec. T4: 30 sec.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 47
Electrical Wiring Diagram of Room Lamp
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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48 8510
Sunroof Switch
Close
Open
Sunroof Sliding Operation Sunroof Tilting Operation
Open Tilt-up
To fully open the sunroof, briefly rotate the sunroof switch To tilt-up the sunroof, rotate the sunroof switch counter-
clockwise (OPEN direction) with the sunroof closed. To clockwise (CLOSE direction) with the sunroof fully
partially open the sunroof, rotate and hold the sunroof closed.
switch until it reaches at the desired position.
Tilt-down
Close
To tilt-down the sunroof, rotate the sunroof switch clock-
To fully close the sunroof, briefly rotate the sunroof switch wise (OPEN direction) with the sunroof tilted-up.
counterclockwise (CLOSE direction) with the sunroof
open. To partially close the sunroof, rotate and hold the
sunroof switch until it reaches at the desired position.
Circuit Diagram of Sunroof Switch
Sunroof switch
connector
The sunroof switch is a Self return type switch and connected to the power supply terminal and sunroof circuit. For
details, refer to “Sunroof” section.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 49
Circuit Diagram of Sunroof
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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50 8510
4. REMOVAL AND INSTALLATION OF OVERHEAD CONSOLE SWITCH
Preceding Works: Disconnect the negative battery cable.
1. Open the sunglasses box and unscrew
NOTE the mounting screws (2 EA).
• For details, refer to the “LAMP” section.
Mounting Mounting
screw screw
2. Remove the overhead console switch assembly and disconnect the connector.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 51
EL
3. Remove the front room lamp switch from the removed overhead console switch assembly.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
4. Unscrew three mounting screws and remove the sunroof switch.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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52 8510
Components
Sunroof switch
Room lamp Lamp
main switch
Lamp
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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8510 53
SWITCH ASSEMBLY ON DRIVER’S DOOR ARMREST
EL
1. LOCATIONS AND FUNCTIONS
STICS
Driver can control all door windows (Open/Close/Lock/Unlock) and doors (Lock/Unlock) power this switch unit.
Driver's door window switch has Auto down/Auto up function. The window can be controlled within 30 seconds even
after turning off the ignition switch. However, if any of front doors is opened or the Lock switch on the remote control
IMMO
key is pressed (theft deterrent mode is activated) during the delaying period, the delaying time is immediately
canceled (power window relay is deactivated).
SPWM
Door lock/unlock switch
When the door lock/unlock switch
is pressed while all doors includ-
ing the tailgate are locked, all
CLUSTER
doors will be unlocked. When the
Driver’s door window switch switch is pressed again, all doors
will be locked.
S/W
Window lock switch
If this switch is pressed, only the
main switch of driver’s door side
is operated. (Sub and RR is not
operated by pressing in the main
Rear LH door Window Switch
AV
switch)
WIPER
R / SENSOR
PAS
Passenger’s Door Window Switch
LAMP
Rear RH Door Window Switch
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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54 8510
2. SWITCH ARRANGEMENT AND APPEARANCE
Power Window Connector
Rated Current Maximum Current
Power window switch (motor operation) 10 A (operating voltage) 20 A (restricted current)
Door lock switch (actuator operation) 0.4 A (operating voltage) 0.7 A (actuator voltage)
Window lock switch (motor operation) 10 A (operating voltage) 20 A (restricted current)
Switch Assembly
Front View Rear View
Side View
Connector
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 55
3. POWER WINDOW OPERATIONS
EL
Power Window Auto-down
When the front of the switch is lightly pressed, the window
STICS
will be lowered while the switch is pressed. When pressed
to its end, the window will open automatically until it is fully
open. If you want to stop the window while automatic
lowering, lightly press the switch again or pull up the switch.
IMMO
Power window versions in this vehicle: Auto Down, Auto
Down/Up
SPWM
The circuit diagram shows the Auto Down version.
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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56 8510
4. CIRCUIT DIAGRAM OF POWER WINDOW
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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8510 57
EL
Time Lag Power Window Control
1. The power window relay output is “ON” when turning on the IGN 1 switch.
STICS
2. The power window relay output is “ON” for 30 seconds for T1 when turning off the IGN 1 switch.
The power window relay output is “OFF” when opening the driver's door or the passenger's door.
The power window relay is turned “OFF” when receiving the remote control key lock signal (armed
IMMO
mode) during its extended operation period of 30 seconds.
SPWM
ON
ING1 SW
OFF
CLUSTER
OPEN
Dr/Ps
DOOR SW CLOSE
S/W
T1 T2
ON
P/WINDOW
RELAY OFF
AV
T1: 30 sec. T2: OFF during T1 output
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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58 8510
5. CENTRAL DOOR LOCK/UNLOCK SWITCH
Switch Arrangement and Functions
This vehicle has five door lock/unlock actuators including tailgate actuator. The doors can be opened separately.
However, the door lock switch on driver’s door armrest locks/unlocks all doors with STICS control. This is a same
control type with Auto door lock function that locks the doors when the vehicle speed exceeds 50 km/h.
Door Lock/Unlock Relay
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 59
EL
Door LOCK/UNLOCK Control
STICS
Door Lock/Unlock by Door Lock Switch
1. The door lock system outputs “LOCK” for 0.5 second when positioning the driver’s or passenger’s door lock
switch to lock position.
IMMO
2. The door lock system outputs “UNLOCK” for 0.5 second when positioning the driver’s or passenger’s door lock
switch to unlock position.
3. “LOCK” or “UNLOCK” by the door lock switch is ignored when outputting the “LOCK” or “UNLOCK” by other
SPWM
functions.
4. All door lock signals are “UNLOCK” for 0.5 second just for once when receiving the “LOCK” signal within
0.5 second after closing the driver’s or passenger’s door. (with the ignition key removed)
CLUSTER
LOCK
DR DOOR
LOCK SW
UNLOCK
S/W
LOCK
PS DOOR
LOCK SW UNLOCK
AV
DR/PS OPEN
DOOR SW CLOSE
WIPER
T1 T3
LOCK ON
RELAY
R / SENSOR
OFF
T2 T4
UNLOCK ON
RELAY
OFF
PAS
T1: 0.5 sec T2: 0.5 sec T3: Within 0.5 sec T4: 0.5 sec
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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60 8510
Door Lock/Unlock by Central Door Lock Switch
1. The door lock system outputs “LOCK/UNLOCK” for 0.5 second when pressing “LOCK/UNLOCK” button on the
central door lock switch.
(However, the door lock system outputs UNLOCK signal when the front doors are locked, and vice versa.)
2. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored.
CENTRAL ON
LOCK SW
OFF
LOCK
MONITOR-
ING UNLOCK
T1
ON
LOCK
RELAY OFF
T2
UNLOCK ON
RELAY OFF
T1: 0.5 sec T2: 0.5 sec
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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8510 61
Door LOCK/UNLOCK by Remote Control Key
EL
1. The door lock system outputs “LOCK” for 0.5 second when receiving “LOCK” signal from the remote control key.
2. The door lock system outputs “UNLOCK” signal for 0.5 second when receiving “UNLOCK” signal from the remote
STICS
control key.
IMMO
LOCK
TX signal
NO SIGNAL
ESCORT
SPWM
T2
LOCK
CLUSTER
RELAY ON
OFF
S/W
UNLOCK ON
RELAY
OFF
T4
AV
ON
HORN RELAY
WIPER
OFF
T6
R / SENSOR
HAZARD ON T5 T5 T5
RELAY
OFF
T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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Auto Door Lock
1. The STICS outputs “LOCK” when the vehicle speed stays over 50 km/h.
However, it doesn't output “LOCK” when all doors are locked or failed.
2. If any of doors is unlocked after outputting “LOCK” in step 1, outputs “LOCK” up to 5 times (except step 1) with
interval of one second.
3. If any of doors is unlocked after 5 times of “LOCK” outputs, the door (driver/passenger/rear/tailgate) is regarded
as “FAIL”.
4. If the door that was regarded as fail changes (UNLOCK to LOCK) to unlock, only one “LOCK” output will be done.
5. If any door is regarded as FAIL, the auto door lock function does not work (if it is occurred when the vehicle speed
is over 50 km/h, the auto door lock output does not occur even if the vehicle speed falls below 50 km/h and
accelerates again to over 50 km/h). Nonetheless, the central door lock function works properly.
6. When the system receives “UNLOCK” signal from a door switch, it outputs five “LOCK” signals. If additional
“LOCK” signal from another door switch is detected during the period, the system outputs five “LOCK” signals for
the door.
7. The door lock system outputs “UNLOCK” automatically if the “LOCK” output conditions are established by this
function or the key is cycled (IGN1 = ON →OFF) (even when there is no “Lock” output while the vehicle speed
stays over 50 km/h under lock condition).
However, when the ignition key is turned to “OFF” position, the lock output conditions will be canceled.
8. The “FAIL” condition of the door will be erased when the ignition key is turned to “OFF” position.
ON
IGN1 SW
OFF
OVER
VEHICLE 50 km/h
SPEED
BELOW
50 km/h
DOOR UNLOCK
LOCK SW
(*1) LOCK
T1
T2
LOCK OUTPUT ON
OFF 5 time
T2 T2 T2 T2
T2: 0.5 sec
1 LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK
UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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8510 63
Electrical Wiring Diagram
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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64 8510
6. REMOVAL AND INSTALLATION OF POWER WINDOW SWITCH
Preceding Works: Disconnect the negative battery cable.
Location
Driver’s Door Power Windows Switch Passenger’s Door Power Windows Switch
Rear Door Window Switch (LH/RH)
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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8510 65
EL
Front Door (Driver’s)
1. Remove the driver’s door trim.
STICS
NOTE
• Be careful not to damage the door trim.
IMMO
• For more information, refer to the “Body” section.
SPWM
CLUSTER
Location
S/W
Inner door handle
assembly
AV
WIPER
R / SENSOR
Door trim armrest
PAS
LAMP
S / ROOF
Power Window Switch Assembly
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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2. Unscrew ten mounting screws on the inner door handle of the door trim.
3. Remove the inner door handle and the memory seat switch assembly.
Switch Assembly
Door Trim Armrest
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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8510 67
4. Remove the switch from the memory seat switch assembly.
EL
STICS
IMMO
Unscrew two mounting screws and
remove the switch.
SPWM
CLUSTER
S/W
AV
WIPER
Front View
R / SENSOR
Connector
PAS
LAMP
Side View
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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Front Door (Passenger’s)
1. Remove the passenger’s door trim.
NOTE
• Be careful not to damage the door trim.
• For more information, refer to the “Body” section.
2. Unscrew the mounting screws and remove the inner door handle and the memory seat switch assembly from the
passenger’s door trim.
Door trim armrest
Power window switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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EL
3. Remove the switch from the power window switch assembly.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Front View
R / SENSOR
Connector
PAS
LAMP
Side View
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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Rear Door Power Window Switch
1. Separate the power window switch assembly with a special tool.
2. Disconnect the switch connector and remove the switch assembly.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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8510 71
EL
3. Remove the switch.
STICS
IMMO
SPWM
CLUSTER
S/W
Front View
AV
WIPER
Connector
R / SENSOR
Side View
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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SEAT POSITION MEMORY SWITCH
1. LOCATION AND FUNCTIONS
The position memory is available for up to three drivers. Each driver can set his/ her own driver's seat, outside
rearview mirror positions and it will be separately stored in the integrated computer. If somebody has moved the
seat, the memory positions can be recalled automatically by pressing the position button.
Driver’s Seat Memory Function
STOP button
SET button
Position buttons
(1, 2, 3)
To Store the Memory Settings To Operate the Memory Settings
1. Place the selector lever in “P” (automatic transmission) 1. Press and hold the one of position buttons ( ,
or “N” (manual transmission) position, and apply the or ) for approx. 1.5 seconds.) At this
parking brake with the ignition switch “ON”. moment, the buzzer sounds once.
2. Adjust the driver’s seat and outside rearview mirrors 2. The driver's seat and the outside rearview mirrors start
to the desired positions. to move. (The memory function stops during its op-
3. Press the “SET” button. Indicating light on the but- eration when driving off the vehicle)
ton will come on. 3. Wait until they stop moving (The buzzer sounds
4. Within 5 seconds, press the button ( ), ( ) or twice).
( ) you want to set.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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2. SWITCH ARRANGEMENT
EL
The driver’s seat position memory switch is installed in door trim and its connector (4 pins) is connected to the
SPWM (Seat Position With Memory) unit.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Driver’s Seat Memory Switch
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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74 8510
3. EXPLODED VIEW
4 Memory switch cover
5 PCB assembly
1 Memory switch button
4-pin connector
3 Memory switch box
3 1 2
2 Clear lens
6 Tact switch
4 5 6 7 7 LED
4. OUTPUT VOLTAGE IN EACH SWITCH POSITION
The memory switch connector receives the position switch signal at the pin no. 1 and the resistance value and
output voltage in each switch differs from others.
The table below shows the output voltage for each switch and the supply voltage is 5 V.
Output Voltage
Function Output voltage
SET 0 ~ 100 mv
2.2K 560 330 1 1K
VCC STOP 0 ~ 100 mv
3 3K Position 1 0.12 ~ 1.36 mv
STOP
SW 3
SW 2
SW 1
SET
2 Position 2 2.12 ~ 2.59 mv
1K
LED
4
Position 3 3.4 ~ 4.15 mv
UNIT
1 2 3 4
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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74 8510
3. EXPLODED VIEW
4 Memory switch cover
5 PCB assembly
1 Memory switch button
4-pin connector
3 Memory switch box
3 1 2
2 Clear lens
6 Tact switch
4 5 6 7 7 LED
4. OUTPUT VOLTAGE IN EACH SWITCH POSITION
The memory switch connector receives the position switch signal at the pin no. 1 and the resistance value and
output voltage in each switch differs from others.
The table below shows the output voltage for each switch and the supply voltage is 5 V.
Output Voltage
Function Output voltage
SET 0 ~ 100 mv
2.2K 560 330 1 1K
VCC STOP 0 ~ 100 mv
3 3K Position 1 0.12 ~ 1.36 mv
STOP
SW 3
SW 2
SW 1
SET
2 Position 2 2.12 ~ 2.59 mv
1K
LED
4
Position 3 3.4 ~ 4.15 mv
UNIT
1 2 3 4
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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5. FUNCTIONS AND OPERATIONS
EL
NOTICE
• The position memory recall is canceled when operating the seat or the outside rearview mirrors during its
STICS
operation.
• In the vehicle equipped with automatic transmission, the position memory recall is not available when the
parking brake is released and the gear shift lever is not in "P" position.
• In the vehicle equipped with manual transmission, the position memory recall is not available when the park-
IMMO
ing brake is released.
• The memory recall is canceled if any position switch is not pressed within 5 seconds after pressing "SET"
switch.
SPWM
CLUSTER
Seat Position Memory Operation
1. To store the seat position and the outside rearview mirror position, press the SET button and, within 5 seconds,
press one of position switches. The memory setting is available up to 3 different drivers.
S/W
2. The memory set mode is only available within 5 seconds after pressing the SET button.
over 100 ms
ON
AV
MEMORY
SW OFF
Memory set Cannot memorize
mode
WIPER
over 100 ms
POSITION ON
SW
R / SENSOR
OFF
5 sec 5 sec
PAS
3. If any of the following conditions is established, the memory set mode is canceled.
1) No switch inputs within 5 seconds after pressing SET button.
LAMP
2) When adjusting the seat or outside rearview mirror positions during the memory recall operation.
3) When turning off the ignition switch.
4) When pressing the STOP button
S / ROOF
5) When the memory setting is completed.
4. The memory recall is not available when the vehicle speed is over 3 km/h or the gear shift lever is not in “P”
position with the parking brake released.
S E AT
5. The memory set can be unlimitedly renewed.
6. The stored positions are erased when disconnecting the battery cables.
7. The buzzer sounds once when the memory set mode is activated.
A / CRUISE
8. The buzzer sounds twice when the memory setting/recalling is completed.
9. The buzzer sounds three times when an error is found from the sensor during the memory recall operation.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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76 8510
Seat Memory Recall Operation
1. When pressing the position switch with the ignition switch ON, the seat and outside rearview mirrors move to the
memorized positions.
2. When pressing another position switch during previously activated memory recall operation, the newly pressed
position switch takes priority and recalls its stored positions.
3. The buzzer sounds once when a position switch is pressed.
4. If any of the following conditions is established, the memory recall function is deactivated.
1) When turning off the ignition switch.
2) When the gear shift lever is not in “P” position with the parking brake released.
3) When the parking brake is released (only for the vehicle equipped with manual transmission)
4) When the vehicle speed is over 3 km/h.
5) When pressing the STOP button during the memory recall operation.
6) When adjusting the seat or outside rearview mirrors during the memory recall operation.
5. Timing Chart
ON
IGN SW
OFF
1.5 ± 0.2 sec
ON
POS SW
OFF
1 2
time times
ON
BUZZER
OFF
Seat & Outside ON
Rearview Mirror
Manual Operation OFF
OVER 3 Km/h
Vehicle
Speed
BELOW 3 Km/h
ON
STOP
SW
OFF
ON
Recall
OFF
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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6. REMOVAL AND INSTALLATION OF SEAT POSITION MEMORY SWITCH
EL
Preceding Works: Disconnect the negative battery cable.
1. Remove the driver’s door trim.
STICS
NOTE
• For details, refer to the “Body” section.
IMMO
SPWM
CLUSTER
Location
S/W
Memory seat
switch
AV
WIPER
Speaker
R / SENSOR
PAS
Power window switch
LAMP
Memory Seat Switch
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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2. Remove the memory seat switch from the door trim.
Switch Arrangement
Memory switch cover
PCB assembly
Memory switch button
4-pin Connector
Memory switch box
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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7. ELECTRICAL DIAGRAM OF POWER SEAT & OUTSIDE REARVIEW
EL
MIRROR
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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80 8510
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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AFFECTED VIN
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AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL
EL
1. LOCATIONS AND FUNCTIONS
STICS
IMMO
SPWM
CLUSTER
S/W
AV
POWER MUTE
WIPER
Turns on and off the audio system. Stops audio output from audio system. To resume
the audio output, press the button again.
R / SENSOR
MODE
VOL
Changes the audio mode in order.
VOL
PAS
Increases or decreases
the volume.
SEEK
SEEK
In radio mode LAMP
- Press briefly: Manual searching for a station.
- Press and hold: Automatic searching for a station.
S / ROOF
In CD (DVD) player/Cassette tape mode
- Press briefly: Replay next/previous track.
- Press and hold: Move forward/backward in current tract.
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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2. COMPONENTS
The remote audio control switch is installed on the the steering wheel. Its rated voltage is 5 V and has three connectors.
Main Connector
Connector and cable
Pin No. Output voltage
31 Audio signal
32 Audio ground
33 Tail lamp power
Switch & PCB Switch & PCB
35 36 43 1 2 3 4 5 6
1 2 3 4 34 33 32 31
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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3. CIRCUIT DIAGRAM
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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84 8510
4. REMOVAL AND INSTALLATION
Preceding Works: Disconnect the negative battery cable.
1. Remove the airbag module assembly from the
steering wheel.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 85
EL
2. Unscrew mounting screws at both sides of the removed airbag module and remove the audio
remote control switch.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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MULTIFUNCTION SWITCH
1. OVERVIEW
The multifunction switch in this vehicle contains basic multifunction switch functions, Auto washer & wiper, fog lamp
switch and Auto hazard lamp switch. When serving the multifunction switch, pay particular attention not to damage
the air bag spring clock installed on the multifunction switch.
Mounted View
Front auto washer and wiper switch
When the front wiper switch is off and this
switch is pressed, washer fluid will be
sprayed and the wiper will automatically
operate 4 times. Then, the fluid will be
sprayed again and the wiper will automati-
cally operate 3 times.
Front fog lamp switch
<For detailed operation logics, refer to “STICS”>
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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2. FUNCTIONS AND OPERATIONS
EL
AUTO Light Function
STICS
AUTO
IMMO
SPWM
These senses the ambient illumination
intensity to determine the timing for turn-
ing the headlamps and tail lamps on or
CLUSTER
off automatically when the light switch is
set to “AUTO”.
S/W
AUTO Light & Rain Sensor
This senses the ambient illumina-
tion intensity to determine the timing
AV
for turning the headlamps and tail
lamps on or off automatically when
the light switch is set to “AUTO”
(integrated with rhe rain sensor). AUTO light sensor
WIPER
Emitter lens
R / SENSOR
Light Switch
Headlamp ON
PAS
Headlight, position, tail, license
plate, fog and instrument panel
lights are illuminated.
LAMP
Tail lamp ON
Position, tail, license plate,
fog and instrument panel
S / ROOF
lights are illuminated.
Automatic light ON
Headlamps and tail lamps
S E AT
automatically turn on or off
based upon the intensity of
the sunlight analyzed by the
A / CRUISE
automatic light sensor.
All lights are off.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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88 8510
Headlamp High Beam
To turn on the headlamp high beam,
push the lever towards the instrument
panel with the headlamp low beam
on. The headlamp high beam indi-
cator in instrument panel comes on
when the headlamp high beam is
turned on. Right Turn Signal Switch
Front Fog Lamp Switch
To turn on the fog lamps, turn
this switch while the tail lamps
or headlamps are turned on.
Passing
To flash the high beam, pull the
lever towards the steering
wheel and release it. The le-
ver will return to the normal
position when released. The
Left Turn Signal Switch
high beam headlights stay on
as long as you hold the lever.
Front Wiper Switch
Front Automatic Wiping Speed
MIST Control Switch
Fast: Fast interval
When moving up the wiper
Slow: Slow interval
lever, the wipers operate
once. The lever will return
to the “OFF” position when
released.
OFF
Stop the operation.
AUTO
Operates automatically ac-
cording to the vehicle speed
or amount of rain.
LO
Continuous wipe,
slow operation
HI
Continuous wipe,
fast operation
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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EL
Front Auto Washer Switch (AFW)
When the front wiper switch is off and this switch is
pressed, washer fluid will be sprayed and the wiper
STICS
will automatically operate 4 times. Then, the fluid
will be sprayed again and the wiper will automati-
Rear Washer and Wiper Switch cally operate 3 times.
When the switch is fully turned,
IMMO
washer fluid will be sprayed onto the
rear window glass and the wiper will
also operate. When the switch is
released, it will stop in the Rear
Wiper Operation mode and only the
SPWM
wiper will keep operating.
Rear Wiper Operaes
CLUSTER
Wiper and Washer Coupled Operation
Pull the lever briefly (below 0.6 seconds):
S/W
One wiping cycle
Pull and hold the lever for more than 0.6
Rear Wiper Stops seconds: Three wiping cycles with washer
spray
AV
Rear Washer and Wiper Switch
When the switch is fully turned, washer
WIPER
fluid will be sprayed onto the rear win-
dow glass and the wiper will also
operate. When the switch is released, it
will return to the “OFF” position and turn
R / SENSOR
off the wiper and washer.
When the wiper switch is in the “AUTO” position, this sensor detects the amount of rain, turns on the wiper, and
controls the intermittent wiper intervals. For details, refer to "Rain Sensor" section.
PAS
Rain & AUTO Light Sensor Wiper Switch AUTO Position
LAMP
AUTO
S / ROOF
It controls the wiping speed by de-
S E AT
tecting the amount of rain drops.
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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3. OPERATING RANGE
29
30
Airbag clock spring
Audio remote control
/Auto cruise
Steering wheel 46 44 45 48 47
angular sensor
29 Air bag (-)
30 Air bag (+)
43 Sound switch
37 ~ 42 Auto cruise
31 ~ 33 Audio remote control
44 ~ 48 Steering wheel angular sensor
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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4. CONNECTOR PIN ARRANGEMENT
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
1 EB Dimmer and passing ground
2 HL Headlamp low beam
3 HU Headlamp high beam
WIPER
4 HS(2) Passing
5 TS Tail lamp switch
6 HS(1) Headlamp switch
7 AUTO AUTO light
R / SENSOR
8 E Light/fog/hazard warning switch ground
9 TB Flasher unit power
10 TL Turn signal (LH) lamp switch
11 TR Turn signal (RH) lamp switch
12 FOG Front fog lamp switch
13 HA Hazard switch
PAS
14 LO Low wiper speed
15 HI High wiper speed
16 S Wiper stop
17 AUTO (W) Intermittent wiper
LAMP
18 INT (T) Intermittent wiper
19 INT (E) Intermittent wiper ground
20 W Front washer switch
21 IG IG
S / ROOF
22 MS Low wiper speed
23 -
24 AW AUTO washer switch
25 IGR IGR
26 RW Rear wiper
S E AT
27 RWA Rear wiper & washer
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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92 8510
5. REMOVAL AND INSTALLATION
Preceding Work: Disconnect the negative battery cable.
1. Remove the air bag module and steering wheel.
Air bag Module Assembly Steering Wheel Assembly
NOTICE
Put an installation mark on the steering wheel,
• Be careful not to drop or shock the air bag
module during removal procedures.
column shaft and nut when removing the steering
wheel. Place the steering wheel to the straight
forward direction.
Lift up the hook when disconnecting the air bag
contact coil connector (A).
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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EL
2. Remove the driver side instrument lower panel, inner bracket and lower undercover. For details, refer to the
“Body” section.
STICS
Inner
bracket
IMMO
Instrument lower panel
SPWM
CLUSTER
Lower undercover
S/W
3. Unscrew four screws from the steering column cover
and remove the upper and lower covers.
4. Unscrew four screws and remove the air bag contact
coil assembly.
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
For installation, align the steering wheel to the
installation mark and tighten the nut to the speci-
S E AT
fied tightening torque.
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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5. Remove the mounting screws (3 EA) from the steering will steering wheel sensor and the multifunction switch
(4 EA) at this moment, disconnect the connectors.
Multifunction switch
Multifunction
switch connector
Steering wheel
angular sensor Light switch
connector
Turn signal &
wiper switch
Steering wheel
angular sensor
6. Remove the steering wheel angular sensor from the re-
moved multifunction switch assembly.
Light switch Turn signal & wiper switch
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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DIGITAL CLOCK
Preceding Works: Disconnect the negative battery cable.
Digital Clock
Rated voltage: DC 12 V
Operating voltage: DC 8 V ~ DC 16 V
Time difference: ±2 sec/day (room temp.)
Current consumption:
Max. 150 mA with IGN ON
Max. 2.5 mA with IGN OFF
Display type: VFD
Brightness: 100% with Tail lamp OFF
40% with Tail lamp ON
Blinking cycle of Colon: Once per second
1. Remove the center fascia panel (refer to the
“Switch” section).
Remove the panel from bottom Disconnect the connector.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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EL
2. Disconnect the digital clock connector.
STICS
IMMO
SPWM
CLUSTER
S/W
3. Unscrew three mounting screws and remove the
digital clock from the center fascia panel.
AV
WIPER
R / SENSOR
PAS
LAMP
Digital Clock
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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CIGARETTE LIGHTER
Preceding Works: Disconnect the negative battery cable.
Cigarette Lighter
1. Remove the center console cover.
Remove the panel from bottom
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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EL
2. Disconnect the cigarette lighter connector.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
3. Remove the cigarette lighter from the cover.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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POWER OUTLET
1. Cap
2. Cap cover
3. Socket
4. Installation holder
5. Insulator
6. (+) terminal
7. (-) terminal
8. Connector
Rated voltage: over DC 12 V, Max. operating current: 10 A, Resistance: over 5 MΩ
Front Power Outlet
1. Remove the power outlet bracket from the center
console (passenger side).
2. Disconnect the power outlet connector. 3. Remove the power outlet from the bracket.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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EL
Rear Power Outlet
STICS
1. Remove the rear lower quarter panel (RH) and dis-
connect the power outlet connector.
IMMO
SPWM
CLUSTER
S/W
2. Unscrew eight screws and remove the power out-
let mounting bracket.
AV
WIPER
R / SENSOR
PAS
3. Remove the power outlet from the bracket.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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Electrical Wiring Diagram of Cigarette and Power Outlet
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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HORN (INCLUDING THEFT WARNING HORN)
EL
1. LOCATION
STICS
IMMO
SPWM
CLUSTER
S/W
AV
Horn Assembly Theft Deterrent Horn
WIPER
Connector
R / SENSOR
PAS
Horn
LAMP
Horn
S / ROOF
Horn
S E AT
A / CRUISE
Tone Connector
Connector
adjusting
screw
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
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2. ELECTRICAL WIRING DIAGRAM OF HORN
Location of horns: One at each side in engine compartment
Location of theft deterrent horn: Under the battery tray in engine compartment
The theft deterrent horn is controlled by STICS in armed mode regardless of horn relay operation.
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
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3. STICS CONTROL FOR THEFT DETERRENT MODE
EL
Functions in Theft Deterrent Mode
Definitions in theft deterrent mode
STICS
1. Door OPEN/CLOSE
Door OPEN: Any of door switches (engine hood, front doors, rear doors, tailgate) output “OPEN” signal.
Door CLOSE: All door switches (engine hood, front doors, rear doors, tailgate) output “CLOSE” signal.
IMMO
2. Door LOCK/UNLOCK
Door LOCK: Any of door lock switches (front doors, rear doors, tailgate) output “LOCK” signal.
SPWM
Door UNLOCK: All lock switches (front doors, rear doors, tailgate) output “UNLOCK” signal.
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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106 8510
Description of Theft Deterrent Function
1. Armed mode activation requirements
1) The “LOCK” output is “ON” when receiving the “LOCK” signal from transmitter while the ignition key is re-
moved 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).
2) The theft deterrent horn and hazard relay outputs are “ON” when receiving the “LOCK” signal from the remote
control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice).
3) When receiving “LOCK” signal from the remote control key while any of doors is not closed, only the “LOCK”
output can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning
flasher). At this moment, if the ignition key is in the ignition switch or the door lock switch is unlocked,
cancels the armed mode and activates the normal mode.
However, in these cases, if closing the door, the theft deterrent horn outputs once and the hazard warning
flasher outputs twice and then activates armed mode.
4) When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after
receiving “UNLOCK” signal, outputs “LOCK” and then activates armed mode (RELOCK operation). Also, at
this moment, the system outputs the theft deterrent horn and hazard warning flasher.
5) The armed mode will not be activated except above conditions.
Ex) The armed mode will not be activated when the door is locked by the ignition key.
REMOTE CON- LOCK
TROL KEY NO SIGNAL
SIGNAL UNLOCK
OPEN
ENTRANCE T5
DOOR SW CLOSE
LOCK
ENTRANCE
DOOR LOCK SW
UNLOCK
ON
DOOR LOCK
RELAY
OFF
ON
(Dr) UNLOCK
RELAY
OFF
T2 T4
T1
ON
HAZARD RELAY
OFF
ON
HORN
OFF
T3
ARMED MODE
OPERATION
STATUS
OTHERS
T1: 0.5 sec T2: 1.0 sec T3: 50 ms T4: 1.0 sec T5: 30 sec
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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8510 107
2. Armed mode cancellation requirements
1) Unlocking by remote control key or engine starting.
EL
3. Warning operation requirements
1) When opening the door in armed mode
STICS
2) When unlocking the door lock switch not by the remote control in armed mode
3) When closing and then opening the door after completion of warning (27 seconds)
IMMO
4. Warning operation
1) The theft deterrent horn and hazard warning flasher output is “ON” for 27 seconds with the interval of 1 second.
5. Warning cancellation requirements
SPWM
1) Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, PANIC, ESCORT) during
warning operation.
2) Cancels warning after 27 seconds (remaining period) while the ignition key is turned to "ON" position.
CLUSTER
3) If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is
canceled immediately and the warning buzzer stops after 27 seconds (remaining time).
6. Operation when warning is cancelled
S/W
1) The theft deterrent horn and hazard warning flasher outputs are “OFF”.
WARNING ESTABLISHED
AV
REQUIRE-
MENTS NO ESTABLISHED
WARNING ESTABLISHED
WIPER
CANCELLA-
TION NO ESTABLISHED
THEFT WARNING
R / SENSOR
DETER-
RENT ARMED
STATE NORMAL T2
ON
HAZARD
PAS
RELAY
OFF
T1
LAMP
ON
HORN
OFF
S / ROOF
T3 T3
WARNING
OPERATION
STATUS
OTHERS
S E AT
T1: 0.5 sec T2: 1.0 sec T3: 27 sec
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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108 8510
7. Operations when removing and installing the battery
Installed
Normal Armed Warning Remark
Removed
Normal Armed
Armed Ready
Armed
Warning
Warning Completion
RELOCK Ready
If the system is in armed mode while installing a battery, the horn sounds and the emergency warning lamp blinks
(Same operations with warning in armed mode).
RELOCK operation
It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the
door with remote control key, the system outputs “LOCK” signal and activates the armed mode.
PANIC Warning
1. The PANIC warning output is “ON” (theft deterrent horn) for 27 seconds when receiving the PANIC signal from the
remote control key (pressing PANIC button.
2. The PANIC warning output is “OFF” when receiving any signal from the remote control key during PANIC warning.
3. Followings are theft deterrent warnings:
1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft
deterrent.
2) The theft deterrent warning output is “ON” when the theft deterrent conditions are established during PANIC
warning (PANIC output is “OFF”).
3) The PANIC warning output is “ON” when receiving the PANIC signal from the remote control key in Armed
Ready / Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode).
4. This function operates only in armed mode.
TX SIGNAL PANIC
(REMOTE
CONTROL NO SIGNAL
KEY SIGNAL)
THEFT WARNING
DETERRENT
MODE OTHERS
T1 T1
T2
ON
HORN
OFF
T3
T1: 27 sec T2: 0.5 sec T3: 1.0 sec
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
8510 109
Electrical Wiring Diagram of Theft Warning Horn
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
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110 8510
4. REMOVAL AND INSTALLATION
Horn Assembly
Preceding Works: Disconnect the negative battery cable.
1. Disconnect the horn connector and unscrew the mounting bolt (10 mm) to remove the horn assembly.
Theft Deterrent Horn Assembly
Preceding Works: Disconnect the battery negative
cable.
1. Disconnect the theft deterrent horn connector and un-
screw the mounting bolt (10 mm) to remove the theft
warning horn assembly.
Horn Theft Warning Horn
Connector
Connector
Tone adjusting screw
CHANGED BY
SWITCHES / ELECTRIC DEVICES
EFFECTIVE DATE
KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
AV SYSTEM
8932 / 8930
TABLE OF CONTENTS
AV SYSTEM .............................................................. 2
1. AV head unit ....................................................................... 2
2. AV system configuration ..................................................... 3
3. Head unit ............................................................................. 6
4. Tuner and DSP amplifier .................................................. 13
5. Subwoofer ......................................................................... 15
6. Removal and installation of AV system ............................. 16
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2 8932
AV SYSTEM
1. AV HEAD UNIT
DVD + Cassette player: 10 speakers (center speaker, woofer speakers, tweeter speakers)
1. AV head unit
MUTE button
DVD + Cassette + Radio
DVD title
insert slot
Cassette 6.5 inch TFT LCD
tape slot
2. Tuner 3. DSP amplifier 4. DVD 6 DISC changer 5. Subwoofer
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 3
2. AV SYSTEM CONFIGURATION
EL
AV System (DVD Head Unit + DVD Changer)
STICS
Front speaker DSP Amplifier and Tuner
Front tweeter speaker
IMMO
DVD change
Radio antenna
Subwoofer module
SPWM
with built-in
Front center amplifier
speaker
Steering wheel
CLUSTER
remote control
switch
TV antenna module
AV Head Unit
S/W
Rear speaker
Rear tweeter speaker
AV
DVD, RADIO and TAPE + TV
Audio System - 6 Speakers
WIPER
Front speaker
Front tweeter speaker Rear speaker
R / SENSOR
Radio antenna
PAS
module
LAMP
Steering wheel
remote control
switch
S / ROOF
2. CD + RADIO
Audio Head Unit
1. 6 DISC changer + 6 DISC changer CD slot
TAPE + RADIO
S E AT
A / CRUISE
Tape
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 8932
DVD changer
It is installed in the center console. Audio signal of DVD changer outputs to
corresponding speakers through the cable. Video signal is transmitted to
the monitor of AV head unit.
Cable
Send
Receive
AV head unit
(with built-in 6.5” TFT LCD monitor)
Tuner
TV video data DVD slot
Sound communication line
(Bus line)
AM/FM radio antenna AMP
The heated wire and radio antenna is in-
tegrated in the tailgate glass. The antenna
transmits AM/ FM audio signals to tuner.
TV antenna AMP (LH and RH)
The glass antennas at both rear quarter glasses are to
receive TV and AM radio (quarter RH glass) signals and
transmits each 2-channel video and audio signals to
tuner. Each AMP amplifies receives TV signals and then
transmits to tuner.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 5
EL
STICS
IMMO
SPWM
Front speaker (LH)
CLUSTER
Tweeter speaker (FL)
Front speaker (RH)
S/W
Tweeter speaker (FR)
AV
Rear speaker (LH)
WIPER
Tweeter speaker (RL)
AMP (with built-in DSP)
Power AMP in the DVD system has built-in
R / SENSOR
DSP function that digitalizes sound to divide Rear speaker (RH)
and control. It amplifies sound goes to each
speaker and has function of allowing dynamic
and vivid sound.
Tweeter speaker (RR)
PAS
LAMP
Center speaker (LH)
S / ROOF
Subwoofer
(without built-in AMP)
Woofer is installed at the
S E AT
bottom of passenger’s seat.
It enforces mid-low sounds.
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 8932
3. HEAD UNIT
Functions
AV system head unit operates Radio, TV, Audio CD, DVD and Video CD.
The touch screen type 6.5” TFT LCD monitor is installed on the system.
DVD slot
Power ON/OFF, Volume control
AV replay, AV reset screen
Replay mode selection (briefly press), Current replay mode (press and hold)
Next channel (radio or TV) or next track (audio or video)
The monitor moves to parking position when turning the ignition switch to OFF position.
It moves to the preset position when turning the ignition switch to ON position again.
Display when turning on the monitor
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 7
EL
Wiring Connection
STICS
GPS connector terminal Fan
IMMO
SPWM
CLUSTER
DVD CHANGER
S/W
TUNER DSP amplifier
AV
WIPER
4 3 2 1 7 6 4 3 2 1
8 7 6 5 3 8 1 8 7 6 5
12 11 10 9 5 4 12 11 10 9
13 2 13
R / SENSOR
1. BACK UP 1. TUNER ON 1. MUTE 1. CAN-HI
2. BACK UP 2. BACK UP + 2. NAVI ON/OFF 2. -
3. VIDEO GND 3. VIDEO GND 3. NAVI Voice GND 3. Illumination (+)
PAS
4. VIDEO signal 4. VIDEO SIGNAL 4. NAVI voice 4. ACC+
5. GND 5. GND 5. GND 5. BACK UP +
6. - 6. BACK UP 6. - 6. -
LAMP
7. RESET 7. R/V VIDEO 7. RESET 7. Speed pulse
8. SPDIF GND 8. R/V GND 8. SPDIF GND 8. Reverse
9. SPDIF signal 9. SPDIF signal 9. CAN-LO
S / ROOF
10. CAN -GND 10. CAN -GND 10. -
11. CAN-HI 11. CAN-HI 11. Illumination (-)
12. CAN-LO 12. CAN-LO 12. -
13. DVDC ON 13. AMP ON 13. -
S E AT
14. GND
15. ALT D+
16. Steering wheel remote control
A / CRUISE
17. Steering wheel remote control GND
18. PARKING SENSOR
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 8932
Head Unit Wiring Connector
Tuner DSP DVD GPS
amplifier changer antenna
connector
AV SYSTEM CHANGED BY
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AFFECTED VIN
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8932 9
Usable Discs (DVD Head Unit)
EL
Following disc types can be used on the system.
STICS
Disc Type and Logo Disc Size Play Time (Max.)
approx. 133 minutes (SS/SL)
approx. 242 minutes (SS/DL)
IMMO
approx. 266 minutes (SD/SL)
DVD video approx. 484 minutes (DS/DL)
SS = Single side
SPWM
SL = Single layer
DL = Double layer
Video CD 5 inch (12 cm) Video CD spec 2.0 PCB compatible disc
CLUSTER
Audio CD 5 inch (12 cm) approx. 74 minutes
CD-R 5 inch (12 cm) Support MP3, WMA, MP3 + WMA
CD-ROM ISO / IEC 10148 (Yellow book)
S/W
DVD head unit and DVD changer cannot play following discs.
1. DVD-R
2. DVD-RAM
AV
3. DVD-ROM
4. DVD-Audio
5. CD-G
WIPER
6. Mlxed CD (Date)
7. Active Audio (Date)
R / SENSOR
8. VSD
9. Multi-section disc
10. DVD with region code other than (2), (3) or (6)
Bulk CD-R or CD-RW that their quality cannot be secured may not be recognized.
PAS
Region code (2, 3, 6)
DVD player and DVD video disc has designated region code. If region code is different, the disc cannot be played.
LAMP
This system cannot play the disc if the region code is other than (2), (3) or (6).
Region Code: 2 →Middle East, 3 →General Area, 6 →China
S / ROOF
PBC (Play back control) - compatible video CD
This system can play PBC - compatible video CD.
Typical audio and video CDs can be played and PBC-compatible video CD uses recorded PBC menu on the disc to
S E AT
play the CD interactively.
Double layer DVD video disc
A / CRUISE
When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer
causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system.
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 8932
Functions of AV Unit
Display 6.5 Wide TFT LCD
Aspect ratio: Full/16x9/4:3
Touch screen key: Full touch
TV Diversity Antenna with high reception performance
Automatic station selection
Radio Automatic station selection
Station memory: 8 channels in each band (AM1, AM2, FM1, FM2)
DVD Automatic replay: Audio CD, DVD title
Playback control supported
Sub woofer speakers
DVD Changer (option) Install 6-discs in the magazine
Automatic replay: Audio CD, DVD title
Others DSP function, Equalizer function
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 11
Function Settings on Touch Panel (Example)
EL
Setting/Adjustment
STICS
2 5
IMMO
1 6
SPWM
3 8
CLUSTER
4 7
S/W
9 10 11 12 14 13
AV
WIPER
1 Equalizer setting: Preset value, Treble/Medium/Bass
2 Balance setting
R / SENSOR
3 DSP (Digital Signal Process) setting
4 Volume control of sub woofer and center speakers
5 Screen setting: brightness, colors, gamma, contrast
PAS
6 Aspect ratio setting: 16:9/4:3/ZOOM1/ZOOM2
7 Initial screen setting of DVD title: sound, caption etc.
LAMP
8 Turning OFF the screen (however, audio system still operates)
9 Turning OFF/ON the button operating sound (“Beep” sound)
S / ROOF
10 Turning OFF/ON the speakers
11 Turning OFF/ON the PBC function
S E AT
12 Turning OFF/ON the driving restriction
13 Moves to replay mode out from SET/ADJUSTMENT mode
A / CRUISE
14 Audio OFF
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 8932
Basic display
Turn the AV system ON.
Press “MODE” button to select a mode.
When pressing “RADIO” section on the screen, the
“RADIO” mode screen is displayed.
DSP control
Selecting an acoustic perspective
Press “DSP SETTING” button in “SET/ADJ” screen and
select one acoustic perspective (HALL, STADIUM,
THEATER, CHURCH, CLUB).
Press “OFF” button to cancel the DSP function.
EQ control
Adjusting the sound according to the music genre
Press “EQ SETTING” button in “SET/ADJ” screen and
adjust the sound.
To adjust the tone, press “TONE” button.
The tone can be adjusted by BAS/MID/TRE bars on
the screen.
BALANCE/POSITION control
Adjusting the sound according to the seated position.
Press “BAL/POS” button in “SET/ADJ” screen and
select a seat position (driver’s, passenger’s, rear seats,
all seats) on the screen (Position setting).
To, adjust the balance, use the arrows on the screen.
* BALANCE function and POSITION function cannot
be used simultaneously.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 13
4. TUNER AND DSP AMPLIFIER
EL
Front View
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Side View Rear View
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 8932
1. MUTE 8. S/PDIF GND 1. SPEAKER FR + 10. SPEAKER RR -
2. - 9. S/PDIF signal 2. SPEAKER RR + 11. SPEAKER WOOFER 1-
3. - 10. CAN -GND 3. WPEAKER WOOFER 1+ 12. SPEAKER WOOFER 2-
4. - 11. CAN-HI 4. SPEAKER WOOFER 2+ 13. GND
5. GND 12. CAN-LO 5. BACK UP 14. GND
6. - 13. ACC ON 6. BACK UP 15. SPEAKER CENTER +
7. RESET 7. SPEAKER RL + 16. SPEAKER CENTER -
4 3 2 1
8 7 6 5 8. SPEAKER FL + 17. SPEAKER RL -
12 11 10 9 9. SPEAKER FR - 18. SPEAKER FL -
13
Audio Terminal
White: AUDIO L channel output
Red: AUDIO R channel output
Rearview camera
(not applied)
Tuner wiring
7 6
3 8 1
5 4
2
1. ACC ON
2. B+
3. VIDEO GND
4. VIDEO SIG
5. CHASSIS GND
6. B+ (BACKUP)
7. RV VIDEO
8. RV GND
TV antenna module LH CAN Wiring
Radio antenna module
TV antenna module RH
CAN-HI
ANT-ON
CAN-LO
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 15
5. SUBWOOFER
EL
STICS
IMMO
SPWM
CLUSTER
Passenger’s
Seat
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
1 2 3 4
1. Subwoofer_1 (+)
S / ROOF
2. Subwoofer_1 (–)
3. Subwoofer_2 (+)
4. Subwoofer_2 (–)
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 8932
6. REMOVAL AND INSTALLATION OF AV SYSTEM
AV Head Unit
Preceding Work: 1. Remove the center panel.
2. Remove the center fascia panel.
1. Unscrew four mounting screws from the AV head unit and AC control panel.
2. Disconnect the head unit harness connector and the
fiber optic cable.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 17
EL
3. Remove the AV head unit.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 8932
Tuner Assembly
Preceding Work: Remove the negative battery cable.
1. Remove the service cover from the right lower quar-
ter panel in the luggage compartment.
2. Remove the OVM tool box.
3. Unscrew eight mounting nuts from the tuner/amplifier deck assembly.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 19
4. Disconnect the harness connectors and the fiber optic cable from the tuner/amplifier deck assembly.
EL
1) Fiber optic cable and connectors for DSP amplifier
STICS
Fiber optic cable
IMMO
SPWM
Connectors
When removed
CLUSTER
2) Radio antenna cable, TV antenna cables and connectors
S/W
Radio antenna
cable
AV
WIPER
TV antenna
R / SENSOR
cables
NOTICE
PAS
• Use the pliers as shown in figure when disconnecting the TV antenna cables.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 8932
5. Unscrew the mounting screws from the removed tuner/amplifier deck assembly and remove the tuner assembly.
NOTE
• Match the colors when inserting TV antenna cables
into the connections.
AV SYSTEM CHANGED BY
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AFFECTED VIN
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8932 21
DSP Amplifier
EL
Preceding Work: Disconnect the negative battery cable.
1. Disconnect the connectors and the fiber optic cable from the AV head unit. Unscrew the mounting bolts and
STICS
remove the amplifier assembly.
IMMO
SPWM
CLUSTER
Check if the fiber optic cable is defective. If the red
S/W
lamp comes on when the ignition switch is in “ON”
position, the system receives the normal input
signal. Unscrew six mounting bolts (10 mm) from the
amplifier.
AV
WIPER
R / SENSOR
PAS
LAMP
Output signal from AV head unit
S / ROOF
S E AT
Optical Main connectors
sensor input
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 8932
DVD Changer
Preceding Work: Disconnect the negative battery cable.
DVD changer box
1. Remove the glove box lamp and release the locking device to lower the glove box.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 23
2. Remove the side instrument panel in passenger compartment and unscrew the mounting screws for lower
instrument panel.
EL
STICS
IMMO
SPWM
CLUSTER
3. Unscrew the inner and outer mounting screws from the glove box and remove the lower instrument panel.
S/W
AV
WIPER
R / SENSOR
PAS
4. Open the DVD changer cover. Unscrew the mounting screws and remove the inner cover and outer cover.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 8932
5. Remove the DVD changer cover.
6. Unscrew the mounting screws from the DVD changer.
7. Disconnect the fiber optic cable from the DVD changer through the opening of lower instrument panel.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 25
8. Slide out the DVD changer and unscrew the mounting screws from the DVD changer case.
EL
STICS
IMMO
SPWM
CLUSTER
9. Disconnect the harness connector and pull out the DVD changer with case.
S/W
AV
WIPER
R / SENSOR
PAS
10. Separate the case from the DVD changer.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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26 8932
DVD Changer
Front view
Connector
Fiber optic cable
terminal
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 27
Speaker
EL
Front (Center Speaker)
Preceding Work: Disconnect the negative battery
STICS
cable.
1. Remove the center speaker cover.
IMMO
SPWM
CLUSTER
2. Unscrew the mounting screws and disconnect the harness connector to remove the center speaker.
S/W
AV
WIPER
R / SENSOR
Components
PAS
LAMP
S / ROOF
Speaker cover Speaker assembly
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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28 8932
Sun Woofer Speaker
Preceding Work: Disconnect the negative battery cable and remove the passenger’s seat.
1. Disconnect the harness connector and unscrew the mounting nuts to remove the sub woofer speaker.
Components
Connection Volume control lever
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 29
Front/Rear Door Speakers
EL
Preceding Work: Disconnect the negative battery cable and remove the door trim.
1. Disconnect the harness connector from the speaker.
STICS
IMMO
SPWM
CLUSTER
2. Unscrew four mounting screws and disconnect the harness connector to remove the speakers from the front
S/W
and rear doors.
AV
WIPER
R / SENSOR
PAS
Front door speaker 40W/2Ω
LAMP
Rear door speaker 40W/2Ω
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 8932
Door Tweeter Speaker
Preceding Work: Disconnect the negative battery cable and remove the door trim. (For details, refer to
“Body” section.)
1. Unscrew the mounting screws (2 EA) from the removed door trim and remove the speaker.
AV SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8932 31
TV Antenna Module (LH/RH) Radio Antenna Module
EL
Preceding Work: Remove the rear quarter up- Preceding Works:
per panel. 1. Remove the luggage room lamp assembly.
STICS
2. Remove the third row and fourth row seats.
3. Remove the rear quarter upper and lower trims.
4. Remove the rear headlining.
IMMO
SPWM
CLUSTER
S/W
AV
Radio antenna module
WIPER
R / SENSOR
TV antenna module
TV antenna module
TV antenna connection at tuner Radio antenna connection at tuner PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AV SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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WIPER & WASHER SYSTEM
7810 / 7820 / 7830
TABLE OF CONTENTS
WIPER AND WASHER SYSTEM ............................. 2
1. System layout of wiper and washer (with rain sensor) ....... 4
2. Wiper & washer related function and specification ............ 6
3. Wiper and washer system related circuit .......................... 11
4. Removal and installation .................................................. 12
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2 7810
WIPER AND WASHER SYSTEM
The wiper and washer system are controlled by STICS according to driver’s wiper switch operation. And the
detection of rain drops by rain sensor is transmitted to STICS as the signal for wiper system control.
The characteristics of the wiper and washer system including basic functions of manual wiper are as follows.
1. Wiper function coupled auto washer
Auto washer operation When the front wiper switch is off and this switch is
Rear wiper/washer switch (press) pressed, washer fluid will be sprayed and the wiper
operation location will automatically operate 4 times. Then, the fluid will
be sprayed again and the wiper will automatically op-
erate 3 times.
2. Integrated auto light sensor in rain sensor unit
The rain sensor unit is installed on a proper location
to detect the rain drops and the illumination intensity.
To control the system, the sensed values of rain sen-
Rain sensor sor and auto light sensor are sent to pin no. 63 in
emitter lens STICS unit.
Light receiving
area of auto
light sensor
3. Rear washer fluid supply system
There is no separate washer fluid reservoir for the rear washer system in this vehicle. The rear washer system
uses the front washer fluid reservoir. Because of this, the washer hose is supposed to be long between front
reservoir tank and rear washer nozzle. To avoid being damaged or interfered while in assembling the vehicle,
the rear washer hose is fixed on headlining with silicone
Rear washer hose and roof wiring harness are
fixed at the headlining section with silicone.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 3
EL
4. Fluidic washer nozzle
STICS
Fluidic Washer Nozzle is applied to the front washer spray system in this vehicle. The inside of nozzle is de-
signed to utilize the fluidic movement.
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
This is a shape of the inside of nozzle. It is designed to change the spraying direction continuously according to
the spraying time (fan-shape). The figure below shows the changes of spraying direction according to the
spraying time.
R / SENSOR
PAS
Whirlwind
Washer fluid outlet
Passage
LAMP
Counter-current
Spray passage
S / ROOF
S E AT
Washer fluid inlet
A / CRUISE
It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle.
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 7810
1. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR)
Auto washer switch
Multifunction Wiper and Washer Switch Rain Sensor Unit
When the front wiper switch
is off and this switch is
pressed, washer fluid will be
sprayed and the wiper will
automatically operate 4
times. Then, the fluid will
be sprayed again and the
wiper will automatically op-
erate 3 times.
The rain sensor unit is integrated
into the auto light sensor. It sends
Front Nozzle Assembly the amount of rain drops to STICS.
Front nozzle
The washer nozzles are in-
stalled at both sides of engine
hood. The spraying pattern is
specially designed to improve
the spraying performance.
Washer Reservoir Tank Assembly
Washer reservoir tank
There is no separate washer res-
ervoir tank for the rear washer fluid.
The rear washer system uses the
front washer fluid reservoir.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 5
EL
Rear washer hose mounting
Rear Washer Hose Mounting
There is no separate washer fluid
STICS
reservoir for the rear washer system
in this vehicle. The rear washer sys-
tem uses the front washer fluid
reservoir. Because of this, the
IMMO
washer hose is supposed to be long
between front reservoir tank and
rear washer nozzle. To avoid being
damaged or interfered while in as-
SPWM
sembling the vehicle, the rear
washer hose is fixed on headlining
with silicone.
CLUSTER
S/W
Rear Washer Nozzle and Check Valve
Rear nozzle assembly
AV
WIPER
R / SENSOR
Check valve
Rear nozzle
PAS
LAMP
STICS
S / ROOF
S E AT
STICS
A / CRUISE
STICS receives the rain sensing data
from the rain sensor and controls the
wiper and washer systems.
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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2. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION
Wiper and Washer Fluid Switch Operation
Wiper speed control switch
When turning up the switch, the wiper When turning to FAST, wiping speed gets faster and
MIST operates once. When releasing the when turing to SLOW, wiping speed gets slower.
switch, the pointers return back to “OFF”
position.
OFF
Wiping stops
AUTO
Wiper speed controls automatically
according to the vehicle speed or
amount of rain (rain sensing wiper).
LO
Wiping speed gets slower when placing the
pointer at the “LO” positon.
Wiping speed gets faster when
placing the pointer at the “HI” HI
positon.
Auto washer switch
If pressing the switch when the wiper
switch turns to the “OFF” position,
Wiper and washer fluid for rear wind- washer fluid is sprayed once and
shield operate simultaneously wiper operates 4 times.
After a while, washer fluid is sprayed
one more and the wiper operates 3
Only wiper times.
operates
Wiper washer fluid coupled function
Pull the lever briefly (below 0.6 seconds)
: Only wiper operates
Pull and hold the lever for more than 0.6 seconds
Wiping stops : Wiper operates 3 times
Washer fluid coupled operation
Washer fluid for rear
windshield operates once.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 7
STICS Control Logic Related to Wiper and Washer
EL
Wiper MIST and Front Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds after turning “ON” the washer switch for 0.1 ~ 0.59 seconds with the
STICS
ignition key “ON”, and it is turned off when the parking terminal is turned off.
IMMO
ON
KEY IN
& IGN2 SW
OFF
T2
SPWM
ON
WASHER SW
OFF
CLUSTER
ON
WIPER MOTOR
PARKING
OFF
S/W
ON T1
WIPER
LOW RELAY
OFF
AV
T1: 0.3 T2: 0.1 ~ 0.59 sec
WIPER
2. The wiper relay is turned on 0.3 seconds after turning “ON” the washer switch over 0.6 seconds with the ignition
key “ON”, and it is turned on three times immediately after turning off the washer switch.
R / SENSOR
ON
KEY IN
PAS
& IGN2 SW
OFF
T2
ON
LAMP
WASHER SW
OFF
T3
S / ROOF
ON
WIPER MOTOR
PARKING
OFF
T1
ON
S E AT
WIPER
LOW RELAY
OFF
A / CRUISE
T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 7810
3. When the washer switch is ON for more than 0.6 seconds during the wiper operation by the INT switch, the
operation in step (2) is performed. When it is ON for a certain period of time (0.1 to 0.59 seconds), the operation
in step (1) is performed.
ON
KEY IN
& IGN2 SW
OFF
ON
INT SW
OFF
T2 T3
ON
WASHER SW
OFF
T4
ON
WIPER MOTOR
PARKING
OFF
ON T1 T1
WIPER
LOW RELAY
OFF T5
T5
T1: within 0.3 sec T2: 0.1 ~ 0.59 sec T3: over 0.6 sec T4: 3 cycles T5: pause
Rear Washer Motor Control
1. When the rear washer switch is turn on with the ignition switch “ON”, the rear washer motor relay output is
activated from the time when the rear washer switch is turned on, and it is deactivated when the rear washer
switch is turned off.
2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer)
is in operation.
ON
KEY IN
& IGN2 SW
OFF
ON
REAR
WASHER SW
OFF
ON
REAR WASHER
MOTOR RELAY
OFF
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 9
Auto Washer and Wiper Switch (AFW)
EL
1. When the auto washer switch is turned on with the ignition switch “ON” and the INT switch “OFF”, the washer
motor output is activated for 1 second. If the system recognizes this output, the wiper relay output is activated
STICS
during 4 cycles and the washer motor output is activated for 1 second. Then, the wiper relay output is deactivated
after 3 cycles.
IMMO
ON
KEY IN
SPWM
& IGN2 SW
OFF
AUTO
CLUSTER
INT SW AUTO
OFF
T1
ON
AUTO WASHER
SWITH ON
OFF
S/W
T6
ON
WASHER MOTOR T2 T2
OPERATING
AV
OFF
WIPER
ON
WASHER MOTOR
PARKING
OFF
T4 T5
R / SENSOR
ON T3
WIPER
LOW RELAY
OFF
PAS
T1: over 100 ms T2: 1.0 ± 0.1 sec T3: within 0.3 sec T4: 4 cycles T5: 3 cycles T6: 0.5 ± 0.1 sec
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7810
2. The auto washer switch output is overridden during the washer coupled wiper operation.
3. The auto washer switch input is overridden during the auto washer coupled wiper operation.
4. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT
wiper operation.
5. When the auto INT switch input is received during the auto washer operation, the auto washer operation stops
and the auto INT operation is activated.
ON
KEY IN & IGN2
SW
OFF
INT AUTO ON
WITCH OFF
ON
FRONT
WASHER SW T1
OFF
ON
AUTO T2
WASHER SW
OFF
ON
WASHER MOTOR
OUTPUT OFF
ON
WIPER MOTOR
PARKING
OFF
T4
ON
WIPER LOW T3 T3
RELAY
OFF
T1: over 0.6 sec T2: over 100 ms T3: within 0.3 sec T4: 3 cycles
Priorities in Washer Operations
1. The rear washer switch input is overridden during the front washer operation.
2. The rear washer switch input is overridden during the auto washer and wiper (AFW) operation.
3. The front washer switch input is overridden during the rear washer operation.
4. The auto washer switch input is overridden during the rear washer operation.
5. The front washer switch input is overridden during the auto washer and wiper (AFW) operation.
6. The auto washer switch input is overridden during the front washer operation.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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3. WIPER AND WASHER SYSTEM RELATED CIRCUIT
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
STICS
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7810
4. REMOVAL AND INSTALLATION
Front Wiper Assembly
Preceding Work: Disconnect the negative battery cable.
1. Disconnect the mounting nut from the wiper blade assembly and then unscrew the mounting nut.
At this moment, perform the work with the engine hood removed or opened.
Wiper blade assembly
2. Close the engine hood and then remove the wiper blade asembly.
Driver side
Passenger side
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 13
3. Remove the cowl mounting molding.
EL
STICS
IMMO
SPWM
4. Remove the cowl mounting clip and then disconnect the cowl from the left (driver side).
CLUSTER
Driver side cowl
Passenger side cowl
S/W
AV
WIPER
5. Disconnect the wiper motor connector (1) and front windshield heated wire connector (2) connected to the wiper
link assembly.
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7810
6. Unscrew the mounting nut (10 mm - 3EA) from the wiper link assembly.
7. Unscrew the mounting nut (10 mm - 1EA) and bolts (8 mm - 3EA) from the removed wiper linkage assembly and
then remove the wiper motor.
Mark the adjustment mark before
unscrewing the wiper motor cen-
ter mounting nut.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 15
Layout of Front Wiper Assembly
EL
Linkage aseembly
STICS
Wiper motor
Passenger seat cowl Driver seat cowl
IMMO
SPWM
CLUSTER
S/W
Wiper blade (Passenger side) Wiper blade (driver side)
AV
Wiper Motor Assembly
Connector
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 7810
Rear Wiper Assembly
Preceding Work: Disconnection of negative battery cable
1. Disconnect the mounting screws from the each tailgate trim part.
4. Upper mounting screw on the tailgate lower trim
1. Remove the tailgate upper trim.
5. Lower mounting screw on the 3. Disconnect the mounting 2. Remove the inner tailgate
tailgate lower trim clip underside the tailgate. handle.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 17
2. Disconnect the mounting screw and then remove trim and vinyl cover from the tailgate underside.
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Mounting Piece Position
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 7810
3. Close the tailgate and then remove the wiper blade assembly.
Open the cap Unscrew the nut (10 mm - 1EA)
4. Remove the wiper blade and then unscrew the wiper motor cap and the mounting nut (17 mm - 1EA).
Disconnect the cap Disconnect the nut
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 19
5. Open the tailgate, unscrew the connector and mounting bolts (10 mm - 2EA) and then remove the wiper motor.
EL
STICS
IMMO
SPWM
CLUSTER
Rear Wiper Assembly
Passenger seat wiper blade assembly
S/W
Splasher ring-tailgate wiper
AV
Mounting nut
WIPER
Spacer ring-tailgate wiper
R / SENSOR
PAS
Front
Rear wiper motor and linkage assembly
LAMP
S / ROOF
S E AT
A / CRUISE
Inside Rear
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 7810
Reservoir Tank and Nozzle Assembly
Preceding Work:
1. Disconnect the battery negative cable.
2. Remove the tire.
Reservoir Tank
1. Remove the front wheel house cover.
2. Remove the washer motor from the reservoir tank and then drain the washer fluid.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 21
3. Disconnect the washer motor connector from the reservoir tank. Be careful not to contact the washer fluid or
foreign materials into the motor and connector after disconnecting.
EL
STICS
IMMO
SPWM
CLUSTER
4. Disconnect the washer hose connecting the reservoir tank and nozzle from the reservoir tank wheel house.
Unscrew the washer reservoir tank mounting bolt and then remove it.
S/W
Disconnect Wiper Motor Connector Upper Mounting Bolt
AV
WIPER
Be careful not to damage
when disconnecting
R / SENSOR
Rear hose
PAS
Front hose
LAMP
Connection Hose on the
Wheel House Side S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 7810
Nozzle and Hose
Front Side
1. Open the engine hood and then disconnect the hose.
Nozzle Side Connection Point
2. Remove the nozzle by pressing the right/left nozzle located at the engine hood as shown in the figure.
WIPER & WASHER SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7810 23
Rear Side
EL
Preceding Work:
1. Remove the tailgate spoiler.
STICS
2. Remove the tailgate upper trim.
1. Open the tailgate and then disconnect the nozzle hose
from the check valve.
IMMO
SPWM
CLUSTER
S/W
2. Close the tailgate and then remove the nozzle with a flat blade screwdriver or special tool.
AV
WIPER
R / SENSOR
PAS
NOTICE
LAMP
• Be careful not to damage the body and the nozzle.
S / ROOF
S E AT
A / CRUISE
CHANGED BY WIPER & WASHER SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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RAIN SENSOR UNIT
(WITH AUTO LIGHT SENSOR)
8610
TABLE OF CONTENTS
RAIN SENSING SYSTEM
(WITH AUTO LIGHT SENSOR) ............................... 2
1. System layout and overview .................................................. 2
2. Rain sensor operation ........................................................... 4
3. Rain sensor related circuit ....................................................5
4. Functions and specifications of rain sensing wiper ...............6
5. Operation mode of rain sensing wiper system .................... 11
6. Functions and checks of rain sensor .................................. 12
7. Diagnosis procedures ......................................................... 14
8. Trouble shooting ................................................................. 15
9. Electrical wiring diagram ..................................................... 18
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RAIN SENSING SYSTEM (WITH AUTO LIGHT SENSOR)
1. SYSTEM LAYOUT AND OVERVIEW
The rain sensing wiper unit in this vehicle doesn’t control the wiper directly. The rain sensing unit detects the amount
of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
Rain sensing unit Multifunction wiper switch:
(Auto light sensor integrated type) AUTO and sensitivity control
A sensor that emits infrared rays through LED and AUTO: Wiper operates automatically by rain sensor
then detects the amount of rain drops by receiving FAST <-------> SLOW: Auto delay/Auto speed control.
reflected rays against sensing section (rain sensor A position that can control sensitivity against rains
mounting section on the windshield) with photodiode. on the windshield and transmits wiping demand sig-
The auto light sensor is Integrated into the rain sensor. nal accordingly.
(refer to the below picture)
Emitter lens
The LED emits the infrared rays is located
at bottom and the lens guides the infrared
rays to target point.
Horizon autolight sensor
Auto light sensor
Vertical autolight sensor
Enlarged auto light sensor
section
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8610 3
EL
STICS
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.
IMMO
Wiper relay (HI) Wiper relay (LO)
SPWM
STICS Engine compart-
ment fuse box
CLUSTER
S/W
AV
Rear washer Front washer
relay relay
WIPER
R / SENSOR
Auto Light Sensor And Rain Sensor Coupled Control
1. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on
automatically.
PAS
2. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the
rain, the wiper sensitivity is automatically increased by one level. (For example, the AUTO wiper switch is at the
3rd level, but the wiper operates at the 4th level.)
LAMP
S / ROOF
S E AT
A / CRUISE
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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). The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the
amount of rain drops by receiving reflected rays with photodiode.
The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into
the rain sensor.
Followings are the components and functions of the rain sensor unit
Rain Sensor Unit (Including Cover)
Rear Front
PCB Assembly and Emitter Lens
Emitter Lens
The LED emits the infra-
red rays is located at bot-
Unit Latch tom and the lens guides
the infrared rays to target
point.
Rain Sensor
Unit
Housing and PCB
Housing and Receiver Lens
Enlarged auto Light Receiver Lens
Sensor Section The receiver lens
guides the reflected in-
frared rays from wind-
shield to photodiode.
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3. RAIN SENSOR RELATED CIRCUIT
EL
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;
the No. 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor.
STICS
No. 2 terminal sends the wiper and washer operation information such as
washer operation mode,
IMMO
wiper relay, or
multifunction wiper switch is in AUTO wiper position
to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode.
SPWM
Multifunction Switch
CLUSTER
S/W
INT auto switch
AV
IGN 1
Auto washer switch
WIPER
Washer switch
R / SENSOR
Volume (resistance)
Rain
RK STICS
Sensor
NC
PAS
Parking Figure
control
Low speed
LAMP
High speed
S / ROOF
S E AT
A / CRUISE
Wiper Motor
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4. FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING WIPER
Power-up Reminder Wiper
1. When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of
communication with rain sensor.
2. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the wiper switch to
“AUTO” position from any other positions (while the ignition key is in “ON” position).
When the wiper switch is turned to “ON” position again from other positions, the system Drives the wiper motor
through LOW relay one cycle only when the rain sensor detects the “Rain Detected” signal.
ON
KEY IN &
IGN2
OFF
ON
INT AUTO
SW
OFF
Rain
RAIN detected
SENSOR to
RKSTICS OFF
T1 T1 T1
ON
WIPER
LOW RELAY
OFF
T1: 1 cycle
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Washer Coupled Wiper in the Rain Sensing Mode
STICS
1. The washer coupled wiper is operated when receiving the washer switch input with the ignition switch “ON” and
the auto INT switch “ON” in rain sensing mode. At this moment, the communication with the rain sensor is
overridden. However, the washer switch input is overridden during continuous operation.
2. The operation data is sent to the rain sensor even during the washer coupled wiper operation.
IMMO
ON
KEY IN &
SPWM
IGN2
OFF
INT AUTO AUTO
SW OFF
CLUSTER
ON
WASHER
SW
OFF
ON
S/W
WIPER
P-POS
OFF
ON
WIPER
AV
LOW RELAY
OFF
Ignore Rain
RAIN
WIPER
SENSOR
Rain Sensing
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
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Rain Sensing Sensitivity Control
1. The wiper relay (LO) 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” position, and the wiper
motor is in “Parked” position). However, the wiper motor can be operated only when the rain sensor detects the
“Rain Detected” signal.
* If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
Rain
RAIN Detected
SENSOR to
RKSTICS OFF
T1 T1 T1
ON
WIPER
LOW RELAY
OFF
T1 : 1 cycle
Auto Light Control
1. Only when the auto light switch is in “AUTO” position, control the tail lamp and headlamp by communicating with
the rain sensor (while the ignition key is in “ON” position).
ON
KEY IGN2
SW OFF
AUTO LIGHT AUTO
SW OFF
LIGHT
RAIN SENSOR TAIL
Data OFF
ON
TAIL LAMP
RELAY OFF
ON
HEAD LAMP
RELAY
OFF
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Wiper Operation When the Wiper Parking Terminal Is Grounded
EL
1. 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 INT switch is in “ON” position).
STICS
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
WIPER
IMMO
PARKING
GND (Stop)
SPWM
SENSITIVITY SEN.2
CLUSTER
S/W
RKSTICS
to RAIN
SENSOR
AV
WIPER
2. When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current
sensitivity for 2 seconds, then continuously outputs the parking signal of current sensitivity (while the ignition key
R / SENSOR
is in “ON” position and the INT switch is in “ON” position).
* The wiper motor runs only when the rain sensor requires.
IGN (Operation)
PAS
WIPER
PARKING
GND (Stop)
LAMP
SENSITIVITY SEN.2
S / ROOF
S E AT
RKSTICS
to RAIN
A / CRUISE
SENSOR
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Defective Rain Sensor
1. 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 (while the ignition key is in “ON” position
and the INT switch is in “ON” position).
SENSITIVITY
R_RSFAULT
RAIN
SENSOR to
RKSTICS
OTHERS
T1
ON
WIPER
LOW RELAY
OFF
T1 : cycle
2. The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3
from 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in “ON” position
and the INT switch is in “ON” position).
SENSITIVITY
RAIN
SENSOR to S_COMMFAULT
RKSTICS
OFF
T1
ON
WIPER
LOW RELAY
OFF
T1 : cycle
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5. OPERATION MODE OF RAIN SENSING WIPER SYSTEM
EL
Driver Switch Positions Operation Mode
MIST As long as the switch is in MIST position, the wiper motor operates in
STICS
(Transmits the manual operation low speed. The wiper blade returns to parking position if the switch re-
mode signal to sensor) turns to the original position. The rain sensor ignores inputs during park-
ing signal periods.
IMMO
OFF The wiper motor rotates in low speed until it returns to parking position.
(Transmits the manual operation When the system is in manual mode, the sensitivity of sensor will be
mode signal to sensor) set to 2 (AUTO 2) internally. By doing so, immediate wiping with proper
intervals is possible when a driver sets the system from OFF to AUTO.
SPWM
AUTO 1 SLOW Auto delay/auto speed control. Low sensitivity against rains on windshield.
(low sensitivity) When the switch is in AUTO position, the sensor transmits the wiping
request signal to STICS.
CLUSTER
AUTO 2 Auto delay/auto speed control. Low/medium sensitivity against rains on
(low/med sensitivity) windshield.
AUTO 3 Auto delay/auto speed control. Medium sensitivity against rains on
S/W
(medium sensitivity) windshield.
AUTO 4 Auto delay/auto speed control. Medium/high sensitivity against rains on
(med/hi sensitivity) windshield.
AV
AUTO 5 Auto delay/auto speed control. High sensitivity against rains on
(high sensitivity) FAST windshield.
WIPER
LOW SPEED The wiper motor rotates continuously in low speed of approx. 45 rev./
(transmits the manual operation minute at B+=13.5V (in the normal battery voltage). The rain sensor
mode signal to sensor) operations are same as in MIST.
R / SENSOR
HI SPEED The wiper motor rotates continuously in high speed of approx. 70 rev./
(transmits the manual operation mode minute at B+=13.5V (in the normal battery voltage). The rain sensor
signal to sensor) operations are same as in MIST.
PAS
1. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on
automatically.
LAMP
2. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the
rain, the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level,
but the wiper operates at the 4th level.)
S / ROOF
S E AT
A / CRUISE
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6. FUNCTIONS AND CHECKS OF RAIN SENSOR
Front Windshield Glass and Coupler Attachment
Check the outer windshield surface of sensing area for wear, damage and scratch. The sensor is able to compen-
sate the wear up to a specific level. Check the coupler attached surface of windshield for porosity. If the porosity
exists, the sensor cannot function properly.
NOTE
• If the installed wiper brushes are out of specification (size and length), the rain sensing area cannot be fully
wiped.
• In this case, the rain sensor’s sensitivity could be decreased and the wipers are not properly operated.
Recognition of AUTO Mode
1. When the engine is started with the multifunction wiper switch “AUTO” position, the wiper operates one cycle to
remind a driver that the wiper switch is in “AUTO” position.
2. When the wiper switch is turned to “AUTO” from OFF, the wiper operates one cycle.
It always operates one cycle for the initial operation, however, the wiper does not operate afterwards to prevent
the wiper blade wear if not raining when turning the wiper switch to “AUTO” from “OFF”.
However, the wiper operates up to 5 minutes after rain stops.
3. If this function does not occur, check No. 2 terminal on the rain sensor. If any defective cannot be found, check
the wiper relay (LOW) for defective.
NOTE
• As described, the STICS recognizes the wiper switch “AUTO” position. If there are not any problem, go to
diagnosis mode in STICS and check the terminal that receives signal from wiper and communication lines
between rain sensor unit and STICS.
Instant Wipe Function
When the variable resistance knob on the multifunction wiper switch is turned by each 1 stage from low sensitivity
(S mark) to high sensitivity (F mark), the wiper operates one cycle. And, the wiper also operates during raining up to
5 minutes after rain stops.
NOTE
• When the variable resistance knob is rotated by 4 stage from 0 stage without stoping, the wiper operates one
cycle. The wiper operates one cycle when changing the wiping stage (0 →1, 1 →2, 2 →3).
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Washer Coupled Wiper Function
Check the washer coupled wiper operation by pressing the washer switch.
STICS
Irregular Operations (Abrupt Operations)
IMMO
1. Check the sensor for coming off.
2. Check the rain sensor cover installation.
3. Check that the customer is familiar to how to control the wiper sensitivity.
SPWM
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. And, also check whether the sensitivity is selected to the highest value
of FAST (stage 5).
4. Check the wiper blade for wear.
CLUSTER
If the wiper blade cannot wipe the glass uniformly and clearly, the irregular operations could be occurred. And, the
wiper blade should be replaced with new one with same specifications.
S/W
Self Diagnosis
AV
Poor Sensing
WIPER
Position the wiper switch to “AUTO” position and rotate the variable resistance knob from “FAST” toward
“SLOW” by one step. At this moment, check if the wiper operates one cycle.
R / SENSOR
The wiper operates when the windshield glass is excessively worn or scratched, the windshield glass is not cleared
wiped due to using worn wiper blade or different wiper blade, or the rain sensor is not improperly installed.
PAS
Poor Sensor
LAMP
Rotate the variable resistance knob toward “SLOW” by 1 more steps. At this moment, check if the wiper
operates one cycle. S / ROOF
If the wiper operates, this causes when the sensor is defective or the sensor has the communication problem with
STICS.
S E AT
A / CRUISE
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7. DIAGNOSIS PROCEDURES
1. Check the glass and coupler for proper installation.
2. Check the power up function.
3. Check the instant wipe function.
4. Check the washer coupled wiper function.
5. Check the high speed.
6. Find the causes for irregular operations (abrupt operations).
7. Check the system with self-diagnosis function.
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8. TROUBLE SHOOTING
EL
Symptom 1. The wiper does not operate one cycle when turning the multifunction wiper switch to
the “AUTO” from the “OFF” position or starting the engine while the wiper switch is in
STICS
the “AUTO” position.
1. When starting the engine with the multifunction wiper switch in the “AUTO” position, the wiper operates one cycle
to remind a driver that the wiper switch is in the “AUTO” position.
IMMO
2. When the wiper switch is turned to “AUTO” from “OFF”, the wiper operates one cycle. It always operates one
cycle for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if
not raining when turning the wiper switch to “AUTO” from “OFF”. However, the wiper operates up to 5 minutes
after rain stops. If this function does not occur, check No. 8 pin. If the pin is normal, check the wiper relay related
SPWM
terminals in the ICM box.
CLUSTER
Symptom 2. It rains but the system does not work in the “AUTO” position.
1. Check whether the multifunction wiper switch is in the “AUTO” position.
2. Check the power to the sensor. Check the conditions of the pin 3 (Ground) and the pin 4 (IGN).
3. Check the wiper relay for defective.
S/W
Symptom 3. The wiper operates 3 or 4 times at high speed abruptly.
AV
Check whether the variable resistance knob on the multifunction wiper switch is set in “FAST”. The “FAST” is the
highest stage of the sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the
low sensitivity.
WIPER
Symptom 4. The wiper operates continuously even on the dry glass.
R / SENSOR
1. Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could
be occurred. In this case, replace the wiper blade with a new one.
2. Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the
highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the
PAS
low sensitivity.
Symptom 5. The wiper does not operate at high speed even in heavy rain.
Check if the wiper operates at high speed when grounding pin 1 and pin 2. LAMP
S / ROOF
Symptom 6. The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in “FAST" or "SLOW”.
S E AT
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.
A / CRUISE
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Removal and Installation of Rain Sensor
1. Pry off the rain sensor cover by inserting a small flat-blade screwdriver into service holes at both sides (refer to picture).
NOTICE
• Otherwise, the cover or rain sensor components could be damaged.
Service
hole
2. Disconnect the connector from the rain sensor unit located at the front windshield glass and then lift up the rain
sensor unit to disconnect from the glass.
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Components of the Rain Sensor Unit
EL
PCB Assembly and Emitter Lens
STICS
Auto light sensor
IMMO
SPWM
CLUSTER
Emitter lens
S/W
Housing and Receiver Lens
AV
WIPER
R / SENSOR
Receiver lens
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
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9. ELECTRICAL WIRING DIAGRAM
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PARKING AID SYSTEM
8790
TABLE OF CONTENTS
PARKING AID SYSTEM (PAS) ................................ 2
1. System configuration ............................................................2
2. Component specifications ..................................................... 4
3. Alarm interval ........................................................................5
4. Troubleshooting of sensor ..................................................... 5
5. Cautions on parking aid system ............................................ 6
6. Removal and installation of parking aid .................................7
7. Circuit diagram .................................................................... 12
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PARKING AID SYSTEM (PAS)
1. SYSTEM CONFIGURATION
The parking aid device is integrated in the rear bumper and it uses three Piezoelectric elements to measure vertical
and horizontal distance to obstacles.
When placing the gear selector lever to “R” position, the designated unit (PAS unit) activates the parking aid sensors
to measure the distance to obstacles.
Gear Selector Lever (R Position)
PAS buzzer STICS
PAS piezoelectric buzzer
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EL
Left/Right/Center Sensor Location
STICS
IMMO
SPWM
CLUSTER
Center
sensor
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
Parking Aid Unit
S / ROOF
Left sensor
S E AT
Center
sensor
Connector
A / CRUISE
Right sensor
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2. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific
interval and detects the reflected signals from obstacles while the gear selector lever is in “R” position. The number
of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This supplemen-
tary system is to secure the safety distance for parking.
Descriptions Value Descriptions Value
Rated voltage DC 12 V Operating temperature -30°C ~ +80°C
Operating voltage DC 9 V ~ 16 V Storage temperature -40°C ~ +85°C
Current Unit Below 100 mA Relative humidity 95% RH max
consumption Sensor Below 20 mA (each) Weight Unit 160g ± 10g max
Sensor insulating resistance Over 5 MW Sensor 70g ± 10g max
Parking Aid Unit
Detecting type: Super sonic wave
Detecting distance: 25 cm ~ 120 cm (distance between sensor
and obstacle)
Parking Aid Sensor
1. Type: Piezo ceramic element
2. Frequency: 40 KHz ± 2 KHz
3. Detecting range (13.5 V)
1) Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm
2) Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm
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3. ALARM INTERVAL
EL
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
STICS
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage L, C, R sensor Interval (msec) Remark
IMMO
1 81 ~ 120 cm “Beep ”
SPWM
“Beep -,
2 51 ~ 80 cm Beep -,
CLUSTER
Beep -”
3 25 ~ 50 cm “Beep ”
S/W
AV
4. TROUBLESHOOTING OF SENSOR
When the power is applied (gear selector lever is in “R” position), the sensor will be diagnosed once. If found any
WIPER
failure due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on
failed sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer
sounds only for 65 ms.
R / SENSOR
1. Whenever the power is applied, the diagnosis mode is
initiated.
2. Sensor failure conditions (conditions for warning beep
due to failure)
PAS
1) Sensor failure conditions (conditions for warning beep
due to failure)
2) Open in sending circuit
LAMP
3) Open in receiving circuit
4) Open in power circuit (+, -) Back sonar (RH) Back sonar (LH)
Back sonar (center)
S / ROOF
Warning beeps
When failed
S E AT
(also when diagnosing the unit)
A / CRUISE
When normal
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3. ALARM INTERVAL
EL
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
STICS
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage L, C, R sensor Interval (msec) Remark
IMMO
1 81 ~ 120 cm “Beep ”
SPWM
“Beep -,
2 51 ~ 80 cm Beep -,
CLUSTER
Beep -”
3 25 ~ 50 cm “Beep ”
S/W
AV
4. TROUBLESHOOTING OF SENSOR
When the power is applied (gear selector lever is in “R” position), the sensor will be diagnosed once. If found any
WIPER
failure due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on
failed sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer
sounds only for 65 ms.
R / SENSOR
1. Whenever the power is applied, the diagnosis mode is
initiated.
2. Sensor failure conditions (conditions for warning beep
due to failure)
PAS
1) Sensor failure conditions (conditions for warning beep
due to failure)
2) Open in sending circuit
LAMP
3) Open in receiving circuit
4) Open in power circuit (+, -) Back sonar (RH) Back sonar (LH)
Back sonar (center)
S / ROOF
Warning beeps
When failed
S E AT
(also when diagnosing the unit)
A / CRUISE
When normal
CHANGED BY PARKING AID SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 8790
5. CAUTIONS ON PARKING AID SYSTEM
Cautions
• Note that the display does not show everything in the rear area. Always check nobody, especially animals
and children, is behind the vehicle.
• If you can not properly check back, get out of the vehicle and then check it.
1. The parking aid system is just a supplemental device to help your parking operation.
2. Always keep the safety precautions.
3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be
damaged.
4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into
“R” position with the ignition key “ON”.
5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is
moved into “R” position with the ignition key “ON” or engine running. However, it is also occurred when the
obstacle is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1. Certain obstacles that sensors can not detect
1) Wires, ropes, chains.
2) Cotton, sponge, clothes, snow that absorb ultrasonic waves.
3) Obstacles lower than the bumper. (ex. drain ditch or mud puddle)
2. Not defective but improperly working
1) When the sensing portion is frozen. (operates normally after thawed)
2) When the sensing portion is covered by rain, water drops, snow or mud. (operates normally after cleaned)
3) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
4) When a high-power radio is turned on.
3. Narrowed sensing area
1) When the sensing portion is partially covered by snow or mud. (operates normally after cleaned)
2) Surrounding temperature of sensor is too high (approx. over 80 °C) or too low (approx. below -30 °C).
4. Not defective but may occur improper working
1) When driving on the rough roads, gravel road, hill and grass.
2) When the bumper height is changed due to the heavy load.
3) When the sensing portion is frozen.
4) When the sensing portion is covered by rain, water drops, snow or mud.
5) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
6) When a high-power radio is turned on.
7) When some accessories are attached in detecting ranges
PARKING AID SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8790 7
6. REMOVAL AND INSTALLATION OF PARKING AID
EL
Parking Aid Sensor
Center PAS Sensor
STICS
Preceding Work: Disconnect the negative battery cable and remove the spare tire.
IMMO
SPWM
CLUSTER
Center PAS sensor
S/W
1. Disconnect the harness connector and then remove the center sensor by turning the mounting cover.
AV
WIPER
Sensor assembly
R / SENSOR
PAS
Connector
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY PARKING AID SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 8790
RH/LH PAS Sensor
Preceding Work: Disconnect of negative battery cable.
1. Disconnect the center connector and then remove the cover by turning it.
LH sensor RH sensor
2. Remove the RH/LH sensor mounting cover and spring and then remove the sensor from the bumper.
PARKING AID SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8790 9
Components of PAS Sensor
EL
PAS sensor
STICS
IMMO
SPWM
CLUSTER
PAS sensor lower Spring PAS sensor upper
S/W
mounting cover mounting cover
Connector
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY PARKING AID SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Precautions When Installing LH/RH Sensors
Fit The Sensor Into The Mounting Hole.
When Extended When Compressed
1. Align the sensor lower cover with the sensor 2. Insert the sensor upper cover into the sensor
groove. groove.
Align Wigh the Groove
PARKING AID SYSTEM CHANGED BY
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8790 11
PAS Unit
EL
Preceding Work:
1. Disconnection of negative battery cable
2. Removal of rear lower quarter panel and seat belt.
STICS
(For removal and installation, refer to the BODY section.)
IMMO
SPWM
1. Disconnect the connector and mounting bolts (10 mm - 2EA) and then remove the PAS unit.
CLUSTER
Connector
S/W
AV
WIPER
R / SENSOR
Disconnection Removal of
of connector mounting bolt
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
Connector
CHANGED BY PARKING AID SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 8790
7. CIRCUIT DIAGRAM
PARKING AID SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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LAMP
8310 / 8320 / 8610
TABLE OF CONTENTS
LAMPS ..................................................................... 2
1. Locations of exterior lamps and specifications ................... 2
FRONT LAMPS ........................................................ 6
1. Compositions of front lamps ............................................... 6
2. Aiming and adjustment of front lamp .................................. 8
3. Removal and installation of headlamps ............................ 11
REAR COMBINATION LAMP ................................. 18
1. Composition of rear combination lamp ............................. 18
2. Removal and installation of rear combination lamp ......... 20
INTERIOR LAMPS .................................................. 28
1. Composition of interior lamps ........................................... 28
2. Removal and installation of interior lamps ....................... 30
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2 8310
LAMPS
1. LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS
Headlamp Assembly
Low Beam
one at each side (12V / 55W)
High Beam Position lamp and Turn Signal Lamp
one at each side (12V/55W) General: one at each side (12V/28W/8W)
Position Lamp EU: one at each side (12V/P21W)
EU: one at each side (12V/W5W)
Fog Lamp Assembly
Fog lamp
angle adjustment
Fog Lamp
General: one at each side (12V/27W)
EU: one at each side (12V/H27W)
Turn Signal Lamp/Stop Lamp Assembly
T/Stop Lamp
General: LH-1 (12V/27W/8W)
EU: LH-1 (12V/P21W/5W)
Turn Signal Lamp
General: one at each side (12V/27W)
EU: one at each side (12V/PY21W)
LAMP CHANGED BY
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8310 3
Side Repeater Assembly
EL
STICS
General: one at each side (12V/5W)
IMMO
EU: one at each side (12V/W5W)
High Mounted Stop Lamp Assembly
SPWM
CLUSTER
S/W
AV
License Plate Reflector Assembly
WIPER
Lamp Assembly
R / SENSOR
PAS
General: one at each side (12V/5W)
EU: one at each side (12V/W5W)
LAMP
Tail Lamp / Reversing Lamp / Rear Fog Lamp Assembly
Tail Lamp
S / ROOF
General: one at each side (12V/27W/8W)
EU: one at each side (12V/P21W/5W)
S E AT
Reversing Lamp
General: one at each side (12V/16W)
A / CRUISE
Rear Fog Lamp
General: one at each side (12V/P21W)
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
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4 8310
INTERIOR LAMPS
Front Room Lamp Center and Luggage Room Lamp
Toward tailgate Toward dirver side
Center room
lamp
(Lamp: ON)
Luggage room
lamp (coupled
operation with
Center room lamp
tailgate)
(coupled operation
with door)
Luggage room lamp
(Lamp: OFF)
12V/10W -Two at each lamps 12V/10W - One at each lamp
The driver’s room lamp and the passenger’s Center Room Lamp Luggage Room Lamp
room lamp are separately turned on when press-
ing the switch (1, 2). However, the front lamps When this switch is pushed to- When this switch is pushed to-
are turned on when opening a door and turned wards the rear of the vehicle, wards the tailgate, the lamp
off when closing it. The front room lamps and the lamp comes on. If the comes on when the tailgate is
center are turned on when pressing the room switch is pushed to the oppo- open. If the switch is pushed
lamp main switch (3). site direction, the lamp will go to the opposite direction, the
off. But, when any door is open, lamp will go off and will not
the lamp comes on and stays come on even if the tailgate is
for 30 seconds. When the door open.
is closed, the lamp will go off.
Glove Box Door Courtesy Lamp
12V/5W - One at glove box 12V/5W - one at each door
LAMP CHANGED BY
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8310 5
EL
Room Lamp Control
The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the
STICS
center/luggage room lamp switch is at coupled operating position and the key reminder switch is OFF.
1. When the door (Driver’s/Passenger’s/Rear door) is opened, the front and center room lamps come on and
automatically go off after 30 seconds.
IMMO
2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the driver’s door,
passenger’s door or rear doors.
3. The decaying operation must have greater than 32 steps per one second.
SPWM
4. The room lamp output should stop immediately after turning on the ignition key during decaying operation.
5. The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the
remote control key while the door is closed.
CLUSTER
6. The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal
from the remote control key again during output. (The lamp stays on when unlocked by the remote control key).
7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
8. The room lamp output stops immediately after receiving the lock signal from driver’s door, passenger’s door and
S/W
rear doors lock switch while the driver’s door, passenger’s door and rear doors are closed.
9. The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch
is pressed.
AV
OPEN
Dr or Ps
WIPER
DOOR SW
CLOSE
R / SENSOR
ON
IGN KEY
REMINDER SW
OFF
PAS
RECEIVE
REMOCON
UNLOCK
NO SIGNAL
ON LAMP
UNLOCK
OUTPUT
S / ROOF
OFF
ON
CENTER T1
S E AT
ROOM LAMP
OFF
T4
T2 T3
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
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6 8310
FRONT LAMPS
1. COMPOSITIONS OF FRONT LAMPS
Headlamp Assembly
Lamp cap
High beam bulb
Low beam bulb
EU: Position lamp
Connector
Lamp
General: Positon lamp and
turn signal lamp bulb
Front Fog Lamp
Fog lamp bulb
Connector
Lamp and case
LAMP CHANGED BY
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8310 7
EL
STICS
Connection Connector When Installing
IMMO
Positon lamp and turn signal
lamp connector
SPWM
CLUSTER
S/W
AV
Headlamp connector
WIPER
R / SENSOR
Side Repeater
PAS
LAMP
S / ROOF
Connector
S E AT
Lamp
A / CRUISE
Lamp cover
CHANGED BY LAMP
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2. AIMING AND ADJUSTMENT OF FRONT LAMP
Headlamp Aiming
Headlamp Aiming Adjustment of Low Beam
: Adjust the headlamp aiming while turning the aiming
No. 1 adjustment hole: Up and Down
screws (up/down/left/right) in turn with a screwdriver.
No. 2 adjustment hole: Left and Right
Headlamp aiming requirements:
1. parking on a flat surface
2. specified tire pressure Adjustment of High Beam
3. one passenger (driver, 75 kg), No. 3 adjustment hole: Up and Down
4. spare tire and OVM tools loaded (unlade all other No. 4 adjustment hole: Left and Right
loads)
Adjustment Direction
Low Beam Low Beam
1: Left / 2: Right A: Up / B: Down
High Beam High Beam
1: Left / 2: Right A: Up / B: Down
LAMP CHANGED BY
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8310 9
Aiming Procedures When Using a Screen
EL
Install a screen (2 m × 1.5 m) in front of the headlamps in vertical by 3 m away and align the center lines of the
vehicle and the screen.
STICS
IMMO
SPWM
Center line of
!"#$ %&'()
vehicle and screen
Center
)*+ ,-.line of vehicle
Vertical34
/012 of headlamp
56 bulb
CLUSTER
1342
Vertical
/012line34 of Screen
57.
headlamp bulb
'(
A A
S/W
Horizontal
/012 line
89of
57.
headlamp focus
AV
Ground
:; Unit:
!"# mm
$ %%&
WIPER
!"#$" %&'()
'( )(
R / SENSOR
*+ 4-5.
,- ,- ,-
PAS
6-
A A .+
LAMP
/0Allowable
123# /0Allowable
123#
focusing area focusing area
S / ROOF
S E AT
78
Ground Unit:
!"# mm
$ %%&
A / CRUISE
If the focus deviates the “A” point, adjust the headlamp aiming by rotating the aiming screws (Up, Down, Left, Right)
in turn with a screwdriver.
CHANGED BY LAMP
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10 8310
Fog Lamp Aiming Adjustment
The front fog lamps are installed in the front bumper. Front
fog lamp aiming (up/down) can be adjusted by the control
knob installed on the fog lamp.
Up
Down
Down Up
The lamp aiming moves down and The lamp aiming moves up and the
the light faces downward when the light faces upward when the knob
knob is turned counterclockwise. is turned clockwise.
LAMP CHANGED BY
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8310 11
3. REMOVAL AND INSTALLATION OF HEADLAMPS
EL
Headlamp Assembly
Preceding Work: Disconnect the negative battery
STICS
cable.
1. Open the engine hood and unscrew two headlamp up-
per mounting bolts (10 mm).
IMMO
SPWM
CLUSTER
2. Remove the headlamp lower cover from the upper front bumper and unscrew the headlamp lower mounting nut
(10 mm).
S/W
AV
WIPER
R / SENSOR
NOTICE
PAS
• Be careful not to damage the headlamp cover when removing it in order of the above number.
LAMP
3. Disconnect two headlamp connectors (Turn signal lamp/Position lamp, Low beam/High beam).
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
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12 8310
4. Be careful not to damage the headlamp assembly when
removing it.
Headlamp Assembly
High beam
Low beam
Turn signal lamp and Position lamp (General)
Turn signal lamp and Position lamp (EU)
Position lamp
NOTICE
High beam • If the lamp cover rubber ring is damaged
Low beam while installing, replace it with new one.
LAMP CHANGED BY
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8310 13
Replacement of Headlamp Bulb
EL
1. Remove the headlamp dust cover.
STICS
NOTE
• To make the bulb replacement easier, remove the
headlamp assembly.
IMMO
SPWM
CLUSTER
2. Disconnect the high/low beam connectors from the headlamp assembly.
Low Beam Side High Beam Side
S/W
AV
WIPER
R / SENSOR
PAS
3. Remove the clamps.
Low Beam Side High Beam Side
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
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4. Remove the bulb from the headlamp assembly.
Low Beam Side High Beam Side
NOTICE
• Use only specified bulb for replacement.
• Do not touch the bulb with bare hands when it is hot. You may get burnt.
5. Position/turn signal lamp bulb should be removed after removing the headlamp assembly.
NOTICE
• Use only specified bulb for replacement.
• Do not touch the bulb with bare hands when it is hot. You may get burnt.
LAMP CHANGED BY
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8310 15
Fog Lamp Assembly
EL
Preceding Work: Disconnect the negative battery cable.
1. Remove the front wheel house and then remove the
STICS
horn assembly.
IMMO
SPWM
CLUSTER
2. Disconnect the connector and unscrew four mounting screws to remove the front fog lamp assembly.
S/W
Front View
AV
WIPER
R / SENSOR
PAS
Rear View
Fog lamp bulb and connector
LAMP
S / ROOF
S E AT
A / CRUISE
Lamp and case
CHANGED BY LAMP
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16 8310
Replacement of Fog Lamp Bulb
: Disconnect the fog lamp connector located on the front bumper.
Side Repeater
Preceding Work: Disconnection of negative battery cable
1. Push out the side repeater assembly.
Rear
Front
2. Disconnect the connector and remove the lamp.
Connector
Lamp (12V/5W)
Side repeater cover
LAMP CHANGED BY
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REAR COMBINATION LAMP
1. COMPOSITION OF REAR COMBINATION LAMP
Turn Signal Lamp/Stop Lamp Assembly
Turn signal lamp (valve)
Bulb holder & connector
Stop lamp bulb
Combination lamp
License Plate Lamp Assembly
Connector
Bulb
Lamp
LAMP CHANGED BY
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8310 19
EL
High Mounted Stop Lamp
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
Tail Lamp/Back-up Lamp Assembly
Bulb Bulb holder &
(tail lamp) Connector
PAS
LAMP
S / ROOF
S E AT
Bulb
• Passenger: Back-up lamp
• Driver: RR Fog Lamp
A / CRUISE
Combination
lamp
CHANGED BY LAMP
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20 8310
2. REMOVAL AND INSTALLATION OF REAR COMBINATION LAMP
Turn Signal Lamp/Stop Lamp
Preceding Work: Disconnect the negative battery cable.
1. Open the tailgate and unscrew two mounting screws to remove the rear combination lamp assembly.
2. Disconnect the connector and remove the rear combination lamp assembly.
LAMP CHANGED BY
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8310 21
EL
3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
NOTICE
• Use only specified bulb for replacement.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
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22 8310
Tail Lamp/Back-up Lamp/RR Fog Lamp
Preceding Work: Disconnect the negative battery cable.
1. Open the tailgate and remove the bolt cover. Then, unscrew three mounting nuts (10 mm) and remove the rear
combination lamp assembly (tail lamp/back-up lamp/RR fog lamp).
2. Disconnect the connector and remove the rear combination lamp assembly.
3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs.
NOTICE
• Use only specified bulb for replacement.
LAMP CHANGED BY
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8310 23
License Plate Lamp Assembly
EL
Preceding Work: Disconnect the negative battery cable
1. Remove the upper and lower trim of the tailgate. Disconnect the connectors and unscrew eight mounting nuts
STICS
(10 mm) to remove the rear garnish assembly.
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Tailgate Rear Garnish Assembly
R / SENSOR
Inside
PAS
LAMP
Outside
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 8310
2. Disconnect the bulb and bulb cable from the removed rear garnish assembly and then remove the lamp by
pressing (A) section of the lamp.
Disconnect the Bulb Connector Remove the Lamp
Exploded View
Tailgate garnish
Connector
Lamp
LAMP CHANGED BY
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8310 25
3. Install the bulbs into the license plate lamp. Make sure the location and "LOCK" direction are correct.
EL
STICS
IMMO
SPWM
CLUSTER
Replacement of Bulb
1. Pry off the license plate lamp with a flat bladed screwdriver.
S/W
AV
WIPER
R / SENSOR
2. Remove the bulb from the removed license plate lamp.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
NOTICE
• Use only specified bulb for replacement.
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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26 8310
High Mounted Stop Lamp
Preceding Work: Disconnect the negative battery cable.
NOTE
• In the vehicle with tailgate air spoiler, the LED type high mounted stop lamp is integrated in the tailgate air
spoiler. It should be replaced with the tailgate upper garnish assembly.
1. Open the tailgate, remove the upper trim and then 2. Disconnect the rear washer nozzle hose.
disconnect the high mounted stop lamp connector.
LAMP CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8310 27
3. Unscrew four mounting nuts (10 mm)/three cap nuts and remove the air spoiler from the tailgate.
EL
STICS
IMMO
SPWM
Cap nut
CLUSTER
4. Remove the tailgate upper garnish assembly from the removed air spoiler.
S/W
AV
WIPER
R / SENSOR
5. Replace the tailgate upper garnish assembly with new one.
NOTICE
• In the vehicle with tailgate air spoiler, the LED type high mounted stop lamp is integrated in the tailgate
PAS
air spoiler. It should be replaced with the tailgate upper garnish assembly.
• In the vehicle without tailgate air spoiler, the bulb type high mounted stop lamp is used. It can be re-
placed with new one after removing the tailgate upper garnish assembly.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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28 8310
INTERIOR LAMPS
1. COMPOSITION OF INTERIOR LAMPS
Front Room Lamp Assembly
Front room lamp cover
Sunglasses box
Front room lamp bulb
Interior Room/Luggage Room Lamp Assembly
Lamp (lens)
luguage room
Bulb
Front view Rear view
LAMP CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8310 29
EL
STICS
Glove Box Lamp Assembly
Bulb
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Door Courtesy Lamp Assembly
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 8310
2. REMOVAL AND INSTALLATION OF INTERIOR LAMPS
Front Room Lamp
Preceding Work: Disconnect the negative battery cable.
1. Open the sunglasses box and remove two front room lamp assembly mounting screws.
2. Disconnect the connector and remove the front room lamp assembly.
LAMP CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8310 31
EL
Replacement of the Front Room Lamp Bulb
1. Remove the front room lamp cover.
STICS
NOTICE
• The tab can be damaged when removing the room
IMMO
lamp abnormally.
SPWM
CLUSTER
2. Carefully remove the bulb from the lamp and replace it
S/W
with new one.
NOTICE
AV
• Use only specified bulb for replacement.
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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32 8310
Center/Luggage Room Lamp
Preceding Work: Disconnect the negative battery cable.
1. Remove the lamp cover.
NOTICE
• Use the slot around the cover when replacing the
lamp (bulb).
Slot Slot
2. Unscrew the lamp mounting screws (luggage room lamp) and nuts (center room lamp).
Center room lamp Luggage room lamp
3. Disconnect the connector and remove the lamp assembly.
LAMP CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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8310 33
EL
Center Room/Luggage Room Lamp Assembly
STICS
IMMO
SPWM
CLUSTER
S/W
Replacement of Bulb
AV
1. Remove the lamp cover and then carefully remove the bulb. Replace it with new one.
WIPER
Center room lamp Luggage room lamp
R / SENSOR
PAS
LAMP
NOTICE
S / ROOF
• Use only specified bulb for replacement.
S E AT
A / CRUISE
CHANGED BY LAMP
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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34 8310
Door Courtesy Lamp Assembly
Preceding Work: Disconnect the negative battery cable.
1. Disconnect the door courtesy lamp cover (1) from the door trim and remove the bulb (2). Replace the bulb with
new one.
* Location: Toward tailgate use
the slot around the lens when
replacing the lamp (bulb)
12V-5W
Glove Box Lamp Assembly
Preceding Work: Disconnect the negative battery cable.
1. Open the glove box and remove the lamp cover by pressing both sides of the lamp as shown in the figure.
2. Disconnect the connector and remove the lamp assembly. Replace the bulb with new one.
12V-5W
LAMP CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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SUNROOF SYSTEM
7340
TABLE OF CONTENTS
SUNROOF ASSEMBLY ........................................... 2
1. Components and locations ....................................................2
2. Operation and function ..........................................................3
3. Trouble diagnosis ..................................................................6
4. Removal and installation of sunroof assembly ....................... 7
5. Circuit diagram .................................................................... 21
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SUNROOF ASSEMBLY
1. COMPONENTS AND LOCATIONS
Sunroof Motor Sunroof Control Unit (SCU)
Sunroof Switch Sunroof Assembly
SUNROOF SYSTEM CHANGED BY
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7340 3
EL
2. OPERATION AND FUNCTION
STICS
Close
IMMO
SPWM
Open
CLUSTER
S/W
Sunroof Sliding Operation Sunroof Tilting Operation
Open Tilt-up
AV
To fully open the sunroof, briefly rotate the sunroof switch To tilt-up the sunroof, rotate the sunroof switch counter-
clockwise (OPEN direction) with the sunroof closed. To clockwise (CLOSE direction) with the sunroof fully
partially open the sunroof, rotate and hold the sunroof closed.
WIPER
switch until it reaches at the desired position.
Close Tilt-down
R / SENSOR
To fully close the sunroof, briefly rotate the sunroof switch To tilt-down the sunroof, rotate the sunroof switch clock-
counterclockwise (CLOSE direction) with the sunroof wise (OPEN direction) with the sunroof tilted-up.
open. To partially close the sunroof, rotate and hold the
sunroof switch until it reaches at the desired position.
PAS
Anti-trap Function
LAMP
To prevent any body parts from being trapped by the
sliding sunroof, an Anti-Trap function automatically opens
the sunroof when an object is trapped. However, if the
S / ROOF
force against the sunroof is less than the specified value,
the Anti-Trap function doesn't operate.
S E AT
Anti-trap function is built in SCU
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
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4 7340
Hazard (Manual) Operation
The sunroof can be operated by rotating the motor operat-
ing hole on the sunroof motor with a proper tool.
Circuit Diagram
Motor drive A
Power
supply
conditioner Motor drive B
Supply
voltage
monitor
Close position Sensing
Tilt
Puls input
Logic
input
Slide
Controller assembly Motor (HALL I.C &
MICROSWITCH)
SCU Main Connector Motor Connector (SCU)
SUNROOF SYSTEM CHANGED BY
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7340 5
Resetting of Sunroof Control Unit
EL
If the sunroof does not operate properly, check and reset the sunroof control unit.
STICS
1. To prevent any parts damage and personal injury, the sunroof setting is canceled
1) When the battery voltage is disconnected, the fuse is blown, or the abrupt voltage drop occurs due to old
battery while operating the sunroof.
IMMO
2) When an undesired cancellation occurs due to mistake by a technician.
3) When parts damage, shorted circuit, or electric leakage occurs.
4) When keeping the sunroof switch at "OPEN" position.
SPWM
2. Symptoms when the sunroof setting is canceled
1) The one-touch operation cannot be activated.
CLUSTER
2) The sunroof is tilted even after completion of closing operation when closing it.
3) The sunroof opening and tilting level is significantly low.
4) The sunroof does not operate properly when operating the sunroof switch.
S/W
3. [0] point reset of sunroof
1) Close the sunroof with the sunroof switch and keep the position for approx. 10 seconds. If the [0] point setting
is successfully completed, the sunroof should be properly opened from this position.
AV
2) Check if the sunroof is fully closed. Tilt the sunroof with the sunroof switch and keep it at the position for 10
seconds ([0] point setting).
3) Close the sunroof with the sunroof switch.
WIPER
4. Checking after reset
R / SENSOR
1) If the sunroof does not operate properly, check the power supply system.
2) If the sunroof does not operate or operates only during the switch operation even the power supply system is
in normal conditions, check if the ground circuit of switch is securely tightened and reset the sunroof system
again.
PAS
NOTE
• If the power supply system is in normal conditions, replace the sunroof motor or the sunroof control unit.
LAMP
• Replace the sunroof control unit with new one and check if the sunroof operates properly before replacing
the sunroof motor.
S / ROOF
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 7340
3. TROUBLE DIAGNOSIS
Symptom Cause Action
Leakage Clogged or bent drain hose Check and correct drain hose condition.
Gap and clearance between panel and glass Readjust glass location.
Wind noise Gap and clearance between panel and glass Readjust glass location.
Improper operations Malfunction of wire, fuse and ground Check and replace/repair.
Malfunction of relay, motor and unit Replace it.
Damaged side cover by dislocation of sun Reinstall sun shade and side cover.
shade (Replace damaged parts.)
Foreign material in rail Remove foreign material.
Malfunction Caught side cover by dislocation of sun Reinstall sun shade and side cover.
shade (Replace damaged parts.)
Improper operation of anti-trap function Check interference of body and wind
deflector. (Relieve spring tension.)
Improper operation of motor Replace it.
Operation noise Caught side cover by dislocation of sun Reinstall sun shade and side cover.
shade (Replace damaged parts.)
Interference between drain hose and vehicle Install sponge to drain hose.
body
Interference between vehicle body and roof Apply sealant between vehicle body and
panel roof panel.
Gap and clearance between roof panel and Readjust glass location.
glass
SUNROOF SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7340 7
4. REMOVAL AND INSTALLATION OF SUNROOF ASSEMBLY
EL
Exploded View
STICS
IMMO
SPWM
Seal - glass panel
CLUSTER
Glass
Glass panel
S/W
Wind deflector
Side cover - outer
Side cover - inner
Drain channel
AV
Drain channel
support
support bar RH
Drain channel
Sunshade assembly support bar pin
Panel curve on
WIPER
Return spring Rivet roll
Ventilation roof
Front lever Drain lever
spring Slider LH
Front
R / SENSOR
Drain lever LH
lever LH
Main lever LH
Retraction bar
Pin
Breed nail
Drain channel
PAS
Frame assembly
LAMP
Seal - drive tube
Tube cable guide
S / ROOF
Frame
assembly
Drive tube
Sunroof Sunroof control unit
S E AT
motor
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 7340
Wind Deflector With Sunroof Opened
1. Fully open the sunroof.
NOTICE
• Work only when the sunroof is open.
2. Unhook the wind deflector side locks at both sides.
3. Unhook the wind deflector bottom locks as shown in figure (A).
Wind deflector
SUNROOF SYSTEM CHANGED BY
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7340 9
Glass Panel Assembly NOTICE
EL
• Work only when the sunroof is tilted-up.
STICS
Inside Cover of Glass Panel Assembly
1. Remove the inner side covers at both sides by pushing them rearward.
IMMO
SPWM
CLUSTER
S/W
2. Remove the three mounting bolts (TORX bolts) of the glass panel with a special wrench (25 T).
AV
Tightening torque:
5 Nm
WIPER
R / SENSOR
PAS
LAMP
3. Remove the glass panel.
S / ROOF
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7340
Outside Cover of Glass Panel
Preceding Work: Removal of glass panel and inside cover
1. Cut off the locks on the outside cover with a cutter and remove the outside cover.
2. Insert the locks of the new outside cover into the mount-
ing holes.
Sunroof mechanism
3. Push down the outside cover to install into the roof panel and lock it to the sunroof system with a pliers.
SUNROOF SYSTEM CHANGED BY
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7340 11
Installation of Glass Panel
EL
1. Place the glass panel with the sunroof tilted-up and temporarily tighten the three TORX bolts (T25) at both sides.
At this moment, the logo on the glass panel should face the rear side of the vehicle.
STICS
2. Completely close the sunroof using the sunroof switch.
IMMO
SPWM
CLUSTER
S/W
3. Adjust the following items with the specified value and tighten the bolts.
Gap Between Front and Rear Glass Panel
AV
Gap: Distance from roof panel to glass
WIPER
1) Front gap (-1 ~ 0 mm)
Rear
R / SENSOR
Front
PAS
2) Rear gap (0 ~ 1 mm)
LAMP
NOTE
S / ROOF
• To prevent the wind noise during high speed driv-
ing (over 100 km/h), the rear gap should be
greater than front gap.
S E AT
A / CRUISE
Rear Front
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7340
Front/Rear Gap of Glass Panel
To avoid the abnormal noise due to interference between roof panel and rear section of sunroof glass panel while
driving, the installation gap should be maintained the ratio of 4:6 (front:rear) when installation.
Re 4
ar
Re
ar
Ga
p:F
6 : ront Fro
nt
4 Ga
p
After Assembly
Measure the interference between roof and glass panel while moving the glass panel.
Gap between roof and glass panel should be approx. 5 mm. If this gap is too small, the glass panel may be
scratched or the interferencing noise may sound.
Gap between roof and glass
panel: approx. 5 mm
SUNROOF SYSTEM CHANGED BY
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AFFECTED VIN
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7340 13
Drain Channel With Sunroof Tilted-up
EL
Preceding Work: Removal of glass panel
1. Remove the two mounting bolts (TORX bolt) at both sides on the drain channel with the glass panel removed.
STICS
Tightening torque:
1.2 Nm
IMMO
SPWM
CLUSTER
S/W
2. Unhook the locks (A) and remove the drain channel.
AV
in
Dra el
WIPER
n n
cha
R / SENSOR
PAS
3. When installing
Hook the locks (B) of the drain channel.
LAMP
S / ROOF
in
Dra el
nn
cha
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7340
Sun Shade Panel With Sunroof Tilted-up
Preceding Work: Removal of glass panel and drain channel
1. Move the sun shade panel forward and remove the slide blocks of the sun shade panel from the guide rail with a
flat bladed screwdriver as shown in the figure.
2. Remove the sun shade panel from the sunroof.
SUNROOF SYSTEM CHANGED BY
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AFFECTED VIN
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7340 15
Sunroof Control Unit (SCU) and Motor With Sunroof Fully Closed
EL
Preceding Work: 1. Fully close the sunroof with sunroof switch.
2. Remove the sun visor/passenger’s hand grip/A pillar headlining/B pillar headlining to
STICS
deflect the front section of the headlining. (Be careful not to damage the headlining.)
NOTICE
• Work only when the sunroof is closed.
IMMO
SCU Assembly
SPWM
1. Disconnect the connector from the sunroof control unit.
CLUSTER
Sunroof control unit Sunroof motor
S/W
AV
2. Unscrew the mounting screw and remove the SCU assembly.
WIPER
R / SENSOR
PAS
LAMP
3. When installing, completely fit the sunroof rail into the slot of sunroof control unit and tighten the screw.
NOTICE
S / ROOF
• Completely fit the sunroof rail into the slot of
sunroof control unit.
Slot
S E AT
Completely fit
the tab.
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 7340
Motor Assembly
NOTICE
• Work only when the sunroof is closed.
1. Disconnect the connector from the SCU.
2. Unscrew the three mounting bolts (25T) with a special wrench and remove the motor assembly.
NOTICE
• To make the motor positioning easier, do not operate the motor (even for the testing) before installation.
SUNROOF SYSTEM CHANGED BY
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AFFECTED VIN
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7340 17
Sunroof Drain Hose
EL
Removal and installation procedures of drain hoses:
Front Drain Hose - Remove only A pillar, sun visor, sunroof molding and front section of headlining.
STICS
Rear Drain Hose - Remove headlining and rear trim.
IMMO
Release the clamps and remove hoses. (However, the fastener at rear side of rear hose should be removed.)
Rear Hose
SPWM
CLUSTER
S/W
Front Hose
AV
WIPER
R / SENSOR
NOTICE
PAS
• When installing, be careful not to kink, damage
and twist the hose.
LAMP
S / ROOF
Not allowed
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 7340
Note
Fastener location of rear drain hose
The rear drain hose can be removed after releasing the fasteners.
SUNROOF SYSTEM CHANGED BY
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AFFECTED VIN
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7340 19
Sunroof Assembly
EL
Preceding Work: Removal of headlining
1. Disconnect the front and rear drain hoses with the sunroof closed.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
2. Unscrew the two bracket mounting bolts (10 mm) at both sides.
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 7340
3. Unscrew the mounting bolts (10 mm) at both sides.
Installation Notice
Tightening torque 6 ~ 10 Nm
4. Remove the sunroof assembly from the vehicle.
Sunroof Assembly
SUNROOF SYSTEM CHANGED BY
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AFFECTED VIN
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7340 21
5. CIRCUIT DIAGRAM
EL
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SUNROOF SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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SEAT & SEAT BELT
7410 / 7430
TABLE OF CONTENTS
SEAT ASSEMBLY ................................................... 3
1. Seat mounting points ............................................................3
2. Composition of seat .............................................................. 4
3. Removal and installation of seat .......................................... 11
4. Seat heating ....................................................................... 17
5. Seat arrangement ............................................................... 17
SEAT BELT ........................................................... 18
1. Seat belt locations .............................................................. 18
2. Removal and installation of seat belt ................................... 20
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7410 3
SEAT ASSEMBLY
EL
1. SEAT MOUNTING POINTS
STICS
Front Seat
Tightening
torque:
IMMO
35 ~ 55 Nm
SPWM
CLUSTER
Tightening
torque:
35 ~ 55 Nm
S/W
Second Row Seat
AV
WIPER
R / SENSOR
PAS
Tightening
torque:
35 ~ 55 Nm
LAMP
Third Row Seat S / ROOF
Mounting
bolts
S E AT
Tightening
A / CRUISE
torque:
35 ~ 55 Nm
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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2. COMPOSITION OF SEAT
Front Seat (Driver’s Seat)
Reclining Motor
Lumbar
support
lever
SPWM (Seat Position With Memory) Unit
Seat Cushion Motor (Front)
Seat cushion up/
down bar (rear)
Sliding rail Sliding rail
Seat cushion up/
down bar (front)
Reclining
Seat cushion angle
Seat Cushion Motor (Rear) lever
adjusting lever (rear)
Sliding motor
Seat cushion
angle adjusting
lever (front) Seat height
control switch
Sliding lever
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 5
EL
Location of Seat Position With Memory Unit (Bottom of Driver Seat)
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
SPWM unit
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Front Seat (Passenger Seat)
Reclining Motor
Reclining lever
Sliding rail Sliding rail
Sliding lever
(No seat height control
function)
Sliding motor
SEAT & SEAT BELT CHANGED BY
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7410 7
Functions
EL
Switches and Functions of Driver Seat
1. Seat Sliding Adjustment
STICS
IMMO
SPWM
2. Seat Cushion Height Adjustment
CLUSTER
S/W
AV
3. Seat Cushion Angle Adjustment
WIPER
R / SENSOR
4. Seatback Reclining Adjustment
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 7410
Switches and Functions of Passenger Seat
1. Headrest Height Adjustment
To raise the headrest, pull it up without press-
ing the release button. To lower the headrest,
press the release button (1) on top of seatback
and push the headrest down.
2. Seatback Reclining Adjustment 3. Seat Sliding Adjustment
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 9
Second Row Seat
EL
1. Headrest Height Adjustment
STICS
IMMO
SPWM
To raise the headrest, pull it up
without pressing the release
CLUSTER
button. To lower the headrest,
press the release button (1) on top
of seatback and push the headrest
down.
S/W
2. Seatback Reclining Adjustment
To change the seatback angle, lean forward slightly and raise the lever.
AV
Then, lean back to the desired angle and release the lever.
WIPER
R / SENSOR
PAS
LAMP
Full Flatting the Second Row Seat
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7410
Third Row Seat
1. Headrest Height Adjustment
To raise the headrest, pull it up
without pressing the release
button. To lower the headrest,
press the release button (A) on
top of seatback and push the
headrest down.
2. Full flat lever for third row seat
Unfolding/Folding of Third Row Seat
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 11
3. REMOVAL AND INSTALLATION OF SEAT
EL
Driver’s Seat (Power Seat)
1. Move the seat rearward as far as possible and unscrew
STICS
the two front mounting bolts (14 mm) at both sides.
Installation Notice
Tightening torque 35 ~ 55 Nm
IMMO
SPWM
CLUSTER
2. Move the seat forward as far as possible and unscrew
the two rear mounting bolts (14 mm) at both sides.
Installation Notice
S/W
Tightening torque 35 ~ 55 Nm
AV
WIPER
3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly.
Disconnect the connector R / SENSOR
PAS
LAMP
S / ROOF
Connector
(seat side)
S E AT
A / CRUISE
Main connector
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7410
Passenger’s Seat (Power Seat)
1. Move the seat backward as far as possible and unscrew
the two front mounting bolts (14 mm) at both sides.
Installation Notice
Tightening torque 35 ~ 55 Nm
2. Move the seat forward as far as possible and unscrew
the two rear mounting bolts (14 mm) at both sides.
Installation Notice
Tightening torque 35 ~ 55 Nm
3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly.
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 13
Second Row Seat
EL
1. Slide the front seats forward and remove the four front
mounting nuts (14 mm) of the second row seat.
STICS
Installation Notice
Tightening torque 35 ~ 55 Nm
IMMO
SPWM
CLUSTER
2. Lay down the seatback of the second row seat and remove the eight rear mounting nuts (14 mm). Insert a wrench
between seatback and cushion to remove the mounting bolts with arrow mark.
S/W
Tightening torque:
35 ~ 55 Nm
AV
WIPER
R / SENSOR
PAS
3. Remove the second row seat from the vehicle.
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7410
Third Row Seat
1. Unscrew the six mounting bolts (10 mm) and remove
the storage box from the luggage compartment.
2. Unscrew the mounting bolts and remove the third row seat.
Tightening Tightening
torque: torque:
35 ~ 55 Nm 35 ~ 55 Nm
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 15
Power Seat Switch
EL
Preceding Work: Disconnect the negative battery cable.
1. Slide the front seat forward and unscrew the mounting screws of seat side cover.
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
R / SENSOR
2. Disconnect the switch connector and remove the seat side cover.
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 7410
3. Remove the power seat switch cover and unscrew the two mounting screws to remove the switch.
Composition of Power Seat Switch
SEAT & SEAT BELT CHANGED BY
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AFFECTED VIN
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7410 17
4. SEAT HEATING
EL
STICS
IMMO
Driver’s Seat Heating Switch
SPWM
CLUSTER
Passenger’s Seat Heating Switch
Press the button to warm the seat, and
S/W
press it again to stop the operation.
The indicator on the switch comes on
during operation.
AV
WIPER
5. SEAT ARRANGEMENT
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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7410 17
4. SEAT HEATING
EL
STICS
IMMO
Driver’s Seat Heating Switch
SPWM
CLUSTER
Passenger’s Seat Heating Switch
Press the button to warm the seat, and
S/W
press it again to stop the operation.
The indicator on the switch comes on
during operation.
AV
WIPER
5. SEAT ARRANGEMENT
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 7410
SEAT BELT
1. SEAT BELT LOCATIONS
3 Point type seat belt: driver’s seat, passenger’s seat, window side seats of second row seat, third row seat
2 Point type seat belt: center seat of second row seat
Pretensioner: Installed at front seats. The seat belt pretensioner rewinds the seat belt immediately to protect occupant’s
face and chest when a strong frontal collision occurs.
Seat Belt Seat Belt
(3 point type) (3 point type)
Seat Belt
(2 point type)
SEAT & SEAT BELT CHANGED BY
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7410 19
EL
Seat Belt (3 Point Type)
STICS
Seat Belt in Seat Belt (Window Side)
IMMO
Seat Melt in Front Seats
Second Row Seat in Third Row Seat
Bracket
SPWM
Seat belt anchor
CLUSTER
Seat belt
anchor
Seat belt
Seat belt
Seat
S/W
Seat belt
belt O-
O-ring
ring
AV
Pre-tensioner
WIPER
R / SENSOR
Buckle of 3 point
type seat belt
Buckle of 2 point
PAS
type seat belt
Seat Belt (2 Point Type) LAMP
2 point type seat belt is installed only in the center seat of
S / ROOF
second row seat.
S E AT
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 7410
2. REMOVAL AND INSTALLATION OF SEAT BELT
Front Seat Belt
Preceding Work: Removal of front seat
1. Remove the seat belt D-ring cover.
NOTICE
• In order not to damage the O-ring cover, be sure
to observe the following procedures.
1) Press both sides of button (1) and push the bot-
tom of D-ring cover (arrow) to release the upper
hook (2).
2) Raise the arrow section and remove the D-ring cover.
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7410 21
EL
2. Open the bolt cap and unscrew the seat belt anchor bolt.
STICS
IMMO
SPWM
Bolt cap
CLUSTER
Tightening
torque:
S/W
35 ~ 55 Nm
AV
3. Remove the B pillar (lower) and disconnect 4. Unscrew the seat belt upper mounting bolt
the pretensioner connector. from the height adjuster.
WIPER
Tightening
torque:
35 ~ 55 Nm
R / SENSOR
PAS
LAMP
5. Carefully lower the seat belt and unscrew the mounting screws and bolts to remove the seat belt.
S / ROOF
S E AT
A / CRUISE
Tightening
torque:
35 ~ 55 Nm
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 7410
6. Unscrew the mounting screws and remove the B pillar
(upper).
7. Unscrew the mounting bolts and remove the height adjuster.
Tightening
torque:
35 ~ 55 Nm
Tightening
torque:
35 ~ 55 Nm
Composition of Front Seat Belt
Seat belt anchor bolt
Seat belt (35 ~ 55 Nm)
Height adjuster
D-ring
Seat belt mounting bolt
(35 ~ 55 Nm)
SEAT & SEAT BELT CHANGED BY
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AFFECTED VIN
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7410 23
Rear Seat Belt
EL
Preceding Work: Removal of second row seat and third row seat
1. Open the bolt cap and unscrew the up-
STICS
per mounting bolt.
Tightening
torque:
35 ~ 55 Nm
IMMO
SPWM
CLUSTER
2. Unscrew the lower anchor bolt of the
rear seat belt.
S/W
AV
3. Remove the rear quarter panel and un-
screw the guide pin screw and mount- Tightening
ing bolts to remove the seat belt. torque:
WIPER
35 ~ 55 Nm
Tightening
torque:
35 ~ 55 Nm
R / SENSOR
PAS
Tightening Anchor bolt
torque:
35 ~ 55 Nm
LAMP
O-ring
S / ROOF
bracket Seat belt
S E AT
D-ring
D-ring
A / CRUISE
CHANGED BY SEAT & SEAT BELT
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 7410
Buckles and Center Seat Belt
Reel Type Buckles and Center Seat Belt
Buckles for third row seat
Tightening
torque:
35 ~ 55 Nm
Seat belt latch
Buckle for 3 point
type seat belt in
second row seat
Buckle for 2 point
type seat belt in
Buckle for 3 point Center seat belt second row seat
type seat belt in
second row seat
Fixed Type Buckle (Front Seat)
Buckle
Cover
Buckle mounting bolt:
35 ~ 55 Nm
SEAT & SEAT BELT CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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AUTO CRUISE SYSTEM
TABLE OF CONTENTS
AUTO CRUISE ASSEMBLY .................................... 2
1. Cruise control system ........................................................... 2
2. Curise control switch ............................................................2
3. Removal and installation of cruise control switch ..................2
4. Electrical wiring diagrams ..................................................... 3
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2
AUTO CRUISE ASSEMBLY
1. CRUISE CONTROL SYSTEM
The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver. When the
cruise control is activated, speed is maintained or increased by means of an electrically controlled cable attached to
the accelerator assembly. If the vehicle must be slowed to maintain the speed that was set by the driver, the cruise
control system allows the throttle return spring to close the throttle return spring to close the throttle.
Of driving conditions require sudden acceleration after the cruise control had been set, speed can be increased in
the normal manner by manually pressing the accelerator. The cruise control is disengaged if the brakes (or clutch,
with manual transaxle) are applied.
The minimum speed for setting the cruise control is 38.6 km/h (24 mph). When cruise control is operating, the cruise
indicator lamp is on in the instrument cluster. The cruise control system is capable of monitoring internal software
and hardware faults as well as external faults in the connectors and wire harness. If a fault is detected, creise control
is stopped immediately, and the program logic and hardware logic independently prevent the cruise control from
opening the throttle. The cruise control will function in temperatures ranging from -40°C (-40°F) to 80°C (185°F)
maximum temperature could cause the regulation properties to be out of tolerance, but the safety shutdown will still
be operational under maximum temperature conditions. If high temperature interferes with cruise control operation,
the actuator electromagnetic clutch will open, and the throttle, unless the accelerator pedal is pressed.
2. CURISE CONTROL SWITCH
The cruise control switch located under the steering wheel.
3. REMOVAL AND INSTALLATION OF CRUISE CONTROL SWITCH
Cruise Control Switch
1. Disconnect the negative battery cable.
2. Remove the steering wheel air bag and cruise switch
cover.
3. Remove the crew with control switch.
4. Remove the control switch
5. Installation should follow the removal procedure in the
reverse order.
AUTO CRUISE SYSTEM CHANGED BY
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2
AUTO CRUISE ASSEMBLY
1. CRUISE CONTROL SYSTEM
The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver. When the
cruise control is activated, speed is maintained or increased by means of an electrically controlled cable attached to
the accelerator assembly. If the vehicle must be slowed to maintain the speed that was set by the driver, the cruise
control system allows the throttle return spring to close the throttle return spring to close the throttle.
Of driving conditions require sudden acceleration after the cruise control had been set, speed can be increased in
the normal manner by manually pressing the accelerator. The cruise control is disengaged if the brakes (or clutch,
with manual transaxle) are applied.
The minimum speed for setting the cruise control is 38.6 km/h (24 mph). When cruise control is operating, the cruise
indicator lamp is on in the instrument cluster. The cruise control system is capable of monitoring internal software
and hardware faults as well as external faults in the connectors and wire harness. If a fault is detected, creise control
is stopped immediately, and the program logic and hardware logic independently prevent the cruise control from
opening the throttle. The cruise control will function in temperatures ranging from -40°C (-40°F) to 80°C (185°F)
maximum temperature could cause the regulation properties to be out of tolerance, but the safety shutdown will still
be operational under maximum temperature conditions. If high temperature interferes with cruise control operation,
the actuator electromagnetic clutch will open, and the throttle, unless the accelerator pedal is pressed.
2. CURISE CONTROL SWITCH
The cruise control switch located under the steering wheel.
3. REMOVAL AND INSTALLATION OF CRUISE CONTROL SWITCH
Cruise Control Switch
1. Disconnect the negative battery cable.
2. Remove the steering wheel air bag and cruise switch
cover.
3. Remove the crew with control switch.
4. Remove the control switch
5. Installation should follow the removal procedure in the
reverse order.
AUTO CRUISE SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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2
AUTO CRUISE ASSEMBLY
1. CRUISE CONTROL SYSTEM
The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver. When the
cruise control is activated, speed is maintained or increased by means of an electrically controlled cable attached to
the accelerator assembly. If the vehicle must be slowed to maintain the speed that was set by the driver, the cruise
control system allows the throttle return spring to close the throttle return spring to close the throttle.
Of driving conditions require sudden acceleration after the cruise control had been set, speed can be increased in
the normal manner by manually pressing the accelerator. The cruise control is disengaged if the brakes (or clutch,
with manual transaxle) are applied.
The minimum speed for setting the cruise control is 38.6 km/h (24 mph). When cruise control is operating, the cruise
indicator lamp is on in the instrument cluster. The cruise control system is capable of monitoring internal software
and hardware faults as well as external faults in the connectors and wire harness. If a fault is detected, creise control
is stopped immediately, and the program logic and hardware logic independently prevent the cruise control from
opening the throttle. The cruise control will function in temperatures ranging from -40°C (-40°F) to 80°C (185°F)
maximum temperature could cause the regulation properties to be out of tolerance, but the safety shutdown will still
be operational under maximum temperature conditions. If high temperature interferes with cruise control operation,
the actuator electromagnetic clutch will open, and the throttle, unless the accelerator pedal is pressed.
2. CURISE CONTROL SWITCH
The cruise control switch located under the steering wheel.
3. REMOVAL AND INSTALLATION OF CRUISE CONTROL SWITCH
Cruise Control Switch
1. Disconnect the negative battery cable.
2. Remove the steering wheel air bag and cruise switch
cover.
3. Remove the crew with control switch.
4. Remove the control switch
5. Installation should follow the removal procedure in the
reverse order.
AUTO CRUISE SYSTEM CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
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3
4. ELECTRICAL WIRING DIAGRAMS
EL
Diesel
STICS
IMMO
SPWM
CLUSTER
S/W
AV
WIPER
Gasoline
R / SENSOR
PAS
LAMP
S / ROOF
S E AT
A / CRUISE
CHANGED BY AUTO CRUISE SYSTEM
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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BODY INTERIOR
7730 / 7610 / 7330 / 7630 / 7632 / 7850 / 7770
TABLE OF CONTENTS
INTERIOR TRIM ...................................................... 2
1. Locations .............................................................................. 2
INSTRUMENT PANEL ............................................ 4
1. Removal and installation of instrument panel ........................ 4
SUN VISOR ........................................................... 11
1. Removal and installation of sun visor ................................... 11
REAR QUARTER TRIM AND PILLAR .................. 12
1. Removal and installation of rear quarter trim and pillar ........ 12
HEADLINING ASSEMBLY .................................... 14
1. Removal and installation of headlining ................................. 14
CENTER CONSOLE (A/T - DELUXE MODEL) ..... 18
1. Removal and installation of center console (A/T) ................. 18
CENTER CONSOLE (MANUAL TRANSMISSION) 20
1. Removal and installation of center console (M/T) ................ 20
OUTSIDE REARVIEW MIRROR ........................... 22
1. Removal and installation of outside rearview mirror ............. 22
INSIDE REARVIEW MIRROR ............................... 24
1. Removal and installation of inside rearview mirror ................ 24
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2 7730
INTERIOR TRIM
1. LOCATIONS
Instrument Panel Assembly Center Console (A/T) - Deluxe Type
B Pillar Trim (Upper/Lower)
C Pillar Trim
Rear Quarter Panel Door Trim (Driver Side Door)
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7730 3
INT
Hand Grip Sun Visor
EXT
R E PA I R
A Pillar Trim
Door Trim
(Passenger Side Door, Rear Doors)
Headlining Assembly
CHANGED BY BODY INTERIOR
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AFFECTED VIN
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4 7730
INSTRUMENT PANEL
1. REMOVAL AND INSTALLATION OF INSTRUMENT PANEL
Preceding Work: Disconnect the negative battery cable.
Step 1
1) Insert a flat blade screwdriver into the groove (A) and pry off the instrument side cover.
NOTICE
• Be careful not to damage the components around
the instrument panel and clips.
B B
A
A
2) Disconnect the cables for parking brake release lever (A), fuel lid opening lever (B), and
engine hood release lever (C). Unscrew four mounting screws and remove the lower panel.
Hood Release Lever
B
C
Fuel Lid Opening Lever
Parking brake release lever
3) Unscrew the mounting bolts and nuts and
Slot Cable
remove the undercover and bracket.
Guide groove
Insert tab
Parking brake
release lever
Guide bracket
Parking brake pedal
BODY INTERIOR CHANGED BY
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AFFECTED VIN
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7730 5
4) Remove the right side panel from the center 5) Unscrew three mounting screws and remove the left side
fascia. panel from the center fascia panel and AV head unit.
INT
EXT
R E PA I R
6) Remove the panel assembly of outside rearview mir-
ror switch bezel (Refer to “Switch” section.).
Center Speaker
7) Remove the DVD changer and passenger side lower
instrument panel (Refer to “AV System” section.).
9) Remove the steering wheel assembly (steering angle
8) Remove the center console assembly and sensor, air bag, air bag contact coil, multifunction
the center fascia lower tray. switch).
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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6 7730
Step 2
1) Disconnect the harness and remove the sun 2) Unscrew the center bolt in the instrument panel.
sensor.
3) Unscrew the mounting nuts and screws from
the fuse/relay box and side instrument panel
(at driver side).
4) Remove the parking brake lever bracket and fuse/
relay box assembly. 5) Unscrew the meter cluster mounting nuts
Parking Brake Lever Driver Side Fuse/
and lower instrument panel mounting bolts.
Bracket Relay Box
BODY INTERIOR CHANGED BY
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7730 7
6) Remove the center speaker from the instrument panel 7) Unscrew the nuts from the center fascia.
(Refer to “AV System” section.).
INT
EXT
R E PA I R
8) Unscrew the mounting nuts from the DVD changer in
passenger side instrument panel.
9) Unscrew the mounting nuts and screws from the fuse/
relay box and side instrument panel (at passenger side).
10) Disconnect the GPS antenna connector. 11) Remove the instrument panel assembly.
GPS Antena
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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Step 3
1) Unscrew the mounting bolts from the driver 5) Disconnect the A/C main (A) cable and the
side instrument panel frame. sensor cluster (B) connector and the frame
mounting bolt (center side).
2) Unscrew the mounting bolts from the driver
side steering column bracket.
3) Disconnect the main wiring connector (A) 4) Disconnect the center wiring connector and
and air bag connector (B). unscrew the mounting bolt.
BODY INTERIOR CHANGED BY
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AFFECTED VIN
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7730 9
6) Disconnect the air bag connector (A) and A/T connector (B), ground cable (C) and air bag ground
INT
cable (D), then release the clamp (E) from console box.
EXT
R E PA I R
7) Unscrew the mounting bolts (A, B) from the
passenger side instrument panel frame and
air conditioner module.
9) Disconnect the main wiring, the optical cable
8) Unscrew the center mounting bolts at both and the SSPS connector etc. on the pas-
sides in the instrument panel frame. senger side.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 7730
10) Remove the instrument panel frame.
Instrument Panel and Panel Frame Assembly
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 11
SUN VISOR
INT
1. REMOVAL AND INSTALLATION OF SUN VISOR
EXT
Unscrew the screws and disconnect the vanity mirror lamp connector. Remove the sun visor and sun visor hook.
R E PA I R
Mounting Screws (3)
Vanity Mirror Lamp Connector
Sun Visor Components
Driver side Passenger side
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 7730
REAR QUARTER TRIM AND PILLAR
1. REMOVAL AND INSTALLATION OF REAR QUARTER TRIM AND
PILLAR
Preceding Works: Disconnect the negative battery cable and remove the seats.
For seat belt, refer to “Seat and Seat Belt” section.
Rear Quarter Trim
Remove the seat belt and D pillar before removing the rear quarter trim.
Disconnect the power outlet connector before removing the passenger side rear quarter trim.
1. Unscrew the mounting screws and remove the rear quarter trim.
A. Upper Bolt (D Pillar Side)
D Pillar Assembly
C Pillar Assembly
B. Side Bolt
Rear Quarter Trim Assembly
C. Lower Bolt (Tailgate Side)
Remove the tailgate scuff trim before removing the
lower screw of rear quarter trim.
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 13
B Pillar Trim
INT
Remove the front and rear scuff trims (A) and Unscrew the upper screw and remove the up-
remove the lower B pillar. per B pillar.
EXT
R E PA I R
A Pillar
Remove the door weather strip and unscrew the mounting
screws to remove the A pillar.
B Pillar Assembly
A Pillar Assembly
C Pillar
Remove the seat belt and unscrew the mount-
ing screws to remove the C pillar.
D Pillar
Be careful not to damage the pillars and
fasteners.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 7730
HEADLINING ASSEMBLY
1. REMOVAL AND INSTALLATION OF HEADLINING
Preceding Work: Disconnect the negative battery cable.
1. Remove the components shown in the figure below (Refer to “Body” and “Lamp” sections.).
Room lamps
D pillar
Hand grip
Sunroof
Hand grip
C pillar Sun visor
Sun visor
Inside rearview mirror
B pillar (upper) Pillars
A pillar
Headlining
Luggage room
lamp connector
Sunroof unit connector
Room lamp
Front room lamp connector
connector
Rear washer
fluid hose
Rear washer fluid hose
Roof wiring connector Rear washer fluid hose
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 15
INT
2. Disconnect the connectors and washer fluid hoses from the headlining and remove the fasteners.
EXT
Fastener
R E PA I R
Rear Washer Fluid Hose
Sunroof Unit Connector
Rear Washer Fluid Hose and
Roof Wiring Connector
* Use only designated special tool
when removing the fasteners.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 7730
1) Remove the sunroof molding and disconnect the sunroof unit connector.
2) Disconnect the rear washer fluid hose (nozzle side).
3) Remove the roof wiring connector (A) and rear washer fluid hose (B) in driver side.
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 17
4) Pull out the fasteners (rear - 4, front - 2, luggage compartment - 4 at each side) and remove the headlining
assembly.
INT
EXT
R E PA I R
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
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CENTER CONSOLE (A/T - DELUXE MODEL)
1. REMOVAL AND INSTALLATION OF CENTER CONSOLE (A/T)
1. Place the gear selector lever to “D” position and remove the lever knob.
Move the gear selector lever to “N” position.
To remove the lever knob, pull up the knob after turning the fastener
Fastener
2. Disconnect the cigarette lighter connector and
remove the console fascia cover.
3. Remove the gear selector lever cover and storage box.
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 19
4. Unscrew two mounting screws from the center 5. Remove the screw caps and unscrew the mount-
storage box. ing screws at both sides of center console.
INT
EXT
R E PA I R
6. Remove the storage box cover and disconnect two
mounting bolts (10 mm) in center console.
7. Remove the center console.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 7730
CENTER CONSOLE (MANUAL TRANSMISSION)
1. REMOVAL AND INSTALLATION OF CENTER CONSOLE (M/T)
1. Remove the gear shift lever knob by turning it
counterclockwise. Center Console Assembly
2. Remove the rear duct adapter (A) and center console cover (B).
3. Remove the storage box in center console. 4. Unscrew two mounting screws in center storage box.
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 21
INT
5. Unscrew the mounting screws at both sides of 6. Remove the storage box cover and unscrew the
center console. mounting bolts in center console.
EXT
R E PA I R
7. Slacken the equalizer adjusting nut so that the parking brake lever can be raised all the way.
8. Disconnect the cigarette lighter connector and remove the center console assembly.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 7730
OUTSIDE REARVIEW MIRROR
1. REMOVAL AND INSTALLATION OF OUTSIDE REARVIEW MIRROR
Components
Outside Rearview Mirror Switch Assembly
UP
Outside Rearview
Mirror Assembly
Left Right
Down
For removal/installation of switch,
refer to “Switch” section.
1. Remove the inner cover and disconnect the outside rearview mirror connector.
BODY INTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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7730 23
INT
2. Remove the door trim and then remove the inner cover of outside rearview mirror.
EXT
R E PA I R
Unscrew the mounting screws with dotted circle and remove the door trim from lower side
(For details, refer to “Door” section.).
3. Unscrew five mounting bolts (10 mm) and remove the outside rearview mirror.
CHANGED BY BODY INTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 7730
INSIDE REARVIEW MIRROR
1. REMOVAL AND INSTALLATION OF INSIDE REARVIEW MIRROR
1. Pry off the room mirror cover with a flat blade screwdriver.
2. Disconnect the harness connector and remove the inside rearview mirror.
Inside Rearview Mirror
ECM sensor
BODY INTERIOR CHANGED BY
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AFFECTED VIN
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BODY EXTERIOR
4610 / 4620
TABLE OF CONTENTS
BODY EXTERIOR..................................... 2 FENDER.................................................. 26
1. Front .................................................................... 2 1. Removal and installation of fender ................... 26
2. Rear ..................................................................... 3
FRONT DOOR ........................................ 28
BUMPER ................................................... 4 1. Removal and installation of front door .............. 28
1. Construction ....................................................... 4 2. Removal and installation of front door trim ....... 29
2. Removal and installation of bumper ................... 6 3. Components of front door opening system ...... 30
4. Front window regulator ..................................... 31
HOOD ASSEMBLY ................................. 11
1. Construction ...................................................... 11 REAR DOOR ........................................... 33
2. Removal and installation of hood assembly ..... 12 1. Removal and installation of rear door ............... 33
2. Removal and installation of rear door trim ........ 34
ROOF FASHION RAIL ............................ 16 3. Components of rear door opening system ....... 35
1. Construction ..................................................... 16 4. Rear window regulator ...................................... 36
2. Removal and installation ................................... 16
FUEL TANK ............................................ 38
TAILGATE................................................ 17 1. Removal and Installation of Fuel Tank (for remov-
1. Tailgate assembly ............................................. 17 ing rear left upper arm and lower arm) ............. 38
REAR AIR SPOILER .............................. 23 SPARE TIRE ........................................... 40
1. Removal and Installation of Spare Tire ............. 40
SIDE SEAL MOLDING ........................... 24
1. Construction ..................................................... 24
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2 5110
BODY EXTERIOR
1. FRONT
Sunroof Engine Hood
Front Fender Front Door
Front Section
Cover - Front end member, lower
Energy absorber - Front bumper
Fog lamp
Front bumper
Front bumper grille
Headlamp assembly
Front bumper garnish
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5110 3
INT
2. REAR
EXT
Rear Door Rear Air Spoiler
R E PA I R
Tailgate
Roof Fashion Rail
Rear Bumper Assembly
Rear bumper fascia
Parking aid sensors
Energy absorber
Impact beam
Parking aid sensor wiring
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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4 5110
BUMPER
1. CONSTRUCTION
Front Bumper
Cover - Front end member, lower
Energy absorber - Front bumper
Scrivet
Screw Grommet - Screw
Screw
Fascia assembly - Front bumper
Bolt
BODY EXTERIOR CHANGED BY
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5110 5
INT
EXT
R E PA I R
Rear Bumper
Bracket - Rear bumper, upper
Energy absorber - Rear bumper
Cover - Rear Grommet - Screw Grommet - Screw
bumper guide Screw
Scrivet
Screw
Bolt
Lamp assembly -
Screw
Reflector
Fascia assembly - Rear bumper
CHANGED BY BODY EXTERIOR
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2. REMOVAL AND INSTALLATION OF BUMPER
Front Bumper
Preceding Work: Disconnect the negative battery cable and remove the headlamps and fog lamps.
1. Unscrew the bumper mounting bolts around headlamps. 2. Unscrew the center mounting bolts (10 mm).
Bolt
Bolt Bolt
3. Unscrew the lower mounting bolts (10 mm).
4. Remove the scrivets ( ) from the upper cover.
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5110 7
INT
5. Unscrew the mounting screws from the wheelhouse and remove the front bumper assembly.
EXT
Screws (Upper Side)
R E PA I R
Fasteners (Lower Side)
6. Install the front bumper in the reverse order of removal.
Cover - Front end member, lower
Energy absorber -
Front bumper
Front bumper
Fog lamp
Front bumper grille Headlamp assembly
Front bumper garnish
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
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8 5110
Rear Bumper
Preceding Work: Disconnect the negative battery cable and remove the rear combination lamps.
1. Unscrew the mounting bolts from the rear bumper. (arrow
Unscrew the mounting screw from the rear bumper. (arrow
2. Remove the scrivets ( ) from the rear bumper.
3. Unscrew the mounting screws from the wheelhouse. 4. Unscrew the lower mounting screws from the bumper.
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 9
INT
5. Disconnect the parking aid sensor connector. 6. Unscrew the lower mounting bolts from the bumper.
EXT
Left / Right / Center
R E PA I R
7. Remove the rear bumper fascia and the energy absorber.
Rear bumper fascia
Parking aid sensor Energy absorber
Energy absorber
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 5110
8. Disconnect the rear main wiring (parking aid sensor) connector and unscrew the two mounting bolts (12 mm)
at both sides of rear bumper beam. Carefully remove the rear bumper beam assembly.
Rear Bumper Beam Bolts (LH) Rear Bumper Beam Bolts (RH)
Tightening Torque: Tightening torque:
42 ~ 62 Nm 42 ~ 62 Nm
Do not remove the upper bolt. Do not remove the lower bolt.
A. Disconnect the rear main wiring (parking aid sensor) connector.
At this moment, the side fastener for the connector should be removed.
9. Install the rear bumper beam assembly in the reverse order of removal.
BODY EXTERIOR CHANGED BY
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5110 11
HOOD ASSEMBLY
INT
1. CONSTRUCTION
EXT
R E PA I R
Hood hinge
Rear seal - Hood, rear
Hood panel
Hood insulator
Fastener - Hood Bracket - Hood lifter mounting
insulator pad
Hood hinge
Bolt
Screw
Hood lifter
Seal - Hood, front
Seal - Hood, front sub Hood latch release handle
Hood guide
bumper
Overslam bumper -
Hood latch Screw
Trunk lid
Hood latch release cable
Clip
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 5110
2. REMOVAL AND INSTALLATION OF HOOD ASSEMBLY
Preceding Work: Cover the vehicle body and place the chocks under the tires.
Hood
1. Disconnect the washer fluid nozzle from the engine 2. Unscrew the two shock absorber mounting bolts
hood. (10 mm) from the engine hood.
3. Slacken the mounting bolts on the hood hinge
(Do not remove the bolts.)
NOTICE
Alignment mark
• Make an alignment mark on the hood and hinge
for installation.
4. Carefully remove the engine hood.
Pay particular attention to avoid vehicle damage and
personal injury.
BODY EXTERIOR CHANGED BY
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AFFECTED VIN
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5110 13
Hood Shock Absorber
INT
Release the upper (hood) and lower (vehicle body) clips from the shock
absorber and remove the hood shock absorber.
EXT
CAUTION
• The hood may drop due to its weight. Make sure
R E PA I R
to support it with a safety device.
Hood Adjustment
1. Up/Down/Left/Right
: Slacken the hood hinge mounting bolts and adjust the
hood position until it is placed to the desired location.
2. Hood height
: To adjust the height of hood front end, turn the overslam
bumper.
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 5110
Hood Insulation Pad
1. Remove the fasteners and remove the insulation pad.
BODY EXTERIOR CHANGED BY
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5110 15
Hood Latch and Cable
INT
Preceding Work: Remove the front bumper assembly (including headlamp).
1. Remove the lower instrument panel in front of driver’s seat and disconnect the hood release lever cable.
EXT
Hood release lever
R E PA I R
2. Unscrew the three hood latch bolts (10 mm), disconnect the hood release cable, and remove the hood latch.
3. Remove the hood cable from the vehicle.
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 5110
ROOF FASHION RAIL
1. CONSTRUCTION
CAUTION
• To prevent water leaks, apply the liquid
sealant to the bolt thread when install-
ing the roof fashion rail.
2. REMOVAL AND INSTALLATION
Preceding Work: Remove the headlining assembly.
Unscrew the front and rear mounting nuts (10 mm) and remove the roof fashion rail. The front mounting nut is
located behind the hand grip bracket.
BODY EXTERIOR CHANGED BY
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16 5110
ROOF FASHION RAIL
1. CONSTRUCTION
CAUTION
• To prevent water leaks, apply the liquid
sealant to the bolt thread when install-
ing the roof fashion rail.
2. REMOVAL AND INSTALLATION
Preceding Work: Remove the headlining assembly.
Unscrew the front and rear mounting nuts (10 mm) and remove the roof fashion rail. The front mounting nut is
located behind the hand grip bracket.
BODY EXTERIOR CHANGED BY
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AFFECTED VIN
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5110 17
TAILGATE
INT
1. TAILGATE ASSEMBLY
EXT
R E PA I R
Nut
Tailgate handle, outside
Tailgate weather strip Tailgate lifter
Tailgate overslam
bumper
Ball stud
Tailgate overslam
bumper, center Tailgate side guide
Bolt
Body side guide
Tailgate handle, inside
Tailgate
actuator Screw
rod
Striker
Cap - Tailgate Shim - Door striker
handle, inside
Tailgate latch assembly
Nut
CHANGED BY BODY EXTERIOR
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18 5110
Removal and Installation of Tailgate Assembly
Operating Mechanism
Construction - Inside View Construction - Outside View
Tailgate handle,
outside
Tailgate handle and
rod, inside
Actuator
Actuator
Safety crank
assembly
Latch assembly
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5110 19
INT
Tailgate Trim
1. Unscrew the scrivets and remove the upper trim from the tailgate.
EXT
R E PA I R
2. Remove the inside handle.
3. Remove the scrivets.
4. Remove the fasteners and then remove the lower trim.
Locations of Fasteners
CHANGED BY BODY EXTERIOR
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20 5110
Tailgate Assembly
Preceding Work: Remove the upper and lower trims from the tailgate.
1. Disconnect the main wiring connector (A), ground (B), heated wire (C) and heated wire ground (D). Remove the
wiring harness.
2. Disconnect the rear washer nozzle hose.
3. Disconnect the stop lamp connector from the
rear air spoiler.
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 21
INT
4. Disconnect the ground (A) and heated wire
EXT
cable (B) from the tailgate.
R E PA I R
5. Release the fixing clips and remove both shock
absorbers.
6. Unscrew the two hinge bolts (10 mm) and re-
move the tailgate assembly.
Tightening torque: 15 ~ 26 Nm
CAUTION
• Pay particular attention to avoid vehicle dam-
age and personal injury.
CHANGED BY BODY EXTERIOR
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22 5110
Tailgate Latch and Actuator
Preceding Work: Remove the trim.
Latch
1. Disconnect the connecting rod in tailgate. 2. Remove the latch assembly.
Actuator
Disconnect the actuator rod and connector and remove the actuator assembly.
BODY EXTERIOR CHANGED BY
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5110 23
REAR AIR SPOILER
INT
EXT
R E PA I R
1. Unscrew four mounting nuts (10 mm) and three cap nuts
(10 mm) from the rear air spoiler.
3. Disconnect the rear washer nozzle hose. 2. Remove the upper trim and disconnect
the high mounted stop lamp.
4. Remove the rear air spoiler from the tailgate.
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
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24 5110
SIDE SEAL MOLDING
1. CONSTRUCTION
Fender panel
Quadrant cover assembly
Clip - Side seal
molding mounting
Garnish assembly - Front door
Garnish assembly - Front side seal
Clip - Door garnish mounting
Garnish assembly - Rear door
Clip - Side seal
molding mounting
Clip - Door garnish mounting
Clip - Side seal molding
mounting, lower
Screw Clip - Side seal molding
mounting
Screw
Clip - Side seal molding
Grommet - Screw mounting, lower
Screw
Screw Clip - Door
garnish mounting
Garnish assembly - Rear side seal
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5110 25
INT
Side Seal Molding
All side moldings can be removed/installed with a similar procedure.
EXT
R E PA I R
1. Unscrew the mounting screw in wheelhouse.
2. Unscrew four mounting screws from the
front/rear side seal moldings.
3. Carefully remove the side molding seal.
CHANGED BY BODY EXTERIOR
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26 5110
FENDER
1. REMOVAL AND INSTALLATION OF FENDER
Preceding Work: Disconnect the negative battery cable and remove the headlamps, front bumper and cowl.
1. Remove the tires and wheelhouse cover.
2. Remove the quadrant cover.
CAUTION
• Be careful not to damage the fasteners.
4. Disconnect the side repeater connec-
3. Remove the insulator sponge in fender. tor and remove the lamp assembly.
BODY EXTERIOR CHANGED BY
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5110 27
INT
5. Unscrew the quadrant cover bolts (A) 6. Unscrew the lower mounting bolts in
and cowl bolt (B). fender.
EXT
R E PA I R
7. Unscrew the mounting bolt on the
fender near the headlamp.
8. Unscrew the bolts and screws from
the fender wheelhouse.
9. Unscrew the upper bolts from the fender. 10. Remove the fender from the vehicle.
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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28 5110
FRONT DOOR
1. REMOVAL AND INSTALLATION OF FRONT DOOR
1. Unscrew the mounting bolt from the 2. Remove the main wiring harness cover
door check link (vehicle side). and disconnect the door main connector.
Tightening torque: 20 ~ 31 Nm
Disconnect the Door Wiring Harness.
3. Unscrew the upper and lower hinge bolts and remove the door assembly.
Upper Door Mounting Bracket Lower Door Mounting Bracket
Tightening torque: 16 ~ 30 Nm Tightening torque: 16 ~ 30 Nm
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 29
INT
2. REMOVAL AND INSTALLATION OF FRONT DOOR TRIM
Front
EXT
1. Unscrew seven mounting screws from the door 2. Remove the door handle cable (A), door
trim (refer to figure below). courtesy lamp connector (B), door
tweeter speaker/memory seat position
R E PA I R
Tightening torque 4 ~ 6 Nm switch connector (C) and power window
switch (D) from the removed door trim.
Remove the components as in order
shown in figure below.
3. Separate the bottom of door trim and pull it up to remove.
Locations of Fasteners
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 5110
3. COMPONENTS OF FRONT DOOR OPENING SYSTEM
Front door outside handle assembly
Front door checker assembly
Nut
Nut - Front door
outside handle
Bolt - Flange
Overslam bumper
Screw - Door
striker mounting
Inside handle
Door striker assembly - front door
Door striker shim
Clip - Door
Rod - Front door outside actuator rod
handle
Cable assembly -
Front door safety
lock knob
Bolt - Door latch
mounting Cable assembly -
Front door inside handle
Cable holder
Door latch and cable assembly
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 31
4. FRONT WINDOW REGULATOR
INT
Dual Rail with Regulator
1. The dual rail with regulator is installed to this vehicle. Its advantages are as below:
EXT
1) Smooth operation 5) Reduced the length of glass run
2) Safety operation 6) Increased durability of lifting mechanism (including glass run)
REPAIR
3) Preventing the glass pinch 7) No contamination due to grease (applied solid coating)
4) Preventing the glass tilting
Components
Driver Side Window and Regulator
Window assembly
Window motor
Window mounting bracket
Window guide rail
Window mounting bracket
Window cable
Passenger Side Window and Regulator
Window assembly
Window mounting bracket
Window mounting bracket
Window motor
Window guide rail
Window cable
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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32 5110
Removal and Installation of Window Regulator
Preceding Work: Disconnect the negative battery cable.
1. Lower the window until the window mounting bracket can be seen. Unscrew the nuts from the window mounting
bracket and remove the window.
2. Disconnect the window motor connector and unscrew the mounting bolts from the window regulator.
Passenger Side
Window Motor
Driver Side Window Motor
3. Remove the window regulator from the door.
Driver Side Passenger Side
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 33
REAR DOOR
INT
1. REMOVAL AND INSTALLATION OF REAR DOOR
EXT
1. Remove the lower B pillar and the front seat belt 2. Unscrew the mounting bolts from the door
and disconnect the rear door main connector. check link (vehicle side).
REPAIR
Tightening torque: 20 ~ 31 Nm
Disconnect the Door Wiring Harness.
3. Unscrew the upper and lower hinge bolts and remove the door assembly.
Upper Door Mounting Bracket Lower Door Mounting Bracket
Tightening torque: 16 ~ 30 Nm Tightening torque: 16 ~ 30 Nm
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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34 5110
2. REMOVAL AND INSTALLATION OF REAR DOOR TRIM
1. Unscrew five mounting screws from the door trim 2. Separate the power window switch con-
(refer to the figure below). nector and disconnect the connector.
Remove the door trim.
Installation Notice
Tightening torque 4 ~ 6 Nm
3. Remove the door handle cable (A) and the door
tweeter speaker (B) as in order shown in figure below.
Locations of fasteners
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5110 35
3. COMPONENTS OF REAR DOOR OPENING SYSTEM
INT
EXT
Rear door outside
handle assembly
REPAIR
Rear door checker assembly
Nut
Bolt - Flange
Overslam bumper
Screw bolt Rear door outside handle
Door striker
Label -
Door striker shim Child safety lock
Cable assembly -
Rod - Rear door Rear door safety
outside handle lock knob
Cable assembly -
Rear door inside handle
Cable holder
Door latch and cable
assembly
Bolt
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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36 5110
4. REAR WINDOW REGULATOR
Preceding Work: Disconnect the negative battery cable.
1. Lower the window. Unscrew the mounting screw and bolts
from and remove the guide channel and windshield dam.
Mounting screw
2. Disconnect the motor connector and un-
screw the mounting screws from the win-
dow guide to remove the rear window.
3. Unscrew the window motor nut (A) and guide rail nut (B)
and remove the window regulator from the door.
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 37
INT
Components
Window assembly
EXT
Fixed glass
assembly
Window motor
REPAIR
Guide channel
Window cable
Guide rail
Window mounting
bracket
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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38 5110
FUEL TANK
1. REMOVAL AND INSTALLATION OF FUEL TANK (FOR REMOVING
REAR LEFT UPPER ARM AND LOWER ARM)
Preceding Works: 1. Remove the tires and place the safety jack under the fuel tank.
2. Drain all fuel.
1. Disconnect the fuel sender connector (A) and supply/return pipe (B).
2. Disconnect the fuel supply hose (C) and air
breather hose (D).
NOTICE
• Kyron does not have service hole from passen-
ger compartment to fuel tank. So, fuel tank
must be disassembled for fuel sender related
job.
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 39
3. Remove the two bolts (14 mm) from the fuel tank and unscrew the fuel tank bracket bolt (F: 14 mm).
INT
EXT
REPAIR
4. Seal the fuel hose opening and carefully lower the fuel tank.
Fuel Tank Assembly
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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40 5110
SPARE TIRE
1. REMOVAL AND INSTALLATION OF SPARE TIRE
NOTICE
• Always install the safety stand under the vehicle body before starting this operation.
1. Remove the butterfly nut from the spare tire carrier and loosen the lock bolt until the hook is released.
BODY EXTERIOR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 41
2. Remove the spare tire by pulling down the carrier.
INT
3. Install in the reverse order of removal.
EXT
REPAIR
4. The spare tire carrier can be removed by pulling out the lock pin (arrow).
CHANGED BY BODY EXTERIOR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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BODY REPAIR
4610 / 4620
TABLE OF CONTENTS
BODY REPAIR ......................................................... 3
1. Dimensions ......................................................................... 3
2. Jack-up points ..................................................................... 4
3. Design changes for improving NVH performance .............. 6
4. Frame ................................................................................ 10
5. Body repair ....................................................................... 21
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5110 3
BODY REPAIR
INT
Unit: mm
1. DIMENSIONS ( ): only for the vehicle with roof fashion rail
EXT
R E PA I R
CHANGED BY BODY REPAIR
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4 5110
2. JACK-UP POINTS
IRS - Lifting Point (Dotted Circles)
BODY REPAIR CHANGED BY
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5110 5
INT
5 Link System - Lifting Point (Dotted Circles)
EXT
R E PA I R
CHANGED BY BODY REPAIR
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6 5110
3. DESIGN CHANGES FOR IMPROVING NVH PERFORMANCE
Dual Type Dash Panel and Engine Tunnel with Foaming Pad
Blocks the noise from engine and transmission and improves the reinforcement of vehicle body.
Dash panel
Deadening sheet
Dash reinforcement
Added an additional member to the bottom of dash panel
to minimize the possibility of engine retreat when collision.
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 7
INT
Improved Reinforcement and NVH According to the Introducing of Front
Floor and Rear Floor
EXT
R E PA I R
Applied BPR (Body Panel Reinforcement) Sealer to the Door Outer Panel
BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise.
BPR sealer
Door impact beam
to reinforce the body
reinforcement
panel and reduce the noise
to reinforce the door
impact beam
Door impact beam
to protect the passengers
in case of side collision
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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8 5110
Applied BPR (Body Panel Reinforcement) Sealer to the Body Panel
BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise.
Anti-vibration pads
(6 positions)
Insulation pad
Foaming pad
Foaming pad
Foaming pad
The foaming pads are applied to the symmetry surface of the vehicle.
Thus, totally 6 foaming pad are applied to the vehicle body.
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 9
Applied the Asphalt to the Body Panel (Improved Anti-Vibration)
INT
EXT
R E PA I R
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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10 5110
4. FRAME
Components
5-Link Type Suspension Frame
Beam assembly - rear
impact bumper, rear
Frame assembly - chassis
Cross member
assembly - No. 6 Bracket - body
mounting No. 1
Bracket - cross Bolt
member support
Cross member assembly -
steering gear box Cap - bumper
Bracket - spare
stopper tire stopper
Bracket - spare tire
Bracket - 2-way Bracket - body carrier, front
Cro Hook
connector mounting mounting No. 2 ass ss m
em emb
bly e
-N r Bracket - front
o.5
Bracket - front Bracket - T/M Cross member brake hose
upper arm cross member assembly - No.4
Bracket - fuel tank Bracket - rear
Bracket - front shock absorber
Cross member
coil spring assembly - No.3
Bracket assembly - lateral rod
Hanger -
Bracket - front exhaust pipe,
front
Bracket - clutch hose
upper arm
Cross member - T/
M Bracket - step bar frame, rear
Bracket assembly -
Bracket - clutch
radiator and brake tube
Bracket - body
Bracket - rear lower link
mounting No. 1
Bolt
Bracket - front upper arm
Bracket assembly - front Bracket - body
lower arm, rear mounting No. 2
Bracket - front coil spring
Beam assembly - Bracket - ABS center cable
impact front bumper Bracket - bumper beam mounting
Hook - towing
Cross member
assembly - No. 2
Bracket assembly - radiator
Bracket assembly -
engine and front axle
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 11
INT
IRS (Independent Rear Suspension) Type Suspension Frame
EXT
R E PA I R
Cross member assembly - No. 6
Beam assembly - impact
rear bumper, rear
Bracket - sub frame
mounting, rear
Bracket - rear lower link
Bracket - sub frame
mounting, front
Bolt
Bracket - step bar
Cross member frame, rear
assembly - No. 3
Bolt Bracket - sub frame
mounting, rear
Bracket - thrust link
Beam assembly - impact
front bumper
Frame assembly - chassis
Cross member
assembly - No. 2
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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12 5110
Frame Dimensions
5-Link Suspension Frame
Unit: mm
BODY REPAIR CHANGED BY
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5110 13
INT
Unit: mm
EXT
R E PA I R
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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14 5110
Sectional Drawing
Unit: mm
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 15
INT
Unit: mm
EXT
R E PA I R
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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16 5110
IRS Suspension Frame
Unit: mm
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 17
INT
Unit: mm
EXT
R E PA I R
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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18 5110
Sectional Drawing
Unit: mm
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 19
INT
Unit: mm
EXT
REPAIR
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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20 5110
Frame Body Mounting
Body No. 2 mounting
Body No. 1 mounting
Body No. 5 mounting
Body No. 4 mounting
Body No. 3 mounting
Body No. 1 Body No. 2 Body No. 3 Body No. 4 Body No. 5
mounting mounting mounting mounting mounting
Washer & Washer & Washer & Washer & Washer &
1. tube tube tube tube tube
assembly assembly assembly assembly assembly
- body - body - body - body - body
No. 1 No. 2 No. 3 No. 4 No. 5
Insulator - Insulator - Insulator - Insulator - Insulator -
2. body No. 1, body No. 2, body No. 3, body No. 4, body No. 5,
upper upper upper upper upper
Insulator - Insulator - Insulator - Insulator - Insulator -
3. body, lower body, lower body, body, body, lower
lower lower
Washer - Washer - Washer - Washer - Washer -
4. plain body plain body plain body plain plain
mounting mounting mounting body body
mounting mounting
Bolt Bolt Bolt Bolt Bolt
5.
Tightening torque Tightening torque Tightening torque Tightening torque Tightening torque
60 ~ 80 Nm 60 ~ 80 Nm 60 ~ 80 Nm 60 ~ 80 Nm 60 ~ 80 Nm
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 21
5. BODY REPAIR
INT
White Body
EXT
Without sunroof
REPAIR
With sunroof
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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22 5110
Body Dimensions
Side Structure Complete Unit: mm
BODY REPAIR CHANGED BY
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5110 23
INT
Engine Compartment Unit: mm
EXT
REPAIR
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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24 5110
Front End Unit: mm
BODY REPAIR CHANGED BY
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AFFECTED VIN
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5110 25
INT
Windshield Glass Mounting Panel Unit: mm
EXT
REPAIR
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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26 5110
Tailgate Unit: mm
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 27
Body Gaps
INT
EXT
REPAIR
Closely adhered against windshield Permissible Gap: 0 mm
(no coming-off)
Especially, any coming-off between
cowl grille end and windshield glass
end is not permissible.
Permissible Gap: 4.5 ± 0.5 mm
Difference: below 1 mm
Permissible Gap: 1.5 ± 0.5 mm
Permissible Gap: Approx. 3.9 mm
Seal should not be protruded and
rolled.
Permissible Gap: Approx. 4 mm
Difference between both
fenders: below 1 mm
Permissible Gap: Approx. 3.9 mm
Permissible Gap: Approx. 5.1 mm Permissible Gap: Approx. 4 mm
Difference between
headlamp and hood:
below 1.5 mm
Seal should not be protruded
and rolled.
Permissible Gap: Approx. 2.3 mm
Difference between both
sides: below 1 mm
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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28 5110
Difference between both sides: below 1.5 mm
Permissible Gap: Approx. 6 mm
Permissible Gap: 0 mm Permissible Gap: 4.5 ± 0.5 mm
Permissible Gap: 4.0 ± 1.0 mm
Difference:
below 1 mm
Permissible Gap: 4.5 ± 0.5 mm
Permissible Gap: 4.0 ± 1.0 mm
Difference: below 1 mm
Permissible Gap:
Permissible Gap:2.8 ± 0.5 mm
Approx. 8.7 ± 1.0 mm
Permissible Gap: 2.0 ± 1.0 mm
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 29
Door Components (Including Engine Hood)
INT
Front Door
EXT
REPAIR
Panel assembly -
front door
Nut assembly - door outside
handle mounting
Hinge assembly -
front door, upper
Hinge assembly - front
door, lower
Clip - door Bolt Bolt
outside rod
Checker assembly -
front door
Nut
Nut assembly - door
outside handle mounting
Bolt - flange
Overslam bumper
Screw - door
striker mounting
Door striker
Inside handle assembly -
Door striker shim front door
Clip - door
actuator rod
Door outside
handle rod
Cable assembly - front door
safety lock knob
Bolt - door latch Cable assembly - front door
mounting inside handle
Door latch and cable assembly
Cable holder
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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30 5110
Glass run - front
door window
Regulator - front door
power window
Motor assembly -
power window, front
Bolt
Trim assembly - front door
Screw
Weather strip -
front door trim
Cap - front
door trim
Cap - front
door trim
Bezel - front
door, center
Panel assembly -
armrest, front door trim
Cap - door trim,
center Clip
Holder assembly - bulb
Bulb
Bracket - front door
Lens - door courtesy lamp pull handle mounting
Screw
Grommet
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 31
Rear Door
INT
EXT
REPAIR
Panel assembly -
rear door
Hinge assembly -
rear door, upper
Hinge assembly - rear
door, lower
Handle assembly -
rear door, outside
Bolt Bolt
Rear door checker assembly
Bolt - flange
Nut
Overslam bumper
Screw
Handle assembly -
Door striker rear door, Inside
Door striker shim
Door outside Label - child safety
handle rod
Cable assembly - rear
door safety lock knob
Cable assembly - rear door
inside handle
Cable holder
Door latch and cable assembly
Bolt
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
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32 5110
Glass run - rear
door window
Regulator - rear door
power window
Rear power
window motor
Bolt - serrated
Nut
Bolt
Trim assembly - rear door
Screw
Weather strip - rear
door trim
Cap - rear door trim
Bezel - rear
door, center
Panel assembly -
armrest, rear door trim
Cap - door
trim, center Clip
Grommet
Screw
Bracket - rear door pull
handle mounting
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
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5110 33
Tailgate
INT
EXT
REPAIR
Hinge assembly - tailgate
Hinge assembly - tailgate
Nut
Nut
Panel assembly
- tailgate
Bolt
Nut
Sill trim - tailgate
Trim assembly -
tailgate, upper
Bracket -
tailgate, lower
Clip - trim
mounting
Screw
Clip
Screw - rivet
Trim assembly - Strap assembly - tailgate, lower
tailgate, lower Cover -
tailgate, Screw
lower Cover - strap
Bracket - strap
mounting
Nut
Grommet - screw
Screw
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
34 5110
Nut Handle assembly -
tailgate, outside
Lifter assembly -
tailgate
Tailgate molding Ball stud
Tailgate overslam
bumper
Bumper assembly - guide
body, side
Bumper assembly - tailgate
overslam, center
Bolt
Handle - tailgate,
inner
Bumper assembly - guide
tailgate, side
Cap - tailgate
inside handle
Screw
Rod - tailgate Tailgate striker
actuator
Tailgate striker shim
Crank assembly - tailgate
Bolt safety lock
Latch assembly -
tailgate
Nut
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 35
Engine Hood
INT
EXT
REPAIR
Hood hinge
Sill assembly - hood rear
Hood panel
assembly
Hood insulator
Bracket - lifter mounting
Fastener - hood Hood hinge
insulator pad
Bolt
Screw
Lifter assembly - hood
Sill assembly - hood, front Handle assembly - hood
Sill assembly - hood front sub latch release
Bumper - hood guide
Bumper - trunk lid overslam
Hood latch assembly
Screw
Cable assembly - hood
latch release
Screw
Clip
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
36 5110
Body Panels
Firewall, Fender and Front End
Panel assembly - Member - cowl
front apron side upper Panel assembly -
dash & cowl
Member - cowl side upper
Bracket - fender mounting
Panel Assembly - Front End
Member assembly - headlamp, upper
Member assembly -
front end, upper Panel assembly -
Panel assembly - cowl side inner
Bolt Member assembly - front apron
headlamp, upper
Bolt
Pad - fender
mounting sealing
Panel -
Bolt front end Panel
assembly -
Member assembly - front end,
front end, center inner Bracket - fender mounting
Panel - fender
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 37
INT
Floor Panels
EXT
Front Floor
REPAIR
Bracket - parking
cable pivot
Bracket - parking
cable guide
Member assembly -
body mounting No. 3
Member assembly - front Bracket - third row
seat mounting, rear seat front mounting
Bracket - third row
Bracket - center support seat front mounting
Member assembly - front Bracket - third row
seat mounting, front seat front mounting
Bracket - third row
Panel - front floor seat front mounting
Member assembly - front seat mounting
Bracket - TCU &
Member assembly - TCCU mounting
body mounting No. 2 Member assembly - front seat
mounting, front
Member assembly -
body mounting No. 2
Panel assembly - side sill, inner
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
38 5110
Rear Floor
Panel - rear floor
Cross member assembly -
rear floor No. 4
Reinforcement -
rear floor,
corner
Cross member
assembly - rear
floor No. 4, upper
Panel assembly -
back, outer
Reinforcement -
Extension - rear Cross member assembly - rear floor,
floor, side rear floor No. 4, lower corner
Extension assembly -
rear floor, corner
Member assembly -
rear floor
Panel - container
Cross member assembly -
Cross member rear floor No. 3
assembly - rear
floor No. 1
Cross member
assembly - rear
floor No. 2 Bracket - third row seat
Member assembly -
rear floor
Extension assembly -
rear floor, corner
Extension -
rear floor, side
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 39
Roof Panel
INT
Roof Panel without Sunroof
EXT
Panel - roof
REPAIR
Rail assembly - roof, rear
Rail - roof, center No. 3
Rail - roof, center No. 2
Rail - roof, center No. 1
Rail assembly - roof, front
Roof Panel with Sunroof
Panel - roof
Rail assembly - roof, rear
Rail - roof, center No. 3
Rail - roof, center No. 2
Reinforcement assembly - sunroof
Rail assembly - roof, front
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
40 5110
Side Panel
Reinforcement assembly -
quarter, inner rear, upper
Reinforcement - D pillar,
outer upper
Pillar assembly - D, outer
Panel assembly -
quarter, inner
Reinforcement assembly -
C pillar, inner
Pillar assembly -
A & B, inner
Housing assembly -
fuel filler
Bracket - rear bumper
Bracket - fender mounting, mounting, lower
rear upper
Panel assembly -
Panel assembly - wheelhouse, rear
side, outer
Bracket, fender
mounting, lower
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 41
Engine Mounting Bracket
INT
Heat shield - insulator
Transmission Side
Bracket - engine
EXT
mounting, rear
REPAIR
Bolt
Bolt
Cross member assembly -
T/M mounting
Insulator - engine
mounting, rear
Bolt
Nut
Engine Insulator Mounting
Insulator - engine mounting, front
Bolt Tightening torque:
62 ~ 93 Nm
Washer
Insulator - engine
mounting, front
Bolt
Tightening torque:
22 ~ 28 Nm
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
42 5110
Bumper
Front Bumper Cover - front end
member, lower
Energy absorber -
front bumper
Scrivet
Bolt Grommet - screw
Screw
Fascia assembly -
front bumper
Bolt
Rear Bumper (Excluding PAS)
Bracket - rear
bumper, upper Energy absorber -
rear bumper
Cover - rear Grommet -
bumper guide screw Grommet - screw
Screw
Scrivet
Screw
Bolt
Screw Lamp assembly -
reflex reflector
Fascia assembly - rear
bumper
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 43
Glass
INT
Glass assembly -
EXT
windshield
REPAIR
Plate - inside rearview
mirror base
Molding assembly - windshield
Glass - front door drop
Glass - rear door drop
Glass - rear door fixed Nut - side glass mounting
Glass assembly - quarter
Bolt - door glass mounting
Grommet - door
glass mounting
Glass assembly - tailgate, tinted
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
44 5110
Key Set
Ignition lock and
cylinder mounting bolt
Key set
Ignition key box Driver’s door Passenger’s door
Key hall
illumination
Immobilizer unit
Blank key Blank key
Transponder
Bulb
Immobilizer key
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
5110 45
Others (I)
INT
Molding assembly - roof
(without roof fashion rail)
EXT
Molding assembly -
roof No. 1
REPAIR
Molding assembly - roof No. 2
Molding assembly - roof No. 3
Rail assembly - fashion
Molding assembly - roof No. 4
Molding assembly - roof No. 5
With roof fashion rail
Tape - door tooling hall sealing
Nut
Plug - tailgate Garnish assembly -
tooling hall tailgate, upper
Nut - Hex flange cap
Nut
Spoiler assembly
Cover - upper
Cover assembly - front wheelhouse Cover assembly - rear
wheelhouse
Garnish assembly -
tailgate
Cover - rear
wheelhouse, front
Screw
Scrivet
Cover assembly - rear wheelhouse, rear
Scrivet
Screw
Grommet - screw
CHANGED BY BODY REPAIR
EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
46 5110
Others (II)
Grille - radiator
Cover assembly - quadrant
Screw (backside -
from bumper fascia)
Clip - side sill molding mounting
Garnish assembly - front side sill
Garnish assembly - front door
Clip - door garnish mounting
Clip - side sill
molding mounting
Garnish assembly - rear door
Clip - side sill molding
mounting, lower
Clip - door garnish mounting
Screw
Clip - side sill molding mounting
Screw
Clip - side sill molding mounting, lower
Grommet - screw Screw
Screw Clip - door garnish mounting
Garnish assembly - rear side sill
BODY REPAIR CHANGED BY
KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
Global EPC Automotive Software - http://globalepc.blogspot.com - email: [email protected]
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