0000-00 01-3

1. LAYOUT
Front view Rear view

Right side view Left side view

01-4

2. MAJOR COMPONENTS
▶ Front View

Cylinder head cover

Cylinder head front cover

Engine mounting bracket

Timing gear case cover

EPS idler pulley

Alternator

Water pump pulley

Hydraulic tensioner assembly

A/C compressor

Crankshaft pulley

Oil pan assembly

▶ Rear View

Camshaft position sensor

Breather nipple

Coolant temperature sensor

Purge control solenoid valve

Electronic throttle body

T-MAP sensor

MCC complete

Dual mass flywheel

Crankshaft position sensor

VIS solenoid valve

 0000-00 01-5

▶ Right side view

Rear oxygen sensor connector

Front oxygen sensor connector

Heat protector

Exhaust manifold

Front oxygen sensor

WCC complete

Crankshaft pulley

Rear oxygen sensor

Coolant outlet port

Oil pan drain plug

▶ Left side view

Injector assembly

Fuel rail

Purge control solenoid valve

T-MAP sensor

Electronic throttle body

VIS solenoid valve

Oil dipstick gauge

Thermostat assembly

Oil pressure sensor

Oil filter assembly

01-6

1. GUIDELINES FOR SERVICE WORKS

1) For Safety
To perform the service works easily ans safely, the service technicians must keep the proper working
procedures and rules.
This manual provides the useful instructions to the service technicians so that they can perform the
servive works with standard working process, skills, tips in time.
Please read this manual and follow the instructions carefully.

Signal words such as “WARNING”, “CAUTION” and “NOTE” have special meanings.

indicates information to assist maintenance and instructions.

indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury or property damage.

indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.

However, above references and cautions cannot be inclusive measures, so should have habits of
paying attentions and cautions based on common senses.
 0000-00 01-7

2) Equipment
- Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
- Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger

Remove the engine and transaxle as a set.

- Manual transaxle: Transaxle can be separated after removing the front module (sub frame, engine
and transaxle).
- Automatic transaxle: Transaxle can be separated after removing the sub frame.

3) General Instructions
(1) Before lifting up the vehicle with a lift, correctly support the lifting points.
(2) When using a jack, park the vehicle on a level ground and place the wheel chocks under the tires.
Position the jack under the frame and lift up the vehicle and then support with chassis stand before
service work.
(3) Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
(4) If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
(5) Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
(6) To improve the efficiency of service work, use only recommended and specified tools.
(7) Use only Ssangyong genuine spare parts.
(8) Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them
with new ones. If reused, normal functions cannot be maintained.
(9) Store the disassembled parts as a set based on disassembly order and unit.
(10) Pay particular attention not to miss or mix the fasteners.
(11) If necessary, especially for inspection, clean the removed parts completely.
(12) Apply the oil or grease on the running and sliding surfeces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
(13) Tighten the fasteners to the specified tightening torque.
(14) As a final stage of service work, check if the serviced system is working properly and the problem
has been eliminated clearly.
01-8

4) Basic Inspection
(1) Horn operation
- Listen for the horn sound when pressing the horn pad on the steering wheel.

(2) Brake operation

- Check if there is any abnormal noise, unusually long braking distance, or uneven braking force. If the
brake warning lamp does not go out even after starting the engien or are flashing during driving,
have the brake system checked immediately.
- Check the brake pipes and hoses for connection, oil leak, crack or interference after changing the
position of tires. When replacing the tires, check the brake disc for surface condition and wear.
Check the parking brake cable and brake operation. Shorten the checking interval if the parking
- brake is used frequently.

(3) Exhaust system

- Be aware to any changes in sound or smell from the exhaust system. These may be caused by leak or
overheat. Have the exhaust system checked and repaired immediately.
- Inspect the exhaust system including catalytic converter. Inspect all the components and body frame
near the exhaust system.

(4) Tires
- Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads
may indicates the uneven tire inflation pressure or poor wheel balance.

(5) Steering and suspension system

- Inspect the front and rear suspension and the steering system for damage, looseness or missing
parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for
connection, leak, crack and chafing. Inspect the drive axle boot and seals for damage, tear or leak.
Replace or repair the system if necessary.

(6) Engine oil

- Check the oil level when the engine is still warm and add the specified engine oil if necessary.

(7) Coolant
- Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material),
and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed.

(8) Engine drive belt

- Check all drive belts on the engine for wear, crack and looseness. Retighten or replace the belt, if
needed.
 0000-00 01-9

5) Guidelines on Engine Service

To prevent the personal injuries and vehicle damages that can be caused by mistakes during service
and to provide the optimized performance and safety after service works, the service technicials must
keep the basic cautions and service guidelines below. These could be easily forgotten during service
works.

(1) Cautions before service works

- Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
- Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be unexpected
- damage to electric devices or personal injuries due to short-circuit.
To prevent the foreign material from entering into the fuel injection system, completely seal the inlets of
- HP pump, fuel hoses and high pressure pipes.
To remoev the engine, use the dedicated equipments such as engine jack, transmission jack, engine
- stand and engine crane.

(2) Engine and accessories

Engine has a lot of precise components. The specified tightening torque and correct procedures should
be kept during service works. And, the working area is always clean and well prepared.
- When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set.
- Clean the components completely with engine oil before assembling if needed.
- Fully drain the engine oil, coolant and fuel from the vehicle and seal the inlets with the plugs before
removing the engine.
- All the interference should be eliminated before removing the engine.

(3) Electric devices

Extraordinary care should be taken when servicing the electric systems. Currently, the engine uses a lot
of electric devices. Short circuit and poor contact may cause the low engine performance, incomplete
combustion and other abnormalities.
- To prevent any damage to electric systems, make sure to disconnect the negative (-) cable from the
battery and place the ignition switch to OFF position before servicing.
- Use only the specified parts with same ratings when replacing the electric devices. Check the
grounds and connections for looseness.

(4) Fuel and lubrication system

- When working with the fuel or oil systems in enclosed area, always keep the working area well-
ventilated and never allow anybody to smoke.
- Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and nuts
should be tightened as specified.
- Make sure to check the connections for leak after installation.
01-10

2. JACK-UP POINTS
▶ Stand jack-up points and installation status (front side)

Jack-up points and setup

(front side)

Supporting

Jack-up points Jack-up points

for 2-post lift for 2-post lift

Jack-up points and setup

(rear side)

Supporting
 0000-00 01-11

3. STANDARD BOLTS SPECIFICATIONS

1) Metric bolt strength is embossed on the head of each bolt. The strength of bolt can be classified as
4T, 7T, 8.8T, 10.9T, 11T and 12.9T in general.
2) Observe standard tightening torque during bolt tightening works and can adjust torque to be proper
within 15 % if necessary. Try not to over max. allowable tightening torque if not required to do so.
Determine extra proper tightening torque if tightens with washer or packing.
3) If tightens bolts on the below materials, be sure to determine the proper torque.
4)
- Aluminum alloy: Tighten to 80 % of above torque table.
- Plastics: Tighten to 20 % of above torque table.
01-12

4. CODING
1) Variant Coding
Description Selection Coding
Unleaded/leaded Unleaded Select the appropriate system
Leaded
Cruise control No system Select the appropriate system
Cruise control
ACC
Undefined
Vehicle speed Max 180kph Selec : 190kph
190kph
200kph
Description 210kph
Selection Coding
Tire size
MIL MIL215/65R 16
- not illuminate Select the appropriate
: MIL - illuminatesystem
225/60R
MIL 17
- illuminate
Engine fan 225/55R
Relay 18 Select : Relay
undefined
PWM
Air-Conditionation Not equipped Select the appropriate system
Equipped
OBD Information No MIL OBD - I Select the appropriate system
MIL treatment OBD - I
MIL treatment OBD - II
MIL treatment E - OBD
MIL treatment KOBD
Engine E20 Select : E20
E23
E28
E32
E36
Body Sedan Select : Sedan
Limousine
 0000-00 01-13

Description Selection Coding

Transfer case 2WD 2WD : 2WD
4WD : AWD
TOD
P/T 4WD
AWD
EPS Not equipped Select the appropriate system
Equipped
Select lever BTRA lever M/T : M/T lever
A/T : DURA lever
DC lever
DURA lever
M/T lever
EPB Not equipped Select : Not equipped
Equipped
Enable RON RON 89 Select : RON 95
conection
RON 91
RON 93
RON 95
RON 97
RON 98
RON 100
Not defined
MIL MIL - not illuminate Select : MIL - illuminate
MIL - illuminate
Engine fan Relay Select : Relay
PWM
Coding is completed NO Select : YES
YES
01-14

Description Selection Coding

Immobilizer & Key Non - IMMO Select the appropriate system
BCM(IMMO)
SKM
Vehicle variant Not defined Select : Yes
message
No
Yes
Vehicle Chairman Select : KORANDO C
W200
REXTON
Musso
Kyron
KORANDO C
KORANDO (old)
Actyon Sport
Vehicle code, M/T M/T : M/T
transmission A/T : NAGI/HPT
NAGI/HPT
BTRA A/T
ION 6 speed A/T
NAG2 A/T
TPMS Not equipped Select the appropriate system
Equipped
EBS(ABS/ESP) Not equipped Select the appropriate system
ABS
TCS
ESP
Telematics Not equipped Select : Not equipped
Equipped
 0000-00 01-15

Description Selection Coding

EAS Not equipped Select : Not equipped
ECS
2 Corner EAS
4 Corner EAS
Domestic/Export Domestic Select the appropriate system
General export
EU export
01-16

2) Parameter Coding
Parameter Range Remark
Fuel characteristic 1~6
Idle RPM(P) -50 ~ 127
Idle RPM(D) -50 ~ 127
CO correction -6.945 ~ 6.8907
Pedal progress coding 1~3
Idle RPM(P) - cold condition -50 ~ 127
Idle RPM(D) - cold condition -50 ~ 127
 1740-01 04-3

1. SPECIFICATION
Unit Description Specification
Filter type Dry, filter element
Filtering area 0.225 m²
Air cleaner element
Clean every 7,500 km
Service interval
Change every 15,000 km
Weight 1.45 kg
Air cleaner assembly Operating temperature 25℃
Capacity 7L

* Shorten the service interval under severe conditions such as driving on a dusty road or offroad.
04-4

2. LAYOUT

1. Intake Manifold Assy 6. Bolt

2. Bolt 7. Electric Throttle Body
3. T-MAP sensor 8. Bolt
4. Bolt 9. Acoustic Cover
5. Intake Manifold Brkt
 0000-00 04-5

1. Air Cleaner Assy 12.Snorkel Assy

3. Element Assy 13.Water Portector
5. Air Cleaner MTG NO.2 14.Resonator Assy
6. Insulator Collar 17.RR Fascia MTG Screw Rivet
7. Spring Clamp 18.Bolt
8. Resonance Duct 19.Nut
9. Resonance O-Ring 20.Screw
10.Air Cleaner MTG NO.1 21.Air Cleaner to Engine Hose Assy
11.Air Cleaner MTG Bolt
04-6

1. OVERVIEW
To improve the engine performance, the VIS system has been introduced in the intake manifold. It
provides the “Long Runner” in low speed and the “Short Runner” in high speed.
And, to reduce the internal pulsation in the intake manifold, the Runner # 1 and #2 are located in
symmetry position with Runner #3 and #4. To reduce the air resistance, the throttle body is tilted b

2. COMPONENTS

Intake manifold assembly

VIS solenoid valve T-MAP sensor VIS valve

 0000-00 04-7

PCV valve Blow-by hose

Purge control solenoid

valve

Electronic throttle body Air cleaner element

04-8

3. OPERATING PROCESS
When Long Runner is operating When Short Runner is operating

Intake air flows

 1740-01 04-9

4. INPUT/OUTPUT DEVICES
04-10

5. CIRCUIT DIAGRAM
 2221-01 03-3

1. SPECIFICATION
Unit Specification
Fuel Unleaded gasoline
Fuel system Fuel injection MPI (Muilt Point Injecter) type
Fuel supply Returnless Fuel System
Capacity 57 L
Fuel tank Material Plastic
Fuel sender Dual sender type
Fuel filter Service interval Change every 100,000 km
Fuel pump Pressure 3.8 bar
Color Black
Injector
Capacity 187.2 g/min
03-4

2. SYSTEM LAYOUT

1. Fuel tank assy 11.Suction tube assy

3. Fuel tank strap assy 12.Harness wiring assy
4. Heat shield assy 13.Fuel pump plate cover
5. Sub sender assy 14.O-ring
6. Main fuel pump assy 20.clamp
7. Fuel filler assy 21.Nut
8. Fuel filler cap assy 22.Nut
9. Feed tube assy 23.Screw
10.Return tube assy
 2221-01 03-5

1. Fuel Filter Assy

2. Bolt
3. Fuel Return Pipe
4. Fuel Supply pipe
6. Fuel Vapor Pipe Assy
9. Canister Compl
14.Fuel line Holder
15.Fuel line Holder
03-6

1. OVERVIEW
The fuel system is a returnless type that the fuel pressure regulator is mounted inside the fuel tank.
The engine ECU controls the fuel injection in each injector electronically.
According to the engine loads, the engine ECU draws or cuts off the evaporated gas in canister into the
combustion chamber. The fuel system consists of fuel tank, fuel lines, fuel pump and fuel pressure
regulator.

Returnless Type

Fuel supply line to

sub tank

Fuel return line Fuel supply line

Maintain 3.8 bar

03-8

2. COMPONENTS
Canister Fuel filter

Fuel filter

Fuel tank assembly

Fuel pump and fuel sender assembly
Canister

Fuel neck hose

Primary fuel
sender

Fuel tank assembly

 2221-01 03-9

Engine ECU

Engine compartment

Secondary fuel sender

Injector Fuel rail Purge control solenoid

valve
03-10

3. SCHEMATIC DIAGRAM OF FUEL FLOWS

 2221-01 03-11

4. INPUT/OUTPUT DEVICES

The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and
controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective airfuel ratio
control based on these signals.
 1745-01 05-3

1. TROUBLESHOOTING
05-4

2. LAYOUT

1. Exhaust Manifold Assy

2. Exhaust Manifold Gasket
3. Hex Flange Nut
4. Heat Protector Assy
5. Hex Bolt (M6 X 1 X 25)
6. Heat Protector Assy
7. Hex Bolt (M8 X 1.25 X 16)
 1745-01 05-5

1. WCC Compl 10.Hanger

2. Exhaust FRT Pipe Assy 11.Hanger
3. UCC Compl 12.Hanger
4. Muffler Complete ?RR 13.Nut
5. Exhaust FRT Heat Protector 14.Nut
6. CTR Muffler Heat Protector 15.Bolt
7. RR Muffler Heat Protector 16.Gasket Ring
8. Clamp 19.Nut
9. Gasket 20.CTR Muffler Complete
05-6

3. CAUTIONS
- Do not park the vehicle on flammable materials, such as grass, leaves and carpet.
- Do not touch the catalyst or the exhaust gas ignition system when the engine is running.
- If a misfire occurs in the combustion chamber or the emission of pollutant exceeds the specified level,
the catalyst can be damaged.
- When servicing or replacing components of the exhaust system, makes sure that the components
are positioned at regular intervals from all other parts of the under body.
- Be careful not to damage the exhaust system when lifting the vehicle from its side.
- All components and body parts of the engine exhaust system should be inspected for crack, damage,
air hole, part loss and incorrect mounting location. Also check for any deformation which can result in
exhaust gas drawn into the vehicle.
- Make sure that the exhaust pipe is cooled down sufficiently before working on it because it is still hot
right after the engine is stopped.
- Wear protective gloves when removing the exhaust pipe.
 1745-01 05-7

1. OVERVIEW
This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants
and noise during that arise during combustion.
Harmful materials produced in the combustion process is treated and reduced in the exhaust system.
Harmful materials discharged from the crankcase and fuel tank is drawn into the intake system again to
reduce discharge amount of harmful materials.

▶ Emission aftertreatment system

- Catalytic Converter & O2 Sensor

The catalytic converter is a monolith type purification system composed of cordierite which purifies
exhaust gas through the small holes of active monolith catalyst from the exhaust manifold. As exhaust
gas passes through the small holes in the layer in the middle, its CO and HC are reduced by
oxidization reaction and its NOx is reduced by reduction reaction to Pt, Ph and Pd. The oxygen
sensor sends signals for feedback and determination of catalyst condition. For detailed description,
see the corresponding section.

▶ Purge Canister Control

The fuel evaporative gas is a gas evaporated to the atmosphere in the section between the fuel tank and
fuel line, and its main component is hydrocarbon (HC). The fuel evaporative gas is temporarily stored in
the canister, and it is drawn to the engine through the throttle body when the purge control solenoid valve
is open according to the engine operating condition.

▶ Blow-by gas control system (crankcase ventilation system)

Gas in the combustion chamber is sealed by the piston. However, gas is leaked through the gap
between the cylinder and piston and drawn into the crankcase during the compression and explosion
strokes. This gas is blow-by gas and its main components are hydrocarbon and carbon monoxide. If this
gas is drawn into the crankcase, the system can be corroded and oil can be deteriorated. Also, if this
gas is discharged into the air, it can pollute the environment. To prevent these, the blow-by gas
reduction system (also called as crankcase ventilation system) draws the blow-by gas from the
crankcase to the combustion chamber for combustion.
05-8

2. COMPONENTS
WCC Engine ECU Engine CHECK lamp

Exhaust manifold PCV valve Blow-by hose

 2414-00 05-9

Exhaust No.1 Exhaust No.2 Exhaust No.3

(main muffler)

Front oxygen sensor Rear oxygen sensor UCC

05-10

3. WORK FLOW IN EXHAUST SYSTEM

 1745-01 05-11

4. INPUT/OUTPUT DEVICES
 1443-01 06-3

1. SPECIFICATION
Description Specification
Internal resistance 3 ~ 7 kΩ
Center electrode Iridium alloy
Spark plug Ground electrode Platinum alloy
Electrode clearance 1.1 mm
Change interval 160,000 km
Primary operating current 7 ± 0.5A
Generated voltage
Max. 400 V / 5~20 kV
Ignition coil (primary/secondary)
Ignition type Independent ignition type
Ignition sequence 1-3-4-2
06-4

2. LAYOUT

1. Ignition Coil
2. Bolt
3. Spark Plug
 1443-01 06-5

1. OVERVIEW
The ignition system is to supply high voltage generated from the ignition coil to the spark plug. The
G20DF engine is equipped with the independent type direct ignition system that the ignition coil is
installed in each cylinder.
The basic ignition timing in each cylinder is determined by the signals from camshaft position sensor and
crankshaft position sensor.
This ignition system controls the electronic ignition timing received from the engine ECU. To control the
ignition timing precisely, the ECU use the information below:
- Engine load
- Coolant temperature
- Intake air temperature
- Engine rpm
- Camshaft position sensor (CPS)
- Crankshaft position sensor (CKS)
If the signal from the camshaft position sensor is not delivered to the engine ECU, the ignition coil and
fuel system cannot be operated.
06-6

2. COMPONENTS

Ignition coil

Spark plug

Injector Knock sensor Camshaft position

sensor
 1443-01 06-7

Crankshaft position
sensor

Engine ECU

Coolant temperature
sensor

T-MAP sensor Electric throttle valve Accelerator pedal position

sensor
06-8

3. INPUT/OUTPUT DEVICES
06-10

4. CIRCUIT DIAGRAM
1443-01 06-11
 1535-01 07-3

1. SPECIFICATION
Description Specification
Lubrication type Gear pump, forced circulation
Oil pump
Type Internal gear
Oil filter Type Full flow/Paper element
Quality class: Ssangyong genuine engine oil
Oil
Engine oil (Approved by MB 229.51 SAE 5W30)
Capacity 4.5 L
Oil injection nozzle Type Flange and bolt type

The engine oil filter element should be changed at the same time with the engine oil.
- Regularly check the engine oil level and add the engine oil if necessary.
- Remember to check the engine oil level and shorten the cycle to replace the engine oil under
severe driving conditions.

Severe Driving Condition?

- Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance
below 16 km when the outside temperature remains below freezing
- Driving in a hilly or mountainous terrain, sandy, or dusty area
- High load driving such as trailer towing
- Taxi, patrol service or delivery service (extended idling and excessive driving with low speed)
07-4

2. MAINTENANCE
Park the vehicle on a level ground and apply the parking brake. Stop the engine and wait more than 5
minutes.

- Pull out the dipstick and wipe it with a clean cloth. Reinsert it all the way.
- Pull out it again and check the oil level.
- The oil level should be between the maximum (Max) mark and minimum (Min) mark on the oil
dipstick. Oil should be replenished before the level goes below the minimum mark.

Operating vehicle with insufficient amount of oil can damage the engine. Make sure the engine oil level
is correct and add oil if necessary.

Engine oil cap Engine oil dipstick

Min Max

▶ Replenishment
If the level gets to the lower point, open the filler cap on top of the cylinder block and add the genuine oil
without exceeding the level of the upper mark.
Recheck the oil level after 5 minutes.

- Regularly check the engine oil level and add Ssangyong genuine engine oil if necessary.
- Clean the dipstick with clean cloth so that any foreign materials cannot get into the engine.
- The oil should not go above the upper mark on the dipstick.
- The engine oil may be consumed more if the engine is new.
 1535-01 07-5

3. LAYOUT

1. Oil Pump Assy 25.Bolt

6. Seal Ring 31.Oil Dipstick Tube Assy
8. Oil Pan 32.Oil Dipstick Gauge Assy
10.Bolt 33.O-Ring
11.Drain Plug 34.Bolt
21.Bolt 37.O-Ring
22.Oil Pump Chain 44.Sealant
24.Oil Pump Chain Tensioner Assy 45.Dust Cover
07-6

1. Oil Filter Assy 11.O-Ring

2. Oil Filter Cover 26.Oil Filter Bypass Valve Assy
9. Oil Filter Element Kit 30.Oil Filter Housing Gasket
10.Drain Plug 31.Bolt
35.Oil pressure switch
 1535-01 07-7

1. OVERVIEW
The lubrication system supplies oil to each lubrication section to prevent friction and wear and to remove
heat from the friction part. As the engine runs, frictional heat is generated on each lubrication section. If
this condition persists, the bearing can be burned and stuck.
In other words, it creates an oil film on each sliding surface to convert solid friction to liquid friction in
order to minimize wear and prevent temperature increasing on the friction part.

2. COMPONENTS
Oil pressure switch Oil jet Engine oil dipstick

Engine oil pan Oil pump Oil filter module

07-8

3. OPERATING PROCESS
1) Operation Flow

CVVT
Chain Cam journal
tensioner bearing

Main oil gallery

in cylinder block

Oil jet
Oil pressure
Main journal bearing
switch

Oil pump
Oil filter assembly
Oil supply
 2112-01 08-3

1. SPECIFICATION
Description Specification
Cooling system Type Water cooling, forced circulation
Coolant Capacity Approx. 8.0 ~ 8.5 L
Core size 740W X 378.9H X 27T
Radiator
Flow type Cross flow
Type SYC 1025 (LLC)
Antifreeze
Mixing ratio 50:50 (water:antifreeze)
Type Electric
Cooling fan module
Capacity 180 W + 120 W
Control type Series: low speed, Parallel: high speed
Min. capacity 1.6 L
Coolant reservoir Circulation Closed roof type
Pressure cap Screw type, 1.4 bar
Type Wax pallet type
Opening temperature 90℃
Thermostat
Fully open temperature 100℃
Valve lift 8mm
08-4

2. INSPECTION
Problem Possible Cause Action
- Leak from the radiator - Change the radiator
- Leak from the coolant auxiliary tank - Change the coolant auxiliary tank
- Leak from the heater core - Change the heater
- Leak from the coolant hose connections - Reconnect the hose or replace the
Damaged coolant hose clamp
- - Change the hose
Coolant - Leak from the water pump gasket - Change the gasket
level is too low
- Leak from the water pump internal seal - Change the water pump

- Leak from the water inlet cap - Change the water inlet cap gasket
- Leak from the thermostat housing Change the thermostat sealing
-
- Incorrect tightening torque of the cylinder - Tighten the bolts to the specified
head bolts torque
- Damaged cylinder head gasket - Change the cylinder head gasket
- Coolant leakage (Coolant level is low) - Add coolant
Improper coolant mixture ratio - Check the coolant concentration
- Kinked coolant hose (Anti-freeze)
- - Repair or replace the hose
- Defective thermostat - Change the thermostat
- Defective water pump - Change the water pump
- Defective radiator - Change the radiator
- Defective coolant auxiliary tank or tank - Change the coolant auxiliary tank or
Coolant
cap tank cap
temperature is
too high - Cracks on the cylinder block or - Change cylinder block or cylinder
cylinder head head
- Clogged coolant passages in the - Clean the coolant passage
cylinder block or cylinder head
- Clogged radiator core - Clean the radiator core
- Improper operation of cooling fan - Replace the cooling fan or repair the
related circuit
- Defective temperature sensor or faulty - Replace the sensor or repair the
wiring related wiring
 2112-01 08-5

Problem Possible Cause Action

- Thermostat is stuck open - Change the thermostat
Coolant - Improper operation of cooling fan - Replace the cooling fan or repair the
temperature is related circuit
too low
- Defective temperature sensor or faulty - Replace the sensor or repair the
wiring related wiring
08-6

1) Coolant Level Check

A. Park the vehicle on level ground and apply the parking brake. Stop the engine and wait until it is
cooled down. The coolant level should be between the MAX and MIN mark on the coolant reservoir.
If the coolant level is below the “MIN” mark, immediately add coolant.
B.

Coolant reservoir

MAX

MIN

- Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the engine and radiator are hot.
- Avoid any direct contact of the coolant to the painted body of the vehicle.
 2112-01 08-7

2) Leak Test
A. Release the pressure in the system by
loosening the pressure cap of the coolant
reservoir slightly. Then, remove the pressure
cap completely.

Never open the cap until the coolant

temperature becomes under 90℃ to
prevent any burn.

B. Add the coolant so that the coolant level is

between MAX and MIN mark on the coolant
auxiliary tank.
C. Connect the tester to the tank filler and apply
pressure (1.4 bar).
D. Check all the coolant hoses, pipes and
connections for leaks when the pressure of
the tester drops, and replace or tighten, if
necessary.

3) Thermostat
Immerse the thermostat into the water. Heat the
water and check the valve opening temperature.

Valve opening
90±2℃
temperature
08-8

3. CAUTIONS

- If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity can
be decreased resulting in poor circulation in the cooling system which leads to overheated engine.
Use of non-recommended coolant could cause damage to the cooling system and overheating of the
- engine.
Opening the coolant reservoir cap while the engine is running or hot can cause burns by hot steam or
- water.
To open the coolant reservoir cap, wrap the cap with a wet towel or thick cloth after the engine is
- cooled down sufficiently.
If cool water is added to the heated engine, the engine or radiator can be deformed.
- The anti-freeze in the coolant can damage the painted surface, so avoid the contact of the coolant to
- the painted body.
The anti-freeze and water should be mixed in proper mixture ratio. Never add only water when
- adding coolant.
If the anti-freeze content is too low, the coolant can be frozen while the engine can be overheated if
- anti-freeze content is too high.
 2112-01 08-9

4. LAYOUT

1. Water Pump Assy 11.Coolant Pipe Assy

2. Bolt 12.Bolt
3. Water Pump Pulley 13.Bypass Hose
4. Bolt 14.Clamp
7. Thermostat Assy 15.Deaeration Pipe Assy
8. Bolt 16.Bolt
9. Coolant Outlet Port Assy 17.Bolt Deaeration Hose
10.Bolt 18.Clamp
08-10

1. Cooling Radiator Assy 7. Insulator Module MTG LWR

2. Fan & Shroud Assy 8. Module MTG UPR Brkt Assy
3. Cover-Radiator 9. Screw
4. Seal Side 10.Protector-Eroom Hot Air
5. Screw 11.Screw
12.Fastener
 2112-01 08-11

1. Hose-Rad Inlet 10.WDT_Clamp_M24

2. Hose-Rad Outlet 11.WDT_Clamp_M30
3. Hose-Make Up 12.Clip_Closed_CT_M25
4. Hose Assy-Deaeration Rad 13.Bolt-Tapping
5. Hose Assy-Deaeration Rsvr 14.Clamp_Spring_M14
6. Hose Assy-Deaeration Eng 15.Screw
7. Clip-Deaeration Tube mtg 16.Tank Assy-Reservoir
8. WDT_Spring_Clamp_M45 17.Cap-Reservoir Tank
9. WDT_Spring_Clamp_M50
08-12

1. OVERVIEW
The coolant system is to keep the engine temperature stable.

2. COMPONENTS
Coolant reservoir

Water pump

The water pump is driven by the engine drive belt and supplies
the coolant to each area of the engine.

Thermostat

When the engine coolant

reaches 90℃, the thermostat
starts to open (fully open at
100℃) and lets the coolant
flow to the radiator to maintain
the engine temperature.
 2112-01 08-13

Coolant outlet port

Coolant temperature
sensor

Measures the coolant

temperature and sends the result
to the engine ECU.

Radiator PWM fan

Radiates the heat through fins and cools Circulates the fresh air forcibly to exchange
down the hot coolant as the coolant heat with the radiator core fin.
passes through the tube of the radiator
core.
08-14

3. COOLANT FLOW DIAGRAM

Water pump

Bypass

Heater
return

Thermostat
 2112-01 08-15

Coolant outlet port

Coolant outlet port

A: to radiator
B: to water pump (bypass)
to cabin heater
C: to coolant reservoir
D: Coolant temperature
E: sensor mountinh boss
from cylinder head
F: Gasket
G:
 1452-01 09-3

1. SPECIFICATION
Unit Description Specification
Type HPS EPS
Crankshaft pulley : Alternator pulley 1 : 2.66
Normal output
Alternator (idle/2200rpm) 70/140A ←

Regulator voltage 12V ←

Length 12.5mm ←
Brush
Wear limit 7.0mm ←
Type MF ←
Battery
Capacity 90AH ←
09-4

2. LAYOUT
1) Alternator

1. Alternator assembly
2. Bolt
 1452-01 09-5

2) Battery

1. Battery assembly 17.Nut

2. Clamp - Battery 18.Nut
3. Bolt 20.Cab - Earth
5. Cable assembly - Cable positive 21.Box assembly - Battery sub
6. Cable assembly - Battery ground 22.Fuse - MID 80A
8. Bolt - Earth 23.Clamp - Battery cable
9. Cap - Terminal 24.Grommet - Ring terminal
10.Connector - Battery 25.Grommet - Ring terminal
09-6

3. INSPECTION
1) Alternator
▶ Output Test

Item How to check DTC set value / Action

1. Disconnect the cable connected to the B - Pass: If the measured current
terminal on the alternator. Connect one is 45 A or higher.
end of the ammeter to the B terminal and - Fail: If the measured current is
the other end to the cable connected to less than 45 A.
Output current the B terminal. - Check the current of the B
2. Measure the maximum output value. terminal.
(Maintain the engine speed between
2,500 and 3,000 rpm.)
(Turn the headlamp and all the electrical
switches on.)
1. Move the gear selector lever to the neutral - Open circuit: If the measured
position. current is 5 A or higher.
B terminal current
2. Maintain the engine speed at 2,500 rpm
with the vehicle unloaded.
(Turn all the electrical switches off.)
1. Disconnect the negative cable from the - Pass: If the measured
battery. resistance is between 3 and
2. Remove the B terminal and turn off the 6Ω.
Rotor coil
ignition switch. - Faulty rotor coil or slip ring: If
resistance
3. Measure the resistance between the L the measured resistance is
and F terminals with an ohmmeter. less than 3Ω or greater than
6Ω.
1. Connect the B terminal wiring. - Specification: 12.5V to 14.5V
2. Measure the voltage with the engine Faulty IC regulator or field
L terminal voltage
running. - coil: If the measured voltage
is 14.5V or higher.

- Disconnect the negative cable from the battery.

- Connect the negative cable again after connecting the ammeter.
 1452-01 09-7

▶ Troubleshooting

Item Cause Action

Defective alternator voltage regulator Replace
Overcharged battery
Defective voltage detection wiring Repair or replace
Loose alternator drive belt just the belt tension or
replace
Poor connection of related circuit or open Retighten the loose
circuit connection or repair
Discharged battery open circuit
Defective alternator voltage regulator Replace
Terminated battery Replace
Defective ground Repair
Defective alternator voltage regulator Replace
Charge warning lamp does Open circuit in charge warning lamp, fuse Replace or repair the
not come on when turning on or wiring charge warning lamp or
ignition switch with engine fuse
stopped
Defective ignition switch Replace
Defective ground of alternator circuit Repair
Defective alternator voltage regulator Replace

Charge warning lamp does Corroded or worn battery cable Repair or replace
not go off after starting Loose alternator drive belt Adjust the belt tension or
engine replace the belt

Defective wiring harness Repair or replace

09-8

2) Battery
▶ Inspection
 1452-01 09-9

▶ Using battery tester

- PASS (11.0 V or more): Explain to the customer that the battery is reusable.
- Need to be charged (9.0 to 11.0 V): Charge the battery with a charger and reinstall it. Explain it to the
customer.
- Need to be replaced (9.0 V or more): The battery should be replaced due to overdischarging.

▶ How to use battery tester

- Determine battery capacity by fixing current

(load capacity) and time and varying voltage.
Determine battery capacity based on the
- amount of voltage drop when discharging a
fixed load capacity (120 A) for 5 seconds.
Connect the tester to the battery and read the
display while applying a load for 5 seconds.
-

- Red area (①): overdischarge or faulty

battery
- Yellow area (②): Need to be charged
(using a vehicle alternator and a battery
charger)
- Green area (③): Normal
- Red area on the left-hand side of OK (④):
- Impossible to charge with an alternator
- Green area with OK (⑤): Normally charged
Red area on the right-hand side of OK
- (⑥): Overcharged by an alternator
09-10

▶ Jump start
If the battery is weak or terminated, the battery from another vehicle can be used with jumper cables to
start the engine.

▶ Connecting order
1. The positive (+) terminal of the discharged battery
2. The positive (+) terminal of the booster battery
3. The negative (-) terminal of the booster battery
4. Connect one end of the other jumper cable to the body of the discharged vehicle, such as the engine block
or a front towing hook.

▶ Starting
1. Prepare a set of jumper cables.
2. Place another vehicle that has the same 12 V of power near to the discharged vehicle.
3. Switch off all electrical accessories for the discharged vehicle.
4. Apply the parking brake and shift the transaxle to the P position (automatic transaxle) or neutral (N)
position (manual transaxle).
5. Connect the jumper cables.
6. Try to start the discharged vehicle while accelerating the engine rpm in the booster vehicle.
7. Attempt to start the engine with the discharged battery.
8. After starting the engine, carefully disconnect the jumper cables in the reverse sequence of
connection.
 1452-01 09-11

▶ Maintenance
If the charge warning lamp ( ) on the instrument cluster comes on while driving, there is a malfunction
in the charge system including the battery. Therefore, carrying out the system check is needed.

- Make sure that the battery cables are firmly connected.

- If the terminals are corroded, clean them with a wire brush or sandpapers.
- Always disconnect the battery cables with the ignition key removed. When disconnecting the battery
cables with the ignition key turned to ON or ACC position, several electric units can be damaged due
to sudden voltage change.
- Check the battery for crack, damage or fluid leaks. Replace it if necessary.
- Wipe out the battery fluid on the battery surface using a rubber glove and a clean cloth wetted with
soapy water.
09-12

1. OVERVIEW
The charge system is designed to supply electrical energy to the vehicle while driving, and supplies a
constant direct current voltage by converting mechanical rotational movement to electrical energy. The
voltage regulator on the back of the alternator controls the generated voltage in all rotating ranges and
adjusts the system voltage according to the electric load and ambient temperature change.

Body ground Battery

It converts the chemical energy to the

electrical energy and supplies power to the
corresponding electric units when starting the
engine.

Alternator B+ wiring

The alternator charges the battery and

supplies power to each electric unit by
converting the mechanical energy to the
electrical energy.
 1452-01 09-13

2. CHARGING OPERATION
1) Vehicle without Smart key system
09-14

2) Circuit Diagram
1452-01 09-15
 1462-01 11-3

1. SPECIFICATION
Unit Description Specification
Capacity 12V 1.4kw
Engagement Meshed type
Start motor Rotating direction Clockwise
Solenoid operating voltage Max. 8V
Weight 2.5kg
11-4

2. LAYOUT

1. Starter
2. Bolt
 1462-01 11-5

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

Starter does not Faulty starter Repair or replace

stop Faulty ignition switch Replace
Broken pinion gear or faulty starter Replace the starter
Engine cranks
normally, but Broken flywheel ring gear Replace
does not start
Open circuit Repair
11-6

1. OVERVIEW
The starter (start motor) starts the engine with rotational power by converting the electric energy to the
mechanical energy.
When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the
pinion gear clutch overruns to protect the pinion gear.

Start motor assembly

 1462-01 11-7

2. OPERATING PROCESS
11-8

3. CIRCUIT DIAGRAM
1462-01 11-9
 8530-00 12-3

1. OVERVIEW
1) System Description

Auto cruise ECO cruise

operated operated

The cruise control is an automatic speed control system that maintains a desired driving speed without
using the accelerator pedal. The cruise control switch is under the right side of steering wheel and
‘ECO” indicator or “AUTO CRUISE” indicator comes on according to the working conditions.
The vehicle speed must be greater than 38 km/h to engage the cruise control. This feature is especially
useful for motorway driving.

The cruise control system is a supplementary system, which helps the driver to drive the vehicle at a
desired speed without using the accelerator pedal under the traffic condition where the vehicle-to-
vehicle distance meets the legal requirement.
12-4

2) Traffic Conditions for Using Cruise Control

Use the cruise control system only when the traffic is not jammed, driving on motorways or highways
where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc.

Improper use of the cruise control could be dangerous.

- Do not use on winding roads.yy
- Do not use in heavy traffic.yy
- Do not use on slippery, wet roads.
This could result in a loss of control, collision, and/or personal injuries.

The described speed value may vary slightly depending on the road conditions.
 8530-00 12-5

2. CONFIGURATION
1) Circuit Diagram

The engine ECU detects the operating conditions of cruise control system, and monitors the braking
performance, vehicle speed, road conditions and ESP system operation. If the engine ECU determines
that there are not any problem to drive in cruise control mode, the vehicle can be operated by cruise
switch signals (decelerating, accelerating, cruising).
12-6

2) Components

Test voltage(VCC 5V)

FUNCTION KEY VOLUE REMARK

MAIN 0.15 ~ 0.55V -
DES/RES 0.7 ~ 1.1V -
ACC/SET 1.6 ~ 2.0V -
CANCEL 2.52 ~ 2.92V -
ECO 4.22 ~ 4.82V -
 8530-00 12-7

3. OPERATION
1) Setting a Desired Speed

1. To operate the cruise control, accelerate to the desired speed, which must be more than 38 km/h (24
MPH) and less than 150 km/h (90 MPH). In the vehicle equipped with manual transaxle, the gear shift
lever should be in 3rd (GSL: 2nd) or higher gear position.
2. Diesel engine equipped vehicle: When the desired speed is reached, press CRUISE ON (3) switch of
cruise control lever.
Gasoline engine equipped vehicle: When the desired speed is reached, press CRUISE ON (3) switch
of cruise control lever. The system is readyreadyreadyready to activate the cruise control function. To
activate the cruise control function, push up (1) the ACCEL switch of the cruise control lever.
Now, the vehicle is cruised by this system with the set speed.
3. And you can set to other vehicle speeds again with above steps after an accelerator pedal intervention
4. during the cruise control running.

Never use the cruise control system until you get used to it.
Improper use or not fully aware of this function could result in collision and/or personal injuries.
12-8

2) Accelerating with the Cruise Control System

(1) While the cruise control system is running

1. Push up the ACCEL switch of the cruise control lever and hold it until the desired speed is reached
without an accelerator pedal intervention.
2. When the desired speed is reached, release the lever.

(2) While the cruise control system is not running

1. Accelerate using the accelerator pedal over 38 km/h.
2. Push up the ACCEL switch of the cruise control lever and hold it.
3. And then release the accelerator pedal slowly.
4. When the desired speed is reached, release the lever.

(3) Tap-up while the cruise control system is running

1. Push up the ACCEL switch of the cruise control lever less than 0.5 second per one switching while the
cruise control system is running. This is a tap-up switching.
2. When you operate a tap-up switching, the vehicle is accelerated by 1.0 km/h over the previous set
speed.
3. If you want to accelerate to 10 km/h, operate the tap-up switching ten times without accelerating with
the cruise control system.
 8530-00 12-9

3) Decelerating with the Cruise Control System

(1) While the cruise control system is running

1. Push down the DECEL switch of the cruise control lever and hold it until the desired speed is reached
without a brake pedal intervention. But the cruise control system cannot maintain the cruise function at
less than 38 km/h.
2. When the desired speed is reached, release the lever.

(2) When the cruise control system is not running

1. Push down the DECEL switch of the cruise control lever and hold it.
2. And then release the accelerator pedal slowly.
3. When the desired speed is reached, release the lever. But the cruise control system cannot maintain
the cruise function at less than 38 km/h.
4. When you push down the cruise control switch, “RESUME” function starts (GSL only).

(3) Tap-down while the cruise control system is running

1. Push down the DECEL switch of the cruise control lever less than 0.5 second per one switching while
the cruise control system is running. This is a tap-down switching.
2. When you operate a tap-down switching, the vehicle is decelerated by 1 km/h below the previous set
speed.
3. If you want to decelerate to 10 km/h, operate the tap-down switching ten times without the brake
pedal intervention.
12-10

4) Recovery of Set Speed (RESUME)

To cancel the cruise control function, pull the cruise switch toward you.

The resume position should only be used if the driver is fully aware of this speed and wishes to
resume this particular speed.
 8530-00 12-11

5) ECO Cruise Control

ECO cruise is ready and ECO cruise indicator on the instrument cluster comes on when pushing down
the cruise control lever. To activate the ECO cruise mode, push down the cruise control lever again. To
cancel the ECO cruise mode while in operation, push down the cruise control lever again. The ECO
cruise mode is canceled and the indicator goes out.

What is ECO Cruise mode?

In this mode, the smooth acceleration to the set cruise speed can be achieved by optimized fuel
consumption.
12-12

6) Normal Cancellation of the Cruise Control

The cruise control system will be canceled when one or more items of the following conditions are
applied;
1. When the brake pedal is depressed.
2. When the cruising speed is decreased less than 38 km/h.
3. When pushing the ON-OFF switch of the cruise control lever.
4. When ESP is activated.
5. When applying the parking brake while driving.
6. When using the clutch in order to shift (M/T only).
7. To cancel the cruise control function, pull the cruise switch toward you. (GSL only).
And the cruise control system can be operated again in driving state.

Keep the main cruise control switch in the neutral position when not using the cruise control.
 8530-00 12-13

(1) Abnormal Cancellation of the Cruise Control

1. When the rapid deceleration is applied without braking.
2. When the rapid acceleration is applied without acceleration pedal intervention (DSL only).
3. When the cruise control lever is failed (DSL only).
4. When the brake switch and the brake light switch input signal are implausible.

And the cruise control system cannot be operated again in driving state. In this case, you should stop the
vehicle, and turn off the ignition switch and then turn it on again. After you do that, you can use the cruise
control system again. But if the cruise control system isn’t recovered, you should contact a
Ssangyong Dealer for diagnosis of the cruise control system.

1. Abnormal changes of the gear selector lever can damage the yyengine. Do not move the gear shift
lever to Neutral while driving at the set speed. Automatic transaxle damage may result.
2. The speed that has been set may not be maintained on uphill or yydownhill slopes.
3. The speed may drop to less than the set speed on a steep uphill yygrade. The accelerator must be
used if you want to maintain that speed.
4. The speed may increase to more than the set speed on a steep yydownhill grade. When the speed
increases too much, turn off the cruise control.

(2) Using the Cruise Control on Hills

How well the cruise control works on hills depends on the speed, load, and the steepness of the hill.
When going up steep hills, you may have to depress the accelerator pedal to maintain your speed.
When going downhill, you may have to brake or shift to a lower gear to keep your speed down.
Applying the brake takes you out of the cruise control.
 1490-00 15-3

1. ENGINE DATA LIST

Data Unit Value
Coolant temperature ℃ 0.436V (130℃) ~4.896V (-40℃)
-40~130℃
Intake air temperature ℃ (varies according to ambient air temperature or
engine mode)
Idle speed rpm 700±50(P/N), 600±(D)
Engine load % 18~25%
Mass air flow kg/h 16~25kg/h
Throttle position angle °TA 0° (Full Open) ~ 78° (Close)
Engine torque Nm varies according to engine conditions
Injection time Ms -
Battery voltage V 13.5V~14.1V
Accelerator pedal position V 0.3~4.8 V
1
Accelerator pedal position V 0.3~2.4 V
2
Oxygen sensor mV 0~5 V
OCV (Oil Control Valve) % 0~100%
VIS solenoid valve 1=ON / 0=OFF -
A/C compressor switch -
1=ON / 0=OFF

Full load 1=ON / 0=OFF -

Knocking control 1=ON / 0=OFF -
Brake switch 1=ON / 0=OFF -
Cruise control 1=ON / 0=OFF -
15-4

1. MAJOR COMPONENTS
Rear oxygen
Ignition coil MCC complete
sensor

Spark plug

OCV (Oil Control

Valve)

PVC valve Oil pressure

Injector Knock sensor
switch
 0000-00 15-5

Camshaft position Coolant Temp Front oxygen G20DF engine

sensor sensor sensor ECU

Purge control
solenoid valve

Crankshaft position
sensor

Electronic throttle Magnetic trigger

VIS solenoid valve T-MAP sensor
body ring
15-6

2. SYSTEM OPERATION
1) Input/Output of ECU
 0000-00 15-7

2) Components for ECU Input

Rear oxygen Coolant temperature Camshaft position Crankshaft position
sensor sensor sensor sensor

Front oxygen sensor G20DF Engine ECU Electronic throttle

body

Knock sensor T-MAP sensor

Refrigerant pressure sensor

Clutch pedal signal
Blower switch signal
Brake pedal signal

CAN

- ABS & ESP

- Instrument cluster
- TCU

Oil pressure Oil pressure warning lamp

switch
15-8

3) Components for ECU Output

OCV (Oil Control Valve) Start motor A/C compressor Injector

VIS solenoid valve G20DF Engine ECU Ignition coil

Purge control solenoid Cooling fan

valve module

CAN

- ABS & ESP unit

- BCM
- E-coupling unit
- EPS
- Instrument cluster
- SKM
- TCU
- Diagnostic tool
 1490-00 15-9

3. ECU CONTROL
1) Functions
ECU receives and analyzes signals from various sensors and then modifies those signals into
permissible voltage levels and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston speed and
crankshaft angle based on input data and stored specific map to control the engine power and emission
gas.
Output signal of the ECU microprocessor activates the injector solenoid valve to control the fuel injection
period and injection timing; so controls various actuators in response to engine changes.
Auxiliary function of ECU has adopted to reduce emission gas, improve fuel economy and enhance
safety, comforts and conveniences. For example, there are autocruise and immobilizer and adopted
CAN communication to exchange data among electrical systems (automatic T/M and brake system) in
the vehicle fluently. And the diagnostic tool can be used to diagnose vehicle status and defectives.
Operating temperature range of ECU is normally -40 to +85°C and protected from factors like oil,
water and electromagnetism and there should be no mechanical shocks.

2) Control Functions
- Controls by operating stages:
To make optimum combustion under every operating stage, ECU should calculate proper injection
volume in each stage by considering various factors.

- Starting injection volume control:

During initial starting, injecting fuel volume will be calculated by function of temperature and engine
cranking speed. Starting injection continues from when the ignition switch is turned to ignition
position to till the engine reaches to allowable minimum speed.

- Driving mode control:

If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and
engine rpm and the drive map will be used to match the drivers inputs with optimum engine power.
15-10

3) Injection Volume Control

(1) Overview
To keep the best engine conditions and to reduce the emission gas, ECU determines the injection
volume and timing.

(2) Components
▶ Input Components

Accelerator pedal Front oxygen Coolant temperature Crankshaft position

position sensor sensor sensor sensor

Camshaft position Electronic throttle

Knock sensor T-MAP sensor
sensor body

▶ Output Components
 0000-00 15-11

(3) Input/Output for Injection Volume Control

15-12

(4) Basic Injection Volume Map

 0000-00 15-13

4) Ignition System Control

(1) Overview
G20DF engine is equipped with the single ignition system. Each spark plug is operated independently
by the ECU and one ignition coil and spark plug are provided for each cylinder.

(2) Components
▶ Input Components

Coolant temperature Crankshaft position Accelerator pedal position

sensor sensor sensor

Camshaft position Electronic

Knock sensor
sensor throttle body

▶ Output Components
15-14

(3) Input/Output for Ignition System

 0000-00 15-15

(4) Features
1. Determines the ignition timing according to input signal
The ECU always analyzes the following elements when determining the ignition timing.

- Crankshaft position sensor

- Camshaft position sensor
- Coolant temperature sensor
- Intake air temperature/air mass

2. Warm-up of catalytic converter

The ignition timing is retarded for about 20 seconds to operate the catalytic converter according to the
operating temperature under the following conditions:

- The coolant temperature is 15°C ~ 40°C at starting.

- The idle speed is increased by the idle speed control to help warming up of the catalytic converter

3. Idle speed control

The ignition timing can be retarded up to 36° or advanced up to 20˚ to help idle speed control.
The ignition timing control can be performed faster than the control through the throttle valve.

4. Fuel cut-off in deceleration

The ignition timing is retarded temporarily to prevent abrupt increase of the torque when the
combustion is restarted.

5. Intake air temperature/coolant temperature

The ignition timing is retarded to prevent knocking if the intake air temperature or coolant temperature
is high. The ignition timing is retarded in the following cases.
- The intake air temperature is above 30°C.
- The coolant temperature is above 105°C.

The ignition timing retard for intake air temperature and for coolant temperature is added up for
correction.

6. ESP/ASR control mode

The ignition timing is retarded to reduce engine torque as fast as possible under the ESP/ASR
control mode.

7. Knocking control
If knocking occurs in the cylinder, the ignition angle of the corresponding cylinder is retarded. The
coolant temperature is 15˚C to 40˚C when starting.
15-16

5) Warm-Up of Catalytic Converter

(1) Components
▶ Input Components

Coolant temperature Crankshaft position

T-MAP sensor
sensor sensor

▶ Output Components
 0000-00 15-17

(2) Warm-up Control Function

▶ Idle speed control
The idle speed is controlled according to the fuel/air mixture when the engine load is changed, the
power steering wheel is turned to its end, the selector lever is in the "D" position and the A/C compressor
is in operation. It is also controlled according to the charge level during the purge control operation.

▶ Ignition timing
The idle speed is controlled according to the fuel/air mixture when the engine load is changed, The
ignition angle can be retarded up to 36˚ or advanced up to 20˚ to help idle speed control.

▶ Air conditioner compressor operation

The air conditioner control unit sends the air conditioner operation signal to the ECU to increase the
throttle valve opening amount in order to prevent reduction of the engine speed when the air conditioner
compressor is in operation at idling.

▶ Low voltage
If low voltage is detected by the ECU, the idle speed increases up to 100 rpm selectively under the
driving mode until the ignition switch is turned off.

(3) Warm-up Control Operating Conditions

To make the catalytic converter reach a operating temperature, the ignition timing is retarded for about
20 seconds under the following conditions:
▶ The coolant temperature is 15°C ~ 40°C when the engine is started.
▶ The selector lever is in the "P" or "N" position.
Also, the idle speed increases to 1100 ~ 1500 rpm simultaneously by the idle speed control. However, as
soon as the selector lever is shifted to the D position, warming up control of the catalytic converter will be
inhibited. The information necessary to perform such control is as follows:

▶ Coolant temperature
▶ Engine rpm
▶ Intake air mass
▶ Recognizing idling status
▶ Selector lever position
15-18

6) Cooling Fan Control

(1) Overview of Cooling Fan and A/C Compressor
The cooling system maintains the engine temperature at an efficient level during all engine operating
conditions. The water pump draws the coolant from the radiator. The coolant then circulates through
water jackets in the engine block, the intake manifold, and the cylinder head. When the coolant reaches
the operating temperature of the thermostat, the thermostat opens. The coolant then goes back to the
radiator where it cools. The heat from automatic transaxle is also cooled down through the radiator by
circulating the oil through the oil pump. There are two cooling fans (180W+120W) in G20DF engine. ECU
controls the electric cooling fans with three cooling fan relays to improve the engine torque and air
conditioning performance.

(2) Components
Refrigerant pressure Coolant temperature G20DF Engine Relay box in engine
sensor sensor ECU compartment

A/C compressor Cooling fan module T-MAP sensor

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(3) Input/Output for Cooling Fan and A/C Compressor

15-20

(4) Cooling Fan and A/C Compressor Control

▶ Conditions for cooling fan

The cooling fan module controls the cooling fan relay, high speed relay and low speed relay.
The cooling fan is controlled by the series and parallel circuits

A/C Cooling Refrigerant A/C

Coolant temperature
switch fan pressure compressor
OFF Coolant temp.<90℃ -
OFF LO 90℃≤Coolant temp.<105℃ -
HI 105℃≤Coolant temp. -

LO Refrigerant
pressure<18 bar
Coolant temp.<105℃
18 bar≤Refrigerant ON
ON HI
pressure
HI 105℃≤Coolant temp.<115℃ -
HI 115℃≤Coolant temp. - OFF (cut)

▶ A/C compressor OFF conditions

- Coolant temperature: over 118℃

- Approx. 4 seconds after starting the engine
- When abrupt acceleration
- Refrigerant pressure:
* OFF below 2.0 kg/㎠, then ON over 2.4 kg/㎠
* OFF over 32 kg/㎠, then ON below 26.0 kg/㎠

▶ Output voltage according to refrigerant pressure

The output voltage from refrigerant pressure sensor is 1.7 V to 3.5 V when the refrigerant pressure is 10
to 24 kgf/㎠ with A/C "ON".

▶ Cooling fan control by ATF temperature

ATF temperature Cooling fan speed Remark

Over 110˚C HI -
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7) Immobilizer Control
(1) Overview
The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and
prevents it from being started by unauthorized persons. The transponder integrated in the key and the
engine control unit have the same code. When the ignition key with the integrated transponder is turned
to the ON position, the ECU (Engine Control Unit) checks the crypto code of the key and, if correct,
allows the vehicle to start the engine.

For details, refer to Chapter "BCM".

(2) Components
▶ Conditions for cooling fan

Immobilizer Instrument
antenna cluster

Immobilizer BCM
key

G20DF ECU
Start motor
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▶ Key approval process

When turning the ignition switch to ON position, the power is supplied to BCM and ECU. ECU
communicate with the immobilizer key to check if it is valid crypto code. If it is valid, ECU start to control
the engine when turning the ignition switch to START position.
The system has 10 seconds of valid time-out period. If the engine does not start in this period, the key
approval process should be done again.
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8) CAN Configuration (P-CAN/B-CAN)

(1) CAN Configuration (P-CAN/B-CAN)

Name Function
ECU Electronic Control Unit
TCU Transmission Control Unit
EPS Electronic Power Steering Unit
BCM Body Control Moudule
SKM Smart Key Moudule

CAN system communicates with the system units in vehicle. It consists of P-CAN and B-CAN according
to the communication speed.
P-CAN & B-CAN: SKM, Instrument cluster, BCM, Disgnostic connector
P-CAN: ECU, ABS & ESP, TCU, E-coupling, EPS unit
Terminal resistance: installed on ECU and BCM
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(2) Wiring Connection of CAN Communication

Splice pack Wiring Location

S101 Floor wiring (LH) Under fuse & relay box in engine
compartment
S102 Floor wiring (RH) Inside of right fender
Behind instrument cluster (cowl cross
S201 Main wiring
member)

S202 Main wiring Behind instrument cluster (cowl cross

member)
S205 Floor wiring (LH) Under driver’s door scuff
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(3) Input/Output for CAN communication